WH40H3N (set-04)

Doc. Ref:WH40H3N

OPERATION & MAINTENANCE MANUAL

PET COMPRESSOR TYPE WH40H3N

This document contains confidential information of Gardner Denver Belliss & Morcom Ltd (The Company). The copyright, design right and/or other intellectual property rights in the document belongs to (The Company). All rights conferred by law and by virtue of International Copyright and other conventions are reserved to The Company. This document and the information contained therein or any part thereof must not be reproduced, disclosed or used for any other than those for which the prior written consent of The Company has been given.

Gardner Denver Belliss & Morcom Ltd

Important This Instruction Manual covers Installation & Commissioning, Operation and Maintenance of the Gardner Denver Belliss & Morcom PET range of compressors.

It is ESSENTIAL that this document is read and understood by everyone who will work with this equipment, as failure to do so may result in death, injury or damage to the compressor or its associated equipment.

Disclaimer While every care was taken in the preparation of these instructions, it cannot be guaranteed that every aspect has been covered. Gardner Denver Belliss & Morcom cannot, therefore, accept liability for direct or consequential damage that may arise resulting from non-conformity with this Manual, from repairs carried out improperly, from using other than original spare parts, and from non-observance of good operating and maintenance engineering practices. Should there be any doubt whatsoever, or should any further information or explanation be required, Gardner Denver Belliss & Morcom must be contacted.

This information is given in good faith, no warranty or representation is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon Gardner Denver Belliss & Morcom.

Gardner Denver Belliss & Morcom reserve the right to make changes to any information contained within this manual without prior notice.

Warranty Statement The compressor(s) and ancillary equipment supplied by Gardner Denver Belliss & Morcom are covered under Warranty for the period agreed in the Supply Contract. The equipment provided is well designed to afford many years of trouble free service. However, should the need arise to implement a warranty claim then this can be done using Warranty Claim Form Document No.CM4F2 obtainable from Gardner Denver Belliss & Morcom Service Department. A copy of this form is provided in Appendices located at the end of this manual. It should be noted that consumable parts that require replacement during normal compressor operations are not normally covered under Warranty. Similarly, the Warranty does not cover running adjustments. Point of Contact

Gardner Denver Belliss & Morcom Ltd Chequers Bridge, Gloucester, GL1 4LL, England Tel: +44 (0) 1452 338198 Email: [email protected] Fax: +44 (0) 1452 338317 Web: www.belliss.com

Foreword

www.belliss.com

Gardner Denver Belliss & Morcom are well known in the market place for the design, manufacture and supply of high-quality air compressor equipment. This Instruction Manual is produced for the PET' range of compressors. These compressors are constructed from the highest quality materials and are designed and built according to the latest manufacturing techniques. The compressor design will give good service providing that it is operated and maintained in accordance with the information contained within this Manual.

The information and notes presented in the 'Ancillary Devices Instruction Manuals will provide operational and maintenance information for the control and instrumentation system, motor/drive unit and where appropriate, any other device associated with the compressor package.

Targeted Personnel This document is designed to provide competent operatives, who are fully conversant with compressor operating and maintenance techniques, with an understanding of the compressor elements and their operation and subsequent maintenance. It should be noted that the term 'competent' implies that the operative is a compressor engineer suitably trained in the installation, operation and maintenance of the Gardner Denver Belliss & Morcom product.

This Instruction manual is not intended to supersede or take the place of the Gardner Denver Belliss & Morcom product-training course. For further information regarding training courses or to book a place, please contact Gardner Denver Belliss & Morcom Service Department. The address, telephone/facsimile number is provided at the start of this documentation.

How to Use this Instruction Manual The Instruction Manual is designed to enable speedy location of relevant information. To this end the document is divided into six chapters, each of which covers an individual topic. Cross-references between topics and illustrations are identified within the text using bold characters i.e. (Refer to Chap 2 Section 4.1) or see Fig 3.

At appropriate locations within this document you will see 'Information Boxes'. It is VERY IMPORTANT that the information contained within these boxes is adhered to, as failure to do so may result in death, injury or damage to the compressor or its associated equipment. The following outlines the philosophy applied to each of the three levels of boxed notation.

WARNING! This pictogram with the remark "WARNING!" identifies a potential dangerous hazard. Non-compliance will put the operator or a third party at risk of death or injury.

CAUTION! This pictogram with the remark CAUTION! identifies the possibility that if non-compliant the compressor and/or its associated equipment can be damaged.

This pictogram marks important Notes, which identifies supplementary information for the competent and economic use/operation of this compressor package.

Foreword

www.belliss.com

Documentation Storage Always store this Instruction Manual near the compressor so that it is available for reference at all times. If the instruction manual is lost, Gardner Denver Belliss & Morcom can supply a new copy for a small fee. When requesting new or additional copies, of this document, please include your compressor details with your order.

Comments and Suggestions We would welcome comments and suggestions for improvements to this Instruction Manual. If you decide to comment, make a copy of the page or pages concerned and add your comments. Then send your response to Gardner Denver Belliss & Morcom. Please do not forget to include your name and the name of your company, your company address and your telephone and facsimile numbers.

OPERATION & MAINTENANCE MANUAL COMPRESSOR TYPE WH40H3N

CONTENTS

Issue: 1 Date: May 2002 Page: 5 of 145

Gardner Denver Belliss & Morcom www.belliss.com DOC REF: WH40H3N - ISSUE 1, MAY 02

1 TECHNICAL DATA & COMPRESSOR DESCRIPTION.....................................9 1.1 Technical Data..................................................................................................... 9

1.1.1 Operating Data....................................................................................................9 1.1.2 Compressor Data ..............................................................................................10 1.1.3 Tightening Torques (Dry Threads) .....................................................................13 1.1.4 Materials of Construction ...................................................................................14

1.2 Technical Description of the Compressor .......................................................... 15 1.2.1 Purpose of the Equipment .................................................................................15 1.2.2 Compressor Identification ..................................................................................15 1.2.3 Compressor Operation ......................................................................................16 1.2.4 Crankcase and Lower Motion Work ...................................................................16 1.2.5 Cylinders, Pistons and Piston Rod Packings......................................................18 1.2.6 Valves ...............................................................................................................19 1.2.7 Motor and Couplings .........................................................................................19 1.2.8 Control Panel and Controls................................................................................19 1.2.9 Safety Equipment and Systems.........................................................................20

2. SAFETY INFORMATION..................................................................................22 2.1 Safety Policy...................................................................................................... 22

2.1.1 Commonplace Hazards .....................................................................................22 2.1.2 Proper Use........................................................................................................22 2.1.3 Organisational Measures...................................................................................23 2.1.4 General Safety Precautions for Compressors ....................................................23 2.1.5 Installation, Commissioning and Operation ........................................................24 2.1.6 Maintenance......................................................................................................24

3 INSTALLATION & COMMISSIONING .............................................................27 3.1 Safety Precautions............................................................................................. 27 3.2 Installation Requirements .................................................................................. 27

3.2.1 Location ............................................................................................................27 3.2.2 Ventilation .........................................................................................................27 3.2.3 Foundations ......................................................................................................28 3.2.4 Pipework Installation..........................................................................................28 3.2.5 Cooling Water ...................................................................................................31 3.2.6 Electric Cabling .................................................................................................32

3.3 Handling and Unpacking.................................................................................... 32 3.3.1 Stability .............................................................................................................32 3.3.2 Slinging Instructions ..........................................................................................33 3.3.3 Lifting Instructions .............................................................................................34 3.3.4 Unpacking .........................................................................................................34

3.4 Installation Procedure ........................................................................................ 35 3.4.1 Safety Precautions ............................................................................................35 3.4.2 Mounting Arrangements - Anti-Vibration Mounts ................................................35 3.4.3 Levelling and Alignment - Flange Mounted Motors.............................................36

3.5 Preparation for Commissioning.......................................................................... 36 3.5.1 Cleaning the Compressor ..................................................................................36 3.5.2 Preparing the Compressor.................................................................................36 3.5.3 Preparing the Motor...........................................................................................38 3.5.4 Motor Rotation Check........................................................................................38

3.6 Commissioning the Compressor........................................................................ 38 3.6.1 Trial Run ...........................................................................................................38 3.6.2 Completion of Commissioning ...........................................................................39


CONTENTS



4 OPERATING INSTRUCTIONS.........................................................................41 4.1 Controls and Indicators...................................................................................... 41

4.1.1 Starter System...................................................................................................41 4.1.2 Load Control System Functions .........................................................................42

4.2 Preparation for Starting...................................................................................... 43 4.2.1 Before Operating the Machine (Pre-Start Checks) .............................................44

4.3 Starting the Compressor.................................................................................... 44 4.3.1 Under Normal Conditions ..................................................................................44 4.3.2 After An Emergency Stop ..................................................................................45

4.4 Running............................................................................................................. 45 4.4.1 Running Checks ................................................................................................45 4.4.2 Automatic Operation..........................................................................................45 4.4.3 Faults/Hazards ..................................................................................................45

4.5 Stopping the Compressor .................................................................................. 46 4.5.1 Normal Stopping................................................................................................46 4.5.2 Emergency Stopping .........................................................................................46

4.6. Fault Indications ................................................................................................ 46 4.6.1 Fault Finding .....................................................................................................47

5 COMPRESSOR MAINTENANCE.....................................................................51 5.1 Preventive Maintenance .................................................................................... 51

5.1.1 Maintenance Schedule ......................................................................................51 5.2 Maintenance Instructions................................................................................... 56

JOB No. 001 CRANKCASE OIL CHANGE.....................................................................57 JOB No. 002 FIT PISTON ROD CLAMPS......................................................................59 JOB No. 003 CYLINDER TOP COVERS - REMOVE & REFIT.......................................60 JOB No. 004 PISTON RINGS - REMOVE & REFIT .......................................................62 JOB No. 005 PISTON/CYLINDER END CLEARANCES - INSPECTION........................68 JOB No. 006 PACKING GLAND ASSEMBLY - REMOVE & REFIT................................70 JOB No. 007 PACKING GLAND ASSEMBLY - OVERHAUL ..........................................74 JOB No. 008 PISTON ROD OIL SHEDDER - REMOVE & REFIT ..................................76 JOB No. 009 OIL SCRAPER GLAND - REMOVE & REFIT............................................78 JOB No. 010 SUCTION & DELIVERY VALVES - REMOVE & REFIT.............................79 JOB No. 011 SUCTION & DELIVERY VALVES - OVERHAUL.......................................81 JOB No. 012 SUCTION VALVE UNLOADER ACTUATORS - REMOVE & REFIT..........83 JOB No. 013 PISTON RODS - REMOVE & REFIT ........................................................85 JOB No. 014 OIL FILTER - REMOVE & REFIT..............................................................86 JOB No. 015 OIL PRESSURE RELIEF VALVE - ADJUSTMENT ...................................86 JOB No. 016 LUBRICATING OIL PUMP AND DRIVE - INSPECT & OVERHAUL ..........87 JOB No. 017 INTERCOOLER - INSPECT & OVERHAUL..............................................87

5.3 Lists of Tools ..................................................................................................... 88 5.3.1 Commercially Available Tools List......................................................................88 5.3.2 Specialist Service Tools List ..............................................................................89

5.4 Waste Products ................................................................................................. 90 5.4.1 Oil - After Oil Changes.......................................................................................90 5.4.2 Coolant .............................................................................................................90


CONTENTS



6 SPARE PARTS ................................................................................................92 6.1 Ordering Spares and Spares to be Held in Stock............................................... 92 6.2 Spares List......................................................................................................... 93 6.3 Illustrated Parts List - Main Component Location View ...................................... 95

Fig 1 Crankcase Assembly (2-03-288)...........................................................................96 Fig 2 Connecting Rod Assembly (2-76-426)...................................................................97 Fig 3 Crankshaft Assembly (2-06-383)...........................................................................98 Fig 4 Main Guide Assembly (2-07-280)..........................................................................99 Fig 5 Bearing End Cover Assembly (2-25-121) ............................................................100 Fig 6 Flywheel End Cover Assembly (2-25-123) ..........................................................101 Fig 7 Second Stage Piston Rod Assembly (2-30-144)..................................................102 Fig 8 Third Stage Piston Rod Assembly (2-30-202)......................................................102 Fig 9 Crosshead Assembly (2-31-066).........................................................................103 Fig 10 Oil Pump and Cooler Assembly (2-34-562) .......................................................105 Fig 11 Piston Rod Scraper Assembly (2-63-047) .........................................................106 Fig 12 Crosshead Assembly (2-31-067).......................................................................107 Fig 13 First Stage Piston Rod Assembly (2-30-252).....................................................108 Fig 14 First Stage Cylinder Assembly (2-01-908) .........................................................110 Fig 15 First Stage Top Cover Assembly (2-04-467)......................................................111 Fig 16 Distance Piece Assembly (2-07-414) ................................................................112 Fig 17 First Stage Piston Assembly (2-28-660) ............................................................113 Fig 18 First Stage Packing Box Assembly (2-64-285)...................................................114 Fig 19 First Stage Suction Valve Assembly (2-70-489).................................................115 Fig 20 First Stage Delivery Valve Assembly (2-70-490)................................................116 Fig 21 Second Stage Cylinder Assembly (2-01-531) ....................................................118 Fig 22 Second Stage Top Cover Assembly (2-04-274).................................................119 Fig 23 Distance Piece Assembly (2-07-281) ................................................................120 Fig 24 Second Stage Piston Assembly (2-28-481) .......................................................121 Fig 25 Second Stage Packing Box Assembly (2-64-286) .............................................122 Fig 26 Second Stage Suction Valve Assembly (2-70-503)............................................123 Fig 27 Second Stage Delivery Valve Assembly (2-70-504)...........................................124 Fig 28 Third Stage Cylinder Assembly (2-01-481)........................................................126 Fig 29 Third Stage Top Cover Assembly (2-04-305) ....................................................127 Fig 30 Distance Piece Assembly (2-07-281) ................................................................128 Fig 31 Third Stage Piston Assembly (2-28-523) ...........................................................129 Fig 32 Third stage Packing Box (PSB032-060) ............................................................130 Fig 33 Third Stage Suction Valve Assembly (2-70-236) ...............................................131 Fig 34 Third Stage Delivery Valve Assembly (2-70-237) ..............................................132 Fig 35 First Stage Interstage Pipework Assembly (2-71-780) .......................................134 Fig 36 Second Stage Intercooler Assembly (2-71-781) ................................................136 Fig 37 Cooling Water Assembly (2-45-2515)................................................................138 Fig 38 Pressure Gauge Assembly (2-46-1250) ............................................................141 Fig 39 Unloader Assembly (2-68-642) .........................................................................144 Fig 40 Ancillaries (2-150-055)......................................................................................145

APPENDICES Appendix 1 Safe Working Limits Appendix 2 Warranty Authorisation Claim Form Appendix 3 Compressor Log Sheet


CHAPTER 1 TECHNICAL DATA &

COMPRESSOR DESCRIPTION

OPERATION & MAINTENANCE MANUAL COMPRESSOR TYPE WH40H3N CHAPTER 1 - TECHNICAL DATA &




1 TECHNICAL DATA & COMPRESSOR DESCRIPTION The information contained in this section is intended for the use of the engineer responsible for the operation and maintenance of the plant. It is essential that any necessary adjustments, servicing or overhaul work should be carried out by competent persons who are familiar with the installation, operation and maintenance of this product and who have the appropriate authorisation.

When communicating with the Gardner Denver Belliss & Morcom on matters relating to the compressor always quote the compressor type and serial number (e.g.WH40H3N Serial No. 8759).

This manual is written using SI Units of measurement. The three basic units used herein are: the metre, the kilogram and the second. All measurements in this manual are expressed using these units unless otherwise stated. Standards and Legislation

The compressor is manufactured in accordance with the European Economic Community Directive: BS EN 1012-1: 1997, and is tested in accordance with British Standard: BS 1571 Parts 1 and 2.

1.1 Technical Data

1.1.1 Operating Data

Normal Operating Conditions

Instrument Pressure Gauge Range Pressure Range (Normal Operation)

Air Delivery - 1st stage 0 - 7 Bar G 2.3 - 2.9 Bar G

Air Delivery - 2nd stage 0 - 30 Bar G 11.8 - 13.2 Bar G

Air Delivery - 3rd stage 0 - 76 Bar G 45.0 Bar G

Oil Pressure ** 0 - 10 Bar G 3 - 4.8 Bar G

**Oil pressure will fluctuate with ambient conditions, compressor loading and with the type and viscosity of the oil being used. Also; oil pressure peaks during start-up before settling back as the oil achieves its operating temperature.

This machine is fitted with over-temperature monitoring safety switches for final air from both the third stage cylinder and the aftercooler. Details of the settings for these devices are given in Section 1.1.2 Compressor Data.





Flows and Capacities Cooling Water

Flow** 36 m3/h (nominal) 24 m3/h (min)

Pressure 7 Bar G (max) 4 Bar G (min)

Temperature Inlet

38 C. (max) 16 C. (min)

** The cooling water flows are design estimates and may need to be adjusted at site to meet the exact cooling requirements.

It is recommended that the compressor is monitored during its initial running period and that a record is kept of the flows and temperatures for future reference.

Compressed Air Data Crankcase Data Gas being compressed AIR Oil Sump Capacity 91 litres

Delivery Pressure 45.0 Bar G

Air Capacity 2220 m3/h

Inlet Temperature 0-45 C

Relative Humidity 0 - 100%

1.1.2 Compressor Data

Installation Data Instrument Air: Component Weights

Normal Operating Range 7 bar g minimum

Compressor Weight 9000 kg. (without motor).

Maximum Pressure 10 bar g Service/ Maintenance Lift

1000 kg

Vibration:

Vibration on the compressor may exceed 2.5 mm/s2, but there is no bodily contact with the operator. Mechanical Data

Cylinder Data Bumping Clearance (On All Cylinders) 1st Stage Cylinder Bore 515.00 mm Piston Top to Top Cover 2.8 - 3.1 mm

2nd Stage Cylinder Bore 287.75 mm Piston Bottom to Cylinder 1.2 - 1.8 mm

3rd Stage Cylinder Bore 165.10 mm

Piston Stroke 165.10 mm





Piston/Piston Ring Data:

Figures quoted below for new parts. The upper and lower limits arise due to accumulated effect of manufacturing tolerances. All butt gaps are measured with the piston ring in the cylinder.

Diametrical Clearance of Piston Body in Cylinder Bore: 1st Stage 4.65 - 4.81mm 2nd Stage 3.37 - 3.55mm 3rd Stage 3.25 - 3.45mm

First Stage Piston Rings First Stage Bearer Ring Radial Thickness 18.67 - 18.92 mm Radial Thickness 11.53 - 11.67mm Axial Clearance in Groove

0.27 - 0.32mm Axial Clearance in Groove

0.50 - 0.55mm

Gap at Butt Joint 11.21 - 13.31mm

Gap at Joint 15.73 - 18.82mm Diametrical Clearance

in Cylinder 1.66 - 2.10mm

Standout from Piston Body

1.31 - 1.55mm

Second Stage Piston Rings Second Stage Bearer Ring Radial Thickness 15.21 - 15.39mm Radial Thickness 9.15 - 9.25mm Axial Clearance in Groove


0.38 - 0.43mm

Gap at Butt Joint 8.00 - 8.50mm Gap at Joint 8.00 - 8.50mm Diametrical Clearance

in Cylinder 0.55 - 0.80mm


1.31 - 1.41mm

Third Stage Piston Rings Third Stage Bearer Ring Radial Thickness 9.47 - 9.58mm Radial Thickness 9.27 - 9.37mm Axial Clearance in Groove


0.71 - 0.91mm

Gap at Butt Joint (Each Gap)

3.86 - 4.88mm Gap at Joint 6.35 - 7.11mm

Diametrical Clearance in Cylinder

0.57 - 0.89mm


0.21 - 1.42mm





Crankcase Components Clearances

The clearances for new components given are between the limits indicated - the upper and lower limits arise due to accumulated effect of manufacturing tolerances. The corresponding maximum figure is the point where renewal of the component is required. No maximum figure is given against parts which, are not expected to wear to any significant extent in service.

Part New Max

Crankshaft Bearings (radial clearance) 0.06 - 0.11mm

Connecting Rod Bottom End Bearing 0.10 - 0.15mm 0.20mm

Connecting Rod Top End Bearing 0.10 - 0.07mm 0.15mm

Crosshead to Main Guide Slide 0.22 - 0.30mm 0.38mm Compressor Performance Data

Speed 735 rpm Direction of Rotation Clockwise: looking on flywheel Compressor Absorbed Power 365 kW Drive Type Direct drive shaftless motor Heat radiated (at full load) 365 kW (approx) Cylinder Type Double acting non lubricated Load Control System 3 Step (Full-load or Half-load or No-load).

Safety Device Data

Pressure Relief Valve Data: Safety relief valve settings: 1st Stage 2nd Stage 3rd Stage

3.5 Bar G 15.0 Bar G 47.8 Bar G

Lubricating oil pump relief valve setting 5.5 Bar G

Setting of Protection Switches/Devices High air temperature (AST) 177 C (rising) High air temperature (Separator) 65 C (rising)** Low lubricating oil pressure 1.8 Bar G (falling) Low cooling water flow 65% of normal flow (falling)

** Switch is factory set to 65 C. for temperate (UK type) climates. The switch may be adjusted up to a maximum of 75 C. to suit tropical climates during or after installation. However, adjustments MUST only be performed by a competent, authorised person.





Normal Settings for the Load Control System (40 Bar G Delivery) Pressure Switch 1 (PS1) *40.0 Bar G. (unload trip)

*38.0 Bar G. (reload trip) Pressure Switch 2 (PS2) *39.0 Bar G. (unload trip)

*37.0 Bar G. (reload trip)

Differential Pressure (between unload and reload trips): = *1.0 Bar G (minimum)

The settings quoted above are typical and may be adjusted to suit site requirements during or after installation. However, the switch setting must not exceed the specified design operating pressure.

Adjustments MUST only be performed by competent, authorised persons. Noise Data

With compressor running at 735 rpm the following design figures are available: Sound Pressure Level 90 dBA at 1m Sound Power Level 110 dBA (ref 2 x 102Pa)

1.1.3 Tightening Torques (Dry Threads)

CAUTION! Over-tightening (over-torquing) of the fasteners can lead to damage to the fasteners and/or the components.

Component Thread Size

Torque Nm (Newton metres)

CRANKCASE COMPONENTS: Bearing End Cover M20 190 - 210 Flywheel End Cover M16 65 - 72 Oil Pump to End Cover M8 15 - 20 Crankcase Access Covers M10 25 - 30 Scraper Gland Fasteners M12 45 - 55 Flywheel Retaining M42 375 - 400

DISTANCE PIECE COMPONENTS: Distance Piece to Crankcase M20 190 -210 Cylinder to Distance Piece M24 200 - 220 Distance Piece Access Cover M6 10 - 15

1ST STAGE CYLINDER COMPONENTS: Cylinder/Top Cover M24 330 - 364 Valve Covers M20 128 - 140 1st Stage Suction/Delivery Valve Nut M20 178 - 215 Inlet/Outlet Flange M24 330 - 364 Packing Gland Fasteners M24 200 - 220





Component Thread Size

Torque Nm (Newton metres)

2ND STAGE CYLINDER COMPONENTS: Cylinder to Top Cover M20 190 -210 Valve Covers M20 128 - 140 Inlet/Outlet Flange M16 98 -108 Packing Gland Fasteners M20 128 - 140

3RD STAGE CYLINDER COMPONENTS: Cylinder to Top Cover M24 330 - 364 Valve Covers M20 128 - 140 Inlet/Outlet Flange M24 330 - 364 Packing Gland Fasteners M20 128 - 140

MOTION WORK COMPONENTS: Crosshead Nut to Crosshead 1/5/8 BSF 950 - 1050 Piston Nut to Piston 1/5/8 BSF 950 - 1050

1.1.4 Materials of Construction

Crankcase & bearing end cover, main guides (for crossheads), distance pieces, cylinders & cylinder top covers valve cages and covers, packing gland containers

Cast Iron - Gr 250, BS1452

Crankshaft S.G. Iron - Gr 420/12, BS2789 Crankshaft Main Bearings Steel (spherical roller) Connecting Rods & Crossheads S.G. Iron - Gr 600/3, BS2789 Connecting Rod End Bearing Top Bottom

Lead-Bronze Lead-Copper on Steel Shells

Crosshead Gudgeon Pin Case Hardened Steel Piston Rod Carbon Steel - 605M36T, BS970

surface hardness 485 Brinell Oil Scraper Gland Rings/Springs Stainless Steel Packing Gland Rings/Springs PTFE/Stainless Steel Packing Boxes Stainless Steel

Piston 1st stage 2nd stage 3rd stage

Aluminium - LM16TF, BS1490 Cast Iron Gr 250, BS1452 Cast Iron Gr 250, BS1452

Piston Rings: PTFE Valve Seats and Guards, Carbon Steel Zinc Plated Valve Plate, Damper Plates, Lift Washers, Springs and Bolts

Stainless Steel

Fixed tubeplates Intercoolers & aftercoolers Carbon Steel with copper tubes + bonded inserts





1.2 Technical Description of the Compressor

1.2.1 Purpose of the Equipment

The compressor provides a constant supply of compressed air, at a regulated pressure and of a known volume. The compressed air can then be used as part of an industrial process.

1.2.2 Compressor Identification

All Gardner Denver Belliss & Morcom compressors have a rating plate located on the crankcase. The information stamped onto this plate identifies the compressor type, capacity and serial number. The compressor designation indicates the following:

W - Denotes cylinder configuration H - Denotes multi-stage compression 40 - Denotes normal capacity H3 - Denotes high pressure three stage N - Denotes oil free cylinder operation

External View of WH40H3N PET Compressor





1.2.3 Compressor Operation

The compressor operates by drawing air from atmosphere via an efficient air filter and silencer system into the 1st stage cylinder where it is compressed to approximately 3 Bar G. The heat generated by compressing the air is dissipated in the water-cooled intercooler, positioned after the 1st stage cylinder. The cooled air then flows through the 2nd stage suction separator, which removes any moisture condensed during cooling. The air then passes to the 2nd stage cylinder where the air is further compressed to approximately 11 Bar G. The heat generated by compressing the air is dissipated in a water-cooled intercooler, positioned after the 2nd stage cylinder. The cooled air then flows through the 3rd stage suction separator, which removes any moisture condensed during cooling. The air then passes to the 3rd stage cylinder where the air is further compressed to its final delivery pressure of 45 Bar G (max). The heat from compression is dissipated in the water-cooled aftercooler positioned after the 3rd stage cylinder. The cooled air then flows through the final delivery separator, which removes any moisture condensed during cooling. The compressed cool dry air is then discharged into the delivery pipework.

1.2.4 Crankcase and Lower Motion Work

Crankcase

The crankcase is a heavily-ribbed iron casting with integral mounting feet and cylinder mounting flanges. Also integral within the crankcase are housings for the two crankshaft drive-end bearings. There are machined faces for the flange mounted motor, bearing end cover, crankcase and main guide doors. The bolt-on bearing end cover incorporates the housing for the third crankshaft bearing.

The crankcase forms the lubricating oil sump, and is complete with tapped holes for the oil level window nut, the oil pump suction feed pipe, the crankcase drain plug and the oil cooler. Oil retention in the crankcase is made possible by a lip seal fitted at the drive-end of the crankshaft and by scraper rings fitted around the piston rods. Immediately beneath the drive-end crankshaft seal housing is an integral oil return passage.

The single throw, cast high-tensile iron, crankshaft has integral design counter-balanced weights. The standard throw is 82.55 mm, giving a piston stroke of 165.10 mm. The crankshaft is supported by three self-aligning, double-race spherical roller bearings, two at the driving end and one at the oil-pump end. Endwise location is by clamping the outer drive-end main bearing (in the oil seal holding cover) against a machined shoulder in the crankcase. The driving end has a tapered shaft which is keyed to accommodate the rotor of a direct mounted motor. The oil pump end of the crankshaft has internal oil passages to the crankpin. Oil Pump

The gear type oil pump is mounted on the crankshaft bearing end cover and is driven via a coupling off the non-drive end of the crankshaft. Oil is drawn by the pump from the crankcase sump through a wire mesh strainer and external pipe. The oil is delivered through a full-flow fine-mesh cartridge filter to the oil ways in the crankshaft. Any excess oil output is by-passed back to the sump by a spring-loaded pressure relief valve mounted on the crankcase main bearing housing.

All the bearing surfaces in the crankcase are lubricated by the oil passing through the bore of the crankshaft and connecting rods. The main roller bearings are splash lubed by the oil from the crosshead, and also by the general oil mist in the crankcase.





Connecting Rods

The connecting rods have detachable bottom end caps to facilitate removal of the rods and rods have split-shell bottom end bearings and bush type top end bearings. The bottom end bearing shells are steel backed copper-lead, lead-tin plated. The pressed-in top end bushes are lead bronze.

An oil passage connects the top and bottom bearings allowing oil under pressure (from the oil pump via passages in the crankshaft) to lubricate both. Oil is sprayed, from an annular groove around the top end bush and through two small holes, onto both slides of the crosshead guide. Crossheads

The crossheads run in the main guides which are bolted to the cylinder mounting flanges of the crankcase. The crossheads are attached to the top of the connecting rods by gudgeon pins (which are retained themselves by circlips). The top face of the crosshead is drilled and tapped for reception of the piston rod. The piston rod is retained by a securing pin which passes through the side of the crosshead into the slot in the end of the piston rod. The piston rod is then clamped by a nut, which is tightened down against the top of the crosshead. The securing pin is prevented from coming loose by a retaining plate.





1.2.5 Cylinders, Pistons and Piston Rod Packings

Cylinders

The double-jacketed cylinders are cast complete with mounting base, lower valve chambers and housing for piston rod packing assembly. They have machined faces for the top cover; lower mating flange, valve covers, distance rings and valves, and air and water inlets and outlets. The inner jacket of the cylinder is for the cooling water, the outer jacket is divided into suction and delivery air chambers.

The cylinder top covers are cast with integral valve chambers, cooling water passages and suction and delivery air chambers. They have machined faces for the cylinder joint, valve covers, distance rings and valves.

The cylinders are non-lubricated, the piston rings being made of low friction material, and are spaced off the crankcase by distance pieces containing oil scraper packings. These prevent oil from the crankcase sump getting into the cylinders.

Cooling is provided by passing water first through the compressor intercoolers, and then, via a series of pipes, around the compressor cylinder water jackets and cylinder top covers. Pistons and Rings

The 1st & 2nd stage pistons are of a two-piece hollow construction with the 3rd stage piston being of solid construction. Each piston is machined with piston-ring grooves with the centre body of each piston drilled and recessed to take the piston rod. Piston Rods and Packings

The piston rods are threaded at both ends. The piston rod bottom end has a cruciform slot to accommodate a securing pin (to prevent rotation of the rod in the crosshead) and is held in the crosshead by a locknut. The top end of the rod is shouldered and waisted inside the piston. A self-locking nut secures the piston to the rod.

The piston/cylinder end clearances at the top and bottom are governed by the distance the piston rod is screwed into the crosshead.

The oil-free cylinder compressor has separate packing gland assemblies. The packing comprises multiple pairs of PTFE rings, each pair of rings being housed in a container and held against the piston rod by a garter spring. The containers are assembled to a base by long studs and nuts, and the assembly held in its housing in the base of the cylinder by studs and nuts. A soft iron ring is recessed into the top surface of the upper container to prevent air leakage around the packing.

The separate scraper assembly is housed in the crosshead-guide loose plate and comprises a number of segmented rings in a split casing, each ring is held in contact with the piston rod by a garter spring.

An oil shedder is also fitted to the piston rod between the packing and the scraper assemblies to prevent any oil-creep along the rod.





1.2.6 Valves

Suction and delivery valves are similar in construction but differ in detail. Care must always be taken when servicing the compressor to ensure that the correct valve is fitted into the correct valve chamber.

All suction valves are controlled by plate depressors (or unloaders), their location being identified by the presence of actuators on the valve covers. The actuators have small bore instrument air pipes connected to them.

To unload a working compressor. the suction valves are rendered inoperative by the valve plates being pressed off their seats. This is accomplished by plate depressors (unloaders) being operated by load control actuators.

A plate depressor is basically an inverted cup-shaped body with fingers protruding from its rim, assembled with a spring-loaded central guide surmounted by a cylindrical cap. The fingers operate through slots in the suction valve seat directly onto the valve plate.

In action the plate is depressed, against its spring, by the pneumatically operated actuator. Compressed air fed to the load control actuator, by the load control solenoid valve, acts on a multi-layer diaphragm, which is sandwiched between the two halves of the actuator body. The diaphragm is in contact with the head of the spring loaded plunger immediately under the disk. The plunger, guided in the lower half of the actuator body, has its stem end in contact with the cap of the plate depressors. When the control air is exhausted by the solenoid valve, springs return the plunger away from the valve plate.

1.2.7 Motor and Couplings

The compressor can be supplied with a flange-mounted motor, or as a bare-shaft machine.

The standard motor is a brush-less cage rotor type, with a power output suited to the delivery requirements of the compressor.

The motor's rotor is keyed directly onto the crankshaft and the stator casing is bolted to the crankcase.

1.2.8 Control Panel and Controls

The compressor can be supplied with or without a starter system. The standard starter system is housed in a two-compartment dust and damp proof wall or floor mounted sheet steel cubicle. The control panel is an integral part of the front of the cubicle and the controls and gauges are divided between the upper and lower compartments. (For full details of the controls their operation and functions refer to the supplementary information provided with your compressor).





1.2.9 Safety Equipment and Systems

There are several safety features fitted to Gardner Denver Belliss & Morcom compressors as standard, with additional features available as options. The following are standard fitments:

a. low lubricating oil pressure indicator and alarm b. high delivery air temperature indicator and alarm - compressor C. low cooling water flow indicator and alarm d. high outlet air temperature indicator and alarm - aftercooler e. pressure relief valves after each of the cylinders f. pressure relief valve after the oil pump

Faults 'a' to 'd' (if supplied with a standard control panel) are indicated on the annunciator panel, which is integral with the main control panel. The fault results in the simultaneous alarm signal on the panel and shutdown of the compressor. The fault protection equipment is interlocked with the starter. Fault 'e' results in the release of pressurised air to atmosphere by the relief valve immediately after the over pressured cylinder. During normal operation 'f' bypasses excess oil back to the crankcase sump.

For full details of the system and its operation refer to the supplementary information supplied with your compressor.


CHAPTER 2 SAFETY INFORMATION


CHAPTER 2 - SAFETY INFORMATION



2. SAFETY INFORMATION

2.1 Safety Policy The compressor and its associated equipment are to be operated in accordance with current Statutory Health & Safety Policies (and any such regulation applicable in the country of installation). It is the responsibility of the operative to familiarise him/her self with these policies/regulations.

Any work practices that may pose a potential health and safety hazard or any faulty/suspect equipment associated with the safe operation or maintenance of the compressor package must be brought to the immediate attention of the supervisor or supervising authority.

Always wear appropriate safety equipment when operating or maintaining this equipment. Personnel safety equipment to include but not limited to:- Ear Defenders Safety Glasses. Industrial Boots. Appropriate Hand Protection (gloves and/or barrier cream). Any other safety item identified under Risk or COSH Assessments. Loose fitting or frayed/ripped clothing MUST NOT be worn while operating or maintaining this equipment.

2.1.1 Commonplace Hazards

If a hazard is identified that is not identified within the Operating Authority 'Standing Safety Instructions' a separate Risk Assessment must be made. Similarly If a hazard in the form of a Control Of Substances Hazardous to Health (COSHH) is identified, steps must be taken to assess the risk of injury to staff.

The compressor and its associated equipment are to be operated in accordance with current statutory Health & Safety at Work policies. It is the responsibility of the operative to familiarise him/herself with these policies. Any work practices that may pose a potential health and safety hazard or any faulty/suspect equipment associated with the safe operation and maintenance of the compressor must be brought to the attention of the supervisor or supervising authority.

2.1.2 Proper Use

The compressor is built to stringent manufacturing guidelines to guarantee safe operation. However, using compressed air can be linked to dangerous occurrences if compressed air is not properly handled. Proper use also includes the following: Follow the guideline laid down within this instruction manual, observing all pertinent

regulations and notes for the compressor. Maintaining the equipment at the mandatory inspection and maintenance intervals. Correct repair of the compressor equipment. The compressor MUST NOT be operated in any other manner than that for which it

was originally designed. Operating in accordance with the relevant environmental and operating regulations.





2.1.3 Organisational Measures

It is the customers responsibility to ensure that the operating manual is adequately supplemented with internal regulations regarding supervision and notification duties, work organisation, and personnel qualification etc.

No modifications may be carried out on the compressor or its peripheral devices without the written consent of Gardner Denver Belliss & Morcom. Unauthorised Modification of the equipment will invalidate the WARRANTY. When renewing compressor components use only original spare parts and accessories supplied by Gardner Denver Belliss & Morcom.

2.1.4 General Safety Precautions for Compressors

Electrical System - Before performing work on the electrical system the compressor and the peripheral devices must be isolated form the mains and secured against switching on accidentally. Work on the electrical system must only be carried out by qualified staff who are aware of the risk involved with the task.

Pressure Relief Valves - These MUST be Full Compressor Capacity relief valves connected directly to the flow pipework to relieve any excess pressure that may build-up between the cylinder discharge flange and in line equipment (e.g., stop valve, non-return valve, cooler, etc).

WARNING! It is forbidden to operate the compressor unless all relief valves are correctly fitted, in fully operational condition and are set at the correct relief pressure for the compressor duty.

There must be no restriction of any kind between the relief valve position and the preceding cylinder. Relief valves must be directly mounted with no isolating valves interposed between the relief valve and the pressure sensing point. The exhaust from the relief valves must only discharge into designated safe areas. The setting of relief valves must be checked regularly as required by statutory codes and regulations.

Pressure vessels must be fitted with a full capacity pressure relief valve. Vessels must not be operated above their stated operation rating and must be checked regularly as required by codes and regulations.

Protection Equipment - All protection, control switches and circuits must be regularly checked for correct operation.

Switches can be tested by checking in calibration rigs, or by carefully controlled simulation of fault conditions at the actual machine. Circuits can be checked by mechanically operating the switches.

Frost Protection - Where, due to its location, the compressor could be exposed to frost, then adequate precautions must be taken to prevent freezing of the water system.

Guards - All guards and covers must be in position and secure before start-up.





Operating Records - It is IMPORTANT that a regular log sheet be kept for the compressor recording operating pressures, temperatures and oil pressure (a copy of a Log Sheet is provided within the Appendices located at the end of this manual). Variances from normal running performance should be brought to the immediate attention of the Supervisor responsible for consideration and action.

Lifting Equipment - Before using any lifting equipment, it is IMPORTANT that the crane, gantry, hoist or chain block and any slings employed must be certified capable of lifting the weight of the compressor (or motor/compressor assembly). Any such lifting equipment MUST have a current CITB Test Certificate (or an equivalent certificate applicable to the country of installation).

2.1.5 Installation, Commissioning and Operation

In all matters of safety regarding the Installation, Commissioning and Operation of the compressor or package, the reader's attention is directed to the full implementation of the requirements of the Health & Safety at Work Act (and any such regulation applicable in the country of installation). Gardner Denver Belliss & Morcom may be consulted should any doubt exist regarding matters of safety related to their product.

2.1.6 Maintenance

In addition to the General Safety Precautions, the following safety precautions MUST be observed when maintaining your machine. 1) Before commencing any maintenance work on the compressor or its driving unit

or any ancillary, the driving unit must be rendered incapable of being started whilst maintenance and adjustment work is in progress.

In the case of an electric motor for example, the machine must be isolated from the main electricity supply, the isolator locked off and/or the fuses withdrawn. This is particularly important with auto start/stop machines where the machine could be started automatically.

2) Affix "NOT TO BE USED" boards to the compressor and control cabinet. 3) Isolate the compressor from the discharge main and the instrument air. 4) Before opening up the machine, all pressurised compartments MUST be

depressurised down to atmospheric pressure in a safe and controlled manner.

5) Isolate the compressor from the cooling water supply and drain all relevant water containing compartments.

6) If the compressor motion work or rotational parts are to be worked on then piston rod clamps MUST be fitted to prevent accidental movement. Also chocking the crankshaft should be considered where necessary.

7) ALL lifting equipment MUST be correctly rated for the loads being applied and MUST be certified as being in good working condition. Always ensure that when lifting equipment is used, only specified lifting or slinging points are used.

8) Always refer to the applicable procedure when undertaking maintenance and overhaul procedures.

9) Bolts and nuts must not be under or over tightened, see appropriate torque values in Chapter 1 Section 1.1.3.

10) Ensure that ALL tools and spare parts are accounted for after reassembly, since any items left on or within the compressor may cause serious damage upon restarting.





11) DO NOT place the electrical isolating switch to the 'ON' position until your supervisor has inspected and approved the work carried out.

12) Before starting the compressor, bar over the machine by hand where possible to ensure free rotation and that no metallic 'knocking' noise is evident.

CAUTION! Particular care must be taken with compressor valves to ensure that suction valves and associated securing and actuating components are not fitted in delivery valve pockets or vice-versa. Failure to do so could result in severe damage to the compressor.


CHAPTER 3 INSTALLATION

& COMMISSIONING


CHAPTER 3 - INSTALLATION & COMMISSIONING



3 INSTALLATION & COMMISSIONING

3.1 Safety Precautions Before carrying out any work related to this Section, it is a requirement that you read and work in accordance with, the Safety Precautions given in Chapter 2 of this manual. For your own protection, be sure to read and obey the WARNING and CAUTION notices you find in this Section and any associated literature.

WARNING! 1) If the compressor is to be supported on anti-vibration mountings,

air, water and electrical services are to be made with non-rigid (flexible) connections.

2) Due to possible electrical insulation effects of pipe gasket material and anti-vibration mountings, the machine must be provided with a permanent earth continuity connection of a non-rigid (flexible) type, which should comply with local regulations and safety requirements.

3.2 Installation Requirements The installation of the compressor, and its associated pipework, should be the subject of careful consideration before undertaking the actual task. This section of the manual provides the necessary information for the installation engineer to locate and to install the compressor to the best advantage.

3.2.1 Location

The compressor should be located in a clean, well-lit, well-ventilated area with ample space all around it to facilitate inspection and maintenance. Sufficient room must be allowed for the removal of pistons and cylinders, crankshaft and motor, and as the compressor and many of its components are heavy, there must be headroom sufficient to permit the operation of a crane or hoist, which must be certified capable of lifting safely the weight.

Statutory regulations and local by-laws governing the operation of heavy machinery must be complied with, this may have some influence on the choice of location.

3.2.2 Ventilation

Approximately 10% of the energy consumed by a compressor is lost as heat. This is the heat generated by the motor, the mechanical losses of the compressor and straight-forward heat radiation from the air manifolds.

For example, a 365kW water-cooled compressor would require some 486 m3/min of ambient air circulation to limit the compressor room temperature rise to 6C. Natural convection is normally adequate with the outlet vents at a high level to prevent the temperature building down from the roof.





3.2.3 Foundations

For vibration isolator mounted compressors, all that is required is a floor of sufficient strength to carry the weight of the compressor, motor and ancillaries. For solidly mounted compressors the foundation dimensions must be determined for each installation, consideration being given to the nature of the subsoil and local surroundings.

WARNING! The floor must be level and flat.

Foundation depth must be such that the subsoil reached is, in the opinion of an expert, capable of taking the load of the working compressor and preventing the transmission of vibration. Unless the foundation rests on bed-rock or hard-pan, a sub-footing should be made of such a size and design as to provide a solid bottom. In extreme cases of poor subsoil, piling may be required, and in such circumstances a competent foundation engineer should be consulted.

If the compressor is to be mounted on a metal floor, it can be either bolted direct to the floor, or beam or skid mounted. The beams or skids may be bolted or welded to the floor, with due consideration being given to structural vibrations and floor strength.

A foundation plan (for good subsoil conditions) is furnished in advance of the shipment of the compressor, and the foundation used must not be less than given in the plan.

When installing a solidly mounted compressor, it must be ensured that the crankcase feet are ALL flat down and fully supported BEFORE tightening the "Holding Down" fasteners. A detailed foundation drawing is available (on request) from Gardner Denver Belliss & Morcom.

3.2.4 Pipework Installation

These paragraphs give recommendations with regard to both suction and delivery pipework and will help the plant engineer plan the best possible installation.

Pipes must not be fixed inflexibly such that heavy thrust can act back onto the compressor otherwise serious damage could result, examine carefully the anchoring point locations and pipework support arrangements.

WARNING! All inlet and outlet connections to compressors mounted on vibration isolators MUST use suitable flexible pipes. All flexible pipes MUST be installed in accordance with the manufacturer's instructions.

Inlet System

An efficient air intake filtration system is essential to ensure that debris is removed from the air flow to the compressor thereby prolonging the life of the machine. Standard Gardner Denver Belliss & Morcom practice is to fit a machine mounted, combined filter/silencer, however, in hot or dirty locations, or in the presence of difficult combinations (e.g. fumes, alumina or cement dust), filtration may be improved by mounted the intake remotely and ducting the air to the compressor. Special filter/silencer arrangements are available for this type of installation. Only dry type filters must be used with oil-free compressors. Noise regulations should be taken into account when deciding silencer requirements and locations.





Delivery System

The flexible delivery pipe connects the aftercooler to the receiver (where fitted). It must be of the correct specification for the pressure and temperature and nature of the medium being compressed, and not smaller than the size specified below.

'X' and 'Y' dimensions for standard units are usually identical but these can be unequal to suit specific installations. Whatever dimensions apply at x and y, this instruction remains totally applicable. For new pipes, x and y are maintained by the presence of "Tie-Bars" to ensure

correct installation. Once installed, the Tie-Bars must be removed before the machine is operated.

Hose must be mounted in the position shown above, where one leg is completely horizontal and the other completely vertical and fully supported at its connection: no other position is allowable.

When fitted statically, hose must be free of all imposed stresses such as 'torsional', 'distortional', 'compressive', 'tensional' etc.

MOVEMENT DURING RUNNING

(A) During start-up only: Frequency up to 12.5 Hz.

20 mm movement in any plane

0.5 about any axis

(B) During normal running Frequency up to 25 Hz.

< 3 mm movement in any plane

< 0.25 about any axis

The pipe must be well supported to avoid strain on the compressor cylinders, and it's configuration be such that any expansion effect, due to the air/gas temperature rise for whatever reason, can adequately be dissipated within the natural elasticity of the pipework leading from the compressor and cannot act back on the cylinder.





At the junction with the receiver, or pipe main, a shut-off valve should be fitted to isolate the compressor as required. On automatic and multi-machine installations, non-return valves should also be fitted to isolate standby units from system pressure.

A safety valve must be fitted, close to the compressor, in the delivery pipe. The valve must be fitted before any shut-off valve, non-return valve or aftercooler to prevent damage in the event of the compressor being run with the shut-off valve closed. The valve should be a spring-loaded type and of sufficient size to pass safely the maximum compressor output.

A small blow-down valve should be fitted between the compressor and shut-off valve to relieve residual pressure when required for maintenance purposes. Air Receiver

An air receiver of ample capacity is required for use with this equipment. The receiver should have a capacity equal to a one minute supply of compressed air (neglecting temperature rise).

The air receivers should, ideally, be located in the coldest place possible, to ensure that as much condensate as possible is precipitated from the air in the receiver. This means that the receiver must be drained frequently, either by fitting an adequate drain or an automatic drain trap.

To facilitate servicing of the drain trap whilst the receiver is in commission, a by-pass should also be incorporated. Distribution Piping (air systems)

Water collectors of an automatic discharge type should be fitted at suitable points in the pipe system. They should be fitted with three-way cocks (either in connection with the traps or separately) so that pipes may be blown through to disperse condensation.

Delivery pipework must be arranged to prevent condensation running back from the aftercooler or receiver into the compressor cylinders.

The pipe system for air distribution should be carefully considered if optimum results are to be obtained. Moisture-laden air can cause rusting in low-lying parts of the pipe system so, ideally, all distribution pipework should be internally galvanized and angled slightly towards the drain points.

An effective way of eliminating possible water damage is to install a refrigerative air dryer or, for dryer air, an adsorption dryer.





Load Control Piping

Connect (with similar size piping) the load control system on the compressor to the control air take-off points on the compressor panel, the connections on the compressor will indicate the size.

Connect (with similar size piping) the compressor panel control air inlet point to the compressed air/instrument air main - any isolating valve fitted here must be of the lockable-open type. Drain Valves & Drain Valve Piping

It is important that the drain pipes from the water separator drain traps are run individually to open ends (e.g., over OPEN drains). They must NOT be piped together as there would then be a risk of "blow-back" along adjacent pipes in the event of a trap malfunctioning.

Drain valves are fitted to the separators of each compression stage. These valves exhaust the collected moisture at high pressure and must be piped away to a safe area using solid pipework.

MOST IMPORTANT - if the exhausts of any vent valves are piped away, it is essential that these have direct outlets to atmosphere, they must NOT be connected into any other pipe. It is also recommended that a silencer is fitted to the exhaust in order to reduce noise levels.

3.2.5 Cooling Water

An adequate source of clean, cool water for the compressor cylinders, intercoolers and aftercooler should be provided.

Cooling water must be as free as possible from scale forming salts, with (if the water is not clean) an efficient filter(s) placed in the intake pipeline. A Duplex type arrangement is recommended as this will allow one filter to be cleaned whilst the other is in service.

The temperature of the cooling water supply to the compressor (NOT aftercooler) should not be less than the ambient temperature. The methods of achieving this depend on the cooling system employed:

The temperature of the cooling water supply should be in the range 20C to 35C

In situations where the ambient temperature is in excess of 35C., advice should be sought from Gardner Denver Belliss & Morcom.

The pressure in the cooling water pipeline at the compressor must be sufficient to promote the flow required by the size and duty of the machine. This should take into consideration all the friction losses in the overall pipework and valves and across the heat exchanger units (as may be installed) as well as across the compressor.

Except for compressors made to special customer requirements, water pressure in the jackets should not exceed 7 Bar g.





3.2.5 Cooling Water (Cont) It is recommended that thermometer pockets are fitted to the water inlet and outlet pipes to the compressor and, the aftercooler. Temperature differentials between these points will give a good indication of sufficient water flow, 10 to 12C being usual.

CAUTION! Failure of water flow is a cause of major damage and must be avoided. Ensure that cooling water pipes to and from the compressor are constructed to avoid the formation of air locks

For compressors operating in cold environments, drain points are present on the cylinders to empty the water jackets of the machine (when out of service) to prevent damage in the case of frost. Open air vent cocks at the tops of the cylinders at the time of water drainage. Certain water pipe connections should afterwards be disconnected to completely drain the system.

CAUTION! Exposure to frost conditions will damage your machine unless the proper frost precautions are taken. If advice is required, please contact Gardner Denver Belliss & Morcom.

3.2.6 Electric Cabling

The electric cabling to the motor must be run such that small amounts of movement at the motor terminals can be safely absorbed within inherent flexibility of the type of cabling used.

Check that the motor nameplate details agree with those of the electricity supply on which the motor is to be used.

Connect motor in accordance with the instruction supplied. Use cables of adequate size to carry the full load current and also large enough to carry the starting current without excessive voltage drop.

Ensure that the motor frame is properly earthed.

3.3 Handling and Unpacking

3.3.1 Stability

Due consideration must be given to maintaining the compressor's stability during all lifting procedures. The compressor is only in a stable condition when standing on a suitable, level floor surface with all four crankcase feet firmly down. It MUST be noted that the Centre of Gravity (C of G) for each machine will change depending on whether the compressor is 'bare-shaft' or fitted with a 'drive unit'.

WARNING! The crane, gantry, hoist or chain block or any slings employed must be certified capable of lifting the weight of the compressor (or Motor/Compressor assembly).





Compressor Slinging Diagram (Typical)

3.3.2 Slinging Instructions

On all compressors two cradle slings are positioned, one under each of the two outer cylinder crankcase flanges. A third sling is used to balance the compressor. a. In the case of a compressor fitted with a flange mounted motor, a cradle sling is

passed under the motor, taking care to keep it clear of the fan housing. b. In the case of a bare shaft compressor, a sling is passed round the intercooler

pipework. c. If the compressor is fitted with a flywheel, a balancing sling is passed around the

shaft.

WARNING! Under no circumstances use the motor lifting hole for balancing the weight (this lifting point is for the motor only when detached or detaching from the compressor).

Care MUST be taken to ensure that no small bore pipes or other components being trapped by slings.





3.3.3 Lifting Instructions

Because the type of lifting equipment for each installation will be different the following instructions have been written with the intent of being a general guide rather than specific instructions.

For compressor maintenance purposes a one tonne block is usually suitable to give good control of the lifting of components. 1. Whatever your equipment or conditions, good safety procedures must be

practiced, i.e.: a) Establish the actual weight of the load. b) Check whether the lift will be a straight lift, or will an angle rig be needed.

These factors will affect the lifting capacity required. c) The slings must be free of kinks, knots, broken strands or loose

connections etc, and meet the regulation requirements. d) Check the clearance available to make sure the lift can be attempted

safely. e) To prevent damage to the machine's finish or the edges of the machine

from cutting into the slings, use proper blocking and padding. 2. Know your equipment, and anticipate potential hazards. 3. When involved in the lifting of heavy loads, we suggest you protect yourself by

wearing approved protective gear such as: safety helmets, steel toe cap safety shoes, gloves, eye protection, etc.

4. Prepare the installation area before moving the machine. 5. Refer to the machine installation drawings and note the location of the machine

support points. Review all machine installation requirements carefully before positioning the machine.

3.3.4 Unpacking

No special unpacking instructions can be given here as the compressors may be transported fully boxed, crated, or on open bases, depending on destination and mode of transportation. Boxed compressors have directions for lifting and opening on or with the boxes. Some of the cylinder valves will have been replaced with silica-gel bags. The displaced valves and the accessories are packed in a separate container, which should be located and safeguarded until after the installation of the compressor.





3.4 Installation Procedure

3.4.1 Safety Precautions

The following additional safety precautions should be observed before installing the compressor onto its foundation.

Personnel must be a safe distance from the compressor during positioning, guide ropes may be used to assist, but not 'hands-on'. The compressor must be lowered slowly, in small stages with no sudden jerks whilst observing for any indications of potential problems. Once in position the compressor must be properly secured with suitable foundation bolts or anti-vibration mounts (AVM's).

If the floor is to be drilled for foundation bolts, the compressor must be moved away whilst work proceeds.

Each time the compressor is moved check for stability and correct sling placement.

DO NOT apply load tension to the slings if the compressor is held to the floor.

3.4.2 Mounting Arrangements - Anti-Vibration Mounts

A flat and level floor of sufficient strength to support the combined weight of the motor, compressor and ancillaries should be prepared in advance of the compressor delivery. The procedure should then be as follows: 1. Ensure that the underfaces of the compressor feet are clean. 2. Bolt the anti-vibration mountings on to the compressor feet. 3. Move the compressor into position and mark on the floor the position of the

holding down bolt holes in the anti-vibration mounting plate. 4. Remove the compressor and attached mounts and drill the floor for appropriate

size holes for the Raw-bolt shells. 5. Insert shells, reposition compressor and bolt onto floor by means of the mounting

holding down bolts. OR:

The anti-vibration mountings may be held down by bolts or anchors of a similar diameter to the holes in the mounting plate. Use of these will eliminate the need to move the compressor to drill the floor holes. The appropriate instructions supplied with the bolts should be followed precisely. 6. Finally, check the bolts holding the compressor onto the anti-vibration mountings

and use these bolts to finish levelling the compressor (See Levelling and Alignment).





3.4.3 Levelling and Alignment - Flange Mounted Motors

Compressors with flange mounted motors are completely assembled and lined-up before shipping, it is therefore only necessary to set the machine on the foundations and level it in both directions as follows: 1. Adjust the pressure within the pneumatic AVM's around the machine until the

desired level is achieved. Do not inflate AVM's unless the static weight of the compressor is placed on them.

2. Ensure that the final levelled height of each mount is within the makers limits and that each mount is levelled until it carries its correct proportion of the overall machine weight.

3. If any mount is compressed solid, levelling must be carried out on the free mounts to redistribute the load.

4. Using a spirit level on any horizontal surface, check that the compressor is level in both planes (i.e. parallel to and at right angles to the crankshaft).

5. If NOT, then adjust again until satisfied.

3.5 Preparation for Commissioning

3.5.1 Cleaning the Compressor

The compressor must be thoroughly cleaned before preparing for commissioning.

Care should be taken when making connections to see that no grit or impurities of any kind are allowed to enter while the compressor is being piped up and prepared for work.

3.5.2 Preparing the Compressor

After works testing, the compressor is prepared for shipment. Before use therefore, the compressor will require to be prepared for use as follows: 1. Remove the 'mouldable' wrapping from around the piston rods and clean the rod

surfaces. 2. Remove control piping from cylinder valve covers marked with adhesive labels

and remove the covers. 3. Extract the silica gel bags from the valve chambers; ensuring that where more

than one bag is present, ALL bags are removed. 4. Using a plastic or soft metal scraper, remove rust resistant paint from the seating

in the valve chambers. 5. Remove the valve assemblies from their wrappings. 6. Fit components in their correct order, ensuring that suction and delivery valves

are fitted in the correct valve chambers. Where plate lifters are fitted to suction valves, care must be taken to ensure correct assembly.





7. Tighten the valve covers and refit the control air pipes 8. Remove and store the adhesive labels and warning plates with the silica gel

bags. 9. Check that all gauges and small-bore pipework are undamaged, and are properly

connected. 10. Ensure that all external nuts and bolts on the compressor and its ancillary

equipment are tight, including all holding down bolts and bolts of all pipework flanges and supports.

11. Remove the crankcase access covers (and wooden blocks where fitted), and crosshead access aperture covers, and check to ensure that the interior of the crankcase is clean and free of foreign matter.

12. Ensure free movement of compressor motion by turning the crankshaft round a number of times in the correct direction of rotation.

13. Fill the oil sump (in the bottom of the crankcase) with the recommended grade of lubricant to level indicated by the window nut on the front of the crankcase. Initially fill to near the top of the window, the level will fall towards the bottom of the window when the compressor is started, rising to about half-way when the oil has reached its sustained running temperature.

14. Wearing suitable (oil resistant) protective gloves, liberally coat clean oil onto all the main guide slides - turning the crank to different positions to achieve full face coverage (keep hands out of the crankcase when the shaft is being turned).

15. As the compressor may have been in transit/storage for some time, prime the suction side of the lubricating oil pump by disconnecting the suction pipe top fitting. Then using the recommended grade of lubricant pump oil 'in' to 'wet' the gears and fill partially the suction side of the pump body. This promotes a quick pick up of oil pressure on start up of the compressor.

16. Refit the crankcase and crosshead access covers. 17. Ensure that the compressor pressure instrument isolating cocks are open. 18 Ensure that the pipes of the rubber filling plugs are removed to vent the gauge

cases and allow correct gauge indication. 19. Ensure that the pressure signal pipelines of the load control system are open

(i.e., make certain that any isolating valves are fixed open). 20. Fill slowly and carefully (to avoid trapping air) in the cooling water spaces of the

compressor - do not rush this operation. Open the air vent cocks, at the tops of the cylinder covers to rid the system of trapped air. The operation is carried out in association with any other water-cooled ancillary items in the overall cooling water system of the installation.





3.5.3 Preparing the Motor

Check the driving motor insulation resistance (IR) using a 500 volt megohmeter taking note that the insulation resistance in mega-ohms, measured between any terminal and the frame with the machine cool, is infinity.

If the windings have become damp and the insulation resistance is low, then the windings must be thoroughly dried out and re-tested for satisfactory condition before commissioning.

CAUTION! Before using the insulation tester disconnect the supply leads at the motor terminals so that only the motor windings are tested. This will avoid the possibility of the test instrument potential destroying any electronic equipment that may be in ancillary circuits.

3.5.4 Motor Rotation Check

The compressor is designed to rotate in a clockwise direction when viewed from the drive end.

CAUTION! Running the compressor with incorrect rotation will result in serious damage.

After checking it is safe to do so, switch on the electricity supply to the compressor control panel. Prepare the compressor for an 'unloaded' start and press the START button, as soon as the compressor starts press the STOP button. Check motor is rotating in the correct direction (indicated on motor end). In the event of wrong direction of rotation, isolate the machine immediately. A qualified electrician must rectify the problem before rechecking.

3.6 Commissioning the Compressor Before commissioning the compressor, read and fully understand Part 3 "Operation" and any associated literature regarding the control panel and any other ancillary equipment.

3.6.1 Trial Run

When commissioning, the trial run must include certain vital checks, and these should be carried out as follows: 1. Ensure that the factory delivery mains and air using equipment are safe to

pressurise - and all delivery isolating valves in the system are open. 2. Ensure that the load control sensing pipework is open to the compressed air

main. 3. Ensure that the isolating cocks of all pressure gauges are open. 4. Ensure that the by-pass valves situated at the drain traps are closed. 5. Start compressor in the unloaded condition and allow to run up to full speed,

observe oil pressure is quickly established (this will be high with a cold machine) and observe compressor running generally.





6. After a 3 minute run, stop and electrically isolate the compressor. Remove the crankcase main doors and check the temperatures of the motion work bearings and guides. This should be done using a thermometer fitted with a suitable surface probe.

WARNING! Take care during examination, as some of the parts will have become heated.

Al

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WH40H3N (set-04)