ORIGINAL INSTRUCTIONS IE105D Installation, Operation & Maintenance Manual D-Style Two-Stage Gas Compressors Models FD351, WFD351, D391, WD391, FD391, and WFD391 WFD351/391 Compressor Shown 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., 9201 North I-35 Service Road, Oklahoma City, OK. 73131. 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 FITNESS FOR A PARTICULAR PURPOSE, ARE EXPRESSLY NEGATED TO THE EXTENT PERMITTED BY LAW AND SHALL IN NO EVENT EXTEND BEYOND THE 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 model number and serial number are given on the compressor nameplate. Space is provided below for you to keep a written record of this information. Always include the model number and serial number when ordering parts. Model No. Serial No. Date Purchased Date Installed Purchased From Installed By 2 Table of Contents COMPRESSOR FEATURES .....................................................................4 CHAPTER 1—INSTALLING YOUR CORKEN COMPRESSOR ..........................................5 1.1 Location .................................................................................5 1.2 Foundation ...............................................................................5 1.3 Piping ...................................................................................5 1.4 Liquid Trap ...............................................................................6 1.5 Driver Installation/Flywheels .................................................................7 1.6 Crankcase Lubrication ......................................................................7 1.7 Purging, Padding, Venting and Draining of Distance Pieces on Two Stage D-Style Compressors. ...........8 1.8 Relief Valves ..............................................................................9 1.9 Shutdown/Alarm Devices ....................................................................9 1.10 Compressor Cooling .....................................................................10 CHAPTER 2—STARTING UP YOUR CORKEN COMPRESSOR .......................................10 2.1 Inspection After Extended Storage ...........................................................10 2.2 Flywheel and V-belt Alignment ..............................................................10 2.3 Crankcase Oil Pressure Adjustment ..........................................................11 2.4 Startup Check List ........................................................................11 CHAPTER 3—ROUTINE MAINTENANCE CHART ..................................................12 CHAPTER 4—ROUTINE SERVICE AND REPAIR PROCEDURES ......................................13 4.1 Valves ..................................................................................13 4.2 Heads ..................................................................................14 4.3 Piston Rings and Piston Ring Expanders Replacement ...........................................14 4.4 Piston Replacement .......................................................................14 4.5 Piston Rod Packing Adjustment .............................................................15 4.6 Cylinder Replacement .....................................................................15 4.7 Bearing Replacement for Crankcase and Connecting Rod ........................................17 4.8 Oil Pump Inspection. 18 CHAPTER 5—EXTENDED STORAGE PROCEDURES ...............................................19 APPENDICES A. Model Number Identification Code ............................................................20 B. Material and Mechanical Specifications ........................................................23 C. Outline Dimensions ........................................................................26 D. Troubleshooting ...........................................................................31 E. Assembly Details ..........................................................................32 3 Compressor Features Tubing for Valve holddown water connections assembly Water-cooled head ANSI anges Tubing for Water-cooled water connections cylinder Nameplate & oil ll cover Crosshead guide Oil pressure adjustment screw Oil lter adapter Flywheel Flywheel Oil lter Breather hub cap Oil pressure gauge Crankcase Figure 1.1 Why Corken Compressors are Special Corken industrial gas compressors are unique among By utilizing specialized piston-rod sealing systems, compressors their size. Unlike ordinary lubricated gas Corken compressors can compress pressurized, compressors, Corken compressors completely isolate flammable and toxic gases. It is also used to compress the pressurized gas in the compression chamber from harmless gases where oil-free compression or elevated the crankcase. While piston rings seal the piston tightly suction pressures are required. With a large selection of enough for it to do compression work, they do not provide design options available, Corken offers the most versatile enough sealing to isolate the compression chamber from line of small gas compressors in the world. the crankcase. To further seal the compression chamber, a crosshead/piston rod design with seals around the piston rod is required. 4 Chapter 1—Installing Your Corken Compressor 1.1 Location HEX NUT 2” MIN. COMPRESSOR WASHER Compressor must be installed in a well ALL SIDES BASEPLATE ventilated area. GROUT BENEATH WARNING BASE Corken compressors are designed and manufactured for CONCRETE FOUNDATION outdoor duty. For applications where the compressor will WITH REINFORCEMENTS be subjected to extreme conditions for extended periods SHOULD BE USED ON ALL MODELS such as corrosive environments, arctic conditions, etc., 8” MIN. consult Corken. Check local safety regulations and building 1/2” “J” BOLTS codes to assure installation will meet local safety standards. 12” LONG Corken compressors handling toxic or flammable NOTE: LOCATE “J” BOLTS PER gases such as LPG/NH3 should be located outdoors in COMPRESSOR OUTLINE a well ventilated area. A minimum of 18 inches (45 cm) DIMENSION DRAWINGS. clearance between the compressor and the nearest wall is Figure 1.2: Recommended Foundation Details recommended. This will make it accessible from all sides for Corken Compressors and provide unrestricted air flow for adequate cooling. 1.3 Piping Noise Level: Many factors affect the noise level generated Proper piping design and installation is as important as a by a compressor installation. Several of these, including proper foundation is to a smooth operating compressor. motor noise, piping vibration, foundation/skid design, and Improper piping installation will result in undesirable surrounding structures are outside Corken’s control. The transmission of compressor vibration to the piping. use of sufficient pipe supports, flexible hoses, and proper baseplate/skid support will all reduce noise. Thus, Corken can DO NOT SUPPORT PIPING WITH THE not guarantee a particular noise level from our compressors. COMPRESSOR. Unsupported piping is the most However, noise levels from a properly installed Corken WARNING frequent cause of vibration of the pipe. The best compressor typically do not exceed 85dBa at three feet. method to minimize transmission of vibration from the compressor to the piping is to use flexible 1.2 Foundation connectors (see figure 1.3 for details). Proper foundations are essential for a smooth running Pipe must be