Manual IOM Wh29H3N

8/10/2019 Manual IOM Wh29H3N

1/113

INSTALLATION, OPERATION & MAINTENANCE

MANUAL

PET COMPRESSOR

TYPE WH29H3N


2/113

WH29H3NPET Compressor

Introduction

Important

This Instruction Manual covers Installation & Commissioning, Operation and Maintenance of theGardner Denver Belliss & Morcom PETrange of compressors.

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

Disclaimer

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

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

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


3/113


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 DenverBelliss & Morcom product-training course. For further information regarding training courses or tobook a place, please contact Gardner Denver Belliss & Morcom Service Department. Theaddress, telephone/facsimile number is provided at the start of this documentation.

How to Use this Instruction ManualThe Instruction Manual is designed to enable speedy location of relevant information. To this endthe 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 VERYIMPORTANT that the information contained within these boxes is adhered to, as failure to do somay 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.


4/113


Point of Contact

For sales, service or spare parts enquiries, please contact :

Comments and Suggestions

We would welcome comments and suggestions for improvements to this Instruction Manual. If youwould like to comment please make a copy of the page or pages concerned and add your

Address : Gardner Denver Ltd

Belliss & Morcom

Chequers Bridge,

Gloucester,

GL1 4LL,

England

Telephone : +44 (0)1452 338338

Fax : +44 (0)1452 338317

E-mail : [email protected]

Website : www.gardnerdenver.com


5/113


Table of contentsChapter 1 - Technical Data and Description

1.1 Data and Compressor Description . . . . . . . . . 1-2

1.2 Technical Data . . . . . . . . . . . . . . . 1-3

1.3 Technical Description of the Compressor . . . . . . . 1-9

Chapter 2 - Safety Information

2.1 Safety Policy . . . . . . . . . . . . . . . . 2-2

Chapter 3 - Installation and Commissioning

3.1 Safety Precautions . . . . . . . . . . . . . . 3-2

3.2 Installation Requirements . . . . . . . . . . . . 3-2

3.3 Handling and Unpacking . . . . . . . . . . . . 3-10

3.4 Installation Procedure . . . . . . . . . . . . . 3-12

3.5 Preparation for Commissioning . . . . . . . . . . 3-13

3.6 Commissioning the Compressor . . . . . . . . . . 3-15


6/113


JOB No: 7 - PACKING GLAND ASSEMBLY - OVERHAUL . . . . . . 5-23

JOB No: 8 - Piston Rod Oil-Shedder - Remove and Re-fit . . . . . . 5-25

JOB No: 9 - Oil Scraper Gland - Remove and Re-fit . . . . . . . . 5-27

JOB No: 10 - Suction and Delivery Valves - Remove and Re-fit . . . . 5-29

JOB No: 11 - Suction and Delivery Valves - Overhaul . . . . . . . . 5-32

JOB No: 12 - Suction Valve Unloader Actuators - Remove and Refit . . . 5-34

JOB No: 13 - Piston and Piston Rods - Remove and Re-fit . . . . . . 5-36

JOB No: 14 - Oil Filter - Remove and Re-fit . . . . . . . . . . . . 5-38JOB No: 15 - Oil Pressure Relief Valve - Adjustment . . . . . . . . 5-39

JOB No: 16 - Lubricating Oil Pump and Drive - Inspect and Overhaul . . 5-40

JOB No: 17 - Intercooler - Inspection and Overhaul . . . . . . . . 5-41

5.4 Lists of Tools . . . . . . . . . . . . . . . . 5-42

5.5 Waste Products . . . . . . . . . . . . . . 5-43

Chapter 6 - Spare Parts

6.1 Spare Parts . . . . . . . . . . . . . . . . 6-2

6.2 Ordering Spares and Spares Stock . . . . . . . . 6-2

6.3 Spares List . . . . . . . . . . . . . . . . 6-2

6.4 Drawings . . . . . . . . . . . . . . . . . 6-4


7/113


Chapter 1 - Technical Data and Description


8/113


1.1 Data and 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 Gardner Denver Belliss & Morcomon matters relating to the

compressor always quote the compressor type and serial number (e.g.WH29H3N Serial No.

C00xxxx).

1 - 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

Part 2.


9/113


1.2 Technical Data

a ) Operating Data

Table 1-1: Operating Data

Compressor

Model WH29H3N

Number of Stages 3

Inlet Pressure Atmospheric

Cylinder Type Double Acting - Non Lubricated

Direction of Rotation Clockwise looking on the flywheel

Metric Imperial

Flow 1700 m3/hr 1003 ft3/min

Stage Pressures

Stage 1 2.0 - 2.4 bar.g 29 - 35 lb/in2

Stage 2 9.8 - 10.4 bar.g 142 - 151 lb/in2

Delivery 45.0 bar.g 650 lb/in2


10/113


Maximum Pressure 10 bar.g 145.04 lb/in2

Cooling

Design Ambient 0 - 40 oC 32 - 104 oF

Cooling Water Flow **383 l/min

84.3 UKgal/min

USgal/min

Cooling Water Pressure 4 - 7 bar.g 58 - 102 lb/in2

Water Pressure Drop bar.g lb/in2

Water Temperature Rise 8 oC 14 oF

Compressor Body

Radiated HeatkW hp

Motor

Motor Rated Power 321 kW 430 hp

Absorbed Power at Full

LoadkW hp

Absorbed Power at Half

LoadkW hp

Absorbed Power at No

LoadkW hp

F ll L d C t A A

Table 1-1: Operating Data (Continued)


11/113


c ) Mechanical Data

Table 1-2: Piston and Cylinder Data

Piston Data Metric Imperial

Piston Stroke 165.10 mm 6.5 in

Stage 1 Cylinder Line

Cylinder Bore 444.55444.50

mm 17.50217.500

in

Diametrical Clearance -

Piston Body in Cyl. Bore4.80 - 5.05 mm

0.189

0.199in

Piston Ring

Radial Thickness 15.89 - 15.73 mm 0.626 - 0.619 in

Axial Clearance in

Groove0.31 - 0.40 mm 0.012 - 0.016 in

Gap at ring Butt joint 13.8 - 14.3 mm 0.543 - 0.563 in

Bearer Ring

Diametrical Clearance in

C li d b 4 70 4 86 0 185 0 191 i


12/113


Axial Clearance in

Groove0.30 - 0.40 mm 0.012 - 0.016 in

Gap at ring Butt joint 8.10 - 8.60 mm 0.32 - 0.33 in

Bearer Ring

Diametrical Clearance in

Cylinder bore

0.55 - 0.80 mm 0.022 - 0.031 in

Radial Thickness 6.46 - 6.51 mm 0.254 - 0.256 in

Axial Clearance in

Groove0.26 - 0.41 mm 0.010 - 0.016 in

Standout from piston

body1.72 - 1.92 mm 0.068 - 0.076 in

Gap at joint N/A mm N/A in

Bumping Clearance

Piston Top to Top Cover 2.61 - 3.12 mm 0.103 - 0.123 in

Piston Bottom to Cyl. 1.74 - 2.08 mm 0.068 - 0.082 in

Stage 3 Cylinder Line

Table 1-2: Piston and Cylinder Data (Continued)


13/113


d ) 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.

Bumping Clearance

Piston Top to Top Cover 3.30 - 3.78 mm 0.130 - 0.149 in

Piston Bottom to Cyl. 2.20 - 2.52 mm 0.087 - 0.099 in

Table 1-3: Crankase Component Clearances

Metric Imperial

Crankshaft Bearings

(radial clearance)0.06 - 0.11 mm 0.002 - 0.004 in

Connecting Rod Bottom

End Bearing

New 0.10 - 0.15 mm 0.004 - 0.006 in

Maximum 0.20 mm 0.008 in

Table 1-2: Piston and Cylinder Data (Continued)


14/113


Differential Pressure (between unload and reload trips): = *1.0 BarG (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 MUSTonly be performed by competent, authorised persons.

e ) Tightening Torques (Dry Threads)

Table 1-5: Pressure switch settings for Load Control System (40 bar.g delivery)

Pressure Switch 1 (PS1)*40.0 BarG. (unload trip)

*38.0 BarG. (reload trip)

Pressure Switch 2 (PS2)*39.0 BarG. (unload trip)

*37.0 BarG. (reload trip)

CAUTION!

OVER-TIGHTENING OF THE FASTENERS CAN LEAD TO

DAMAGE TO THE FASTENERS AND/OR THE COMPONENTS.


15/113


1.3 Technical Description of the Compressor

a ) 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.

b ) Compressor Identification

Inlet/Outlet Flange M20 128 - 140

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

Crankshaft Lock-nut M160 1750

Table 1-6: Component tightening Torques (Continued)


16/113


Illustration 1-1 : External View of WH29H3N Compressor

Inlet Filterand Silencer

1st Stage Cylinder

Distance PieceAccess Cover

Delivery Vessel Intercooler

Separator

Main Guide Access

2nd StageCylinder

3rd StageCylinder

Intercooler


17/113


d ) Crankcase and Lower Motion Work

1 - 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.

2 - Crankshaft

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 bearing housing) 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.


18/113


5 - Crossheads

The crossheads operate inside the main guides. The guides are bolted to the inner flange ofthe crankcase cylinder mounting, and are located top and bottom in the crankcase casting.

Bosses for the gudgeon pin are formed in the walls of the crosshead, and the crown has adrilled boss, internally threaded to take the piston rod. A transverse tapped drilling houses thelocating pin. The case hardened gudgeon pin is retained in position by two circlips housed ingrooves machined in the bosses.

e ) Cylinders, Pistons and Piston Rod Packings

1 - Cylinders

The double-jacketed cylinders are cast complete with mounting base, lower valve chambersand 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 andoutlets. The inner jacket of the cylinder is for the cooling water, the outer jacket is divided intosuction and delivery air chambers.

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

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

Cooling is provided by passing water first through the compressor intercoolers, and then, via a


19/113


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 rodby 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.

f ) 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 correctvalve chamber.

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

The valve assemblies are held in their seats by valve cages. The cages have 'O' ringsrecessed into their upper circumference to prevent leakage of air. The first and second valve

covers have an additional 'O' ring seal between them and their cages. The valve covers arethe 'raised face' type.

To unload a working compressor. the suction valves are rendered inoperative by the valveplates 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 itsrim, assembled with a spring-loaded central guide surmounted by a cylindrical cap. Thefingers operate through slots in the suction valve seat directly onto the valve plate.


20/113


h ) Motor and Couplings

The compressor can be supplied with a direct drive, overhung flange mounted motor, or a foot

mounted motor with a direct in-line drive through a flexible coupling, or indirect drive through a

vee belt pulley wheel.

When a flange mounted motor is used, the rotor is keyed directly onto the crankshaft and the

stator casing is bolted to the crankcase. For a flexible coupling drive, a flywheel is keyed on to

the crankshaft, and for a vee belt drive the heavy crankshaft mounted pulley provides the

flywheel effect.

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.

i ) 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).


21/113

WH29H3N


22/113


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 regulations 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 personal protective equipment (PPE) when operating or maintaining

this equipment. PPE should include, but not limited to:-

Ear Defenders

Safety Glasses.

Industrial Boots.

Safety Headwear

Appropriate Hand Protection (gloves and/or barrier cream).

Any other safety item identified under Risk or COSHH Assessments.

Loose fitting or frayed/ripped clothing MUST NOTbe worn while operating or maintaining this

equipment.

WH29H3N


23/113


Operation is carried out in accordance with the relevant environmental and operating

regulations.

c ) 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 thewritten 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.

d ) General Safety Precautions for Compressors

Electrical System -Before performing work on the electrical system the compressor and the

peripheral devices must be isolated from the mains and secured against accidental switch-on.

Work on the electrical system must only be carried out by qualified staff who are aware of the

risk involved with the task. All electrical work must be carried out in accordance with local laws

relating to electrical working.

Pressure Relief Valves - These MUST be Full Compressor Capacity relief valves


24/113

WH29H3N


25/113


h. Always refer to the applicable procedure when undertaking maintenance and overhaul

procedures.i. Bolts and nuts must not be under or over tightened, see appropriate torque values

(Refer to c Tightening Torques (Dry Threads) on page 1-8)

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

k. DO NOTplace the electrical isolating switch to the 'ON' position until all work has beencompleted by all personel working on the equipment. The site supervisor must inspectand approve the work carried out before re-connecting the equipment to the electrical

supply.l. Before starting the compressor, bar over the machine by hand where possible to ensure

free rotation and that no metallic 'knocking' noise is evident. If any solid resistance torotation is found, investigate the cause.

WH29H3N


26/113


WH29H3N


27/113


Chapter 3 - Installation and Commissioning


28/113

WH29H3N


29/113


c ) 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.

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

WARNING!

THE FLOOR MUST BE LEVEL AND FLAT.

WH29H3N


30/113


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.

2 - 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.

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 pipeworkleading 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

WH29H3N


31/113


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.

5 - Load Control Piping

Connect (with similar size piping) the load control system on the compressor to the control airtake-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.

6 - Drain Valves & Drain Valve PipingIt 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 NOTbe 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.

WH29H3N


32/113


Except for compressors made to special customer requirements, water pressure in the jackets

should not exceed 7 Bar g.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.

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!

FAILURE OF WATER FLOW IS A CAUSE OF MAJOR DAMAGE

AND MUST BE AVOIDED. ENSURE THAT COOLING WATERPIPES TO AND FROM THE COMPRESSOR ARE CONSTRUCTED

TO AVOID THE FORMATION OF AIR LOCK

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.

WH29H3N


33/113


total r.m.s. voltage between live conductors for the sum of the sixth through to the thirtieth

harmonic is permissible.Voltage imbalance -Neither the voltage of the negative sequence component nor the voltage

of the zero sequence component shall exceed 2% of the positive sequence component.

Voltage interruption -Supply interrupted or at zero voltage for not more than 3 s at any

random time in the supply cycle. There shall be more than 1 s between successive

interruptions.

Voltage dips -Voltage dips shall not exceed 20% of the peak voltage of the supply for more

than one cycle. There shall be more than 1 s between successive dips.

h ) Motor Starters

1 - Motor Protection Equipment

The following has been prepared to describe the minimum protection requirements for

shaftless motors used on the compressor.

Protection of the motor should consist of as a minimum the following : -

1. Thermal motor overload by monitoring motor current

2. Motor overheating using PTC thermistor probes

3. Phase imbalance

4. Phase failure

WH29H3N


34/113

PET Compressor

All motor starting equipment should be rated for AC3 motor starting duties and be selected in

accordance with the motor rating information provided. All equipment should conform to thelatest ISO standards.

All thermal overload motor protection relays must be set at the phase current. (rated current of

the motor divided by 1.732).

i ) Drive Motor

The motor used to drive the compressor must comply with the following specification :

1 -Application

Motors should be designed, manufactured and tested in accordance with the following

standards:-BS

EN 60034 - Rotating electrical machines

BS 4999 - General requirements for rotating electrical machines

BS EN 50347 - General purpose three phase induction motors

The motors will be used to drive high pressure three (3) stage reciprocating compressors

which will provide air to expand PET pre-forms into bottles and containers. The compressor is

of a "W" configuration with its cylinders mounted radially on the compressor crankcase. The

design of the motor should take into account the irregular turning effort required for this

application, it should also take into account the requirement for it to overhang the rotor


35/113

WH29H3N


36/113

PET Compressor

Terminations -The stator winding connections shall be brought out to a terminal box to be

mounted in a 60 degree position on the right hand side of the frame looking towards thecompressor. The terminal box shall be large enough to provide adequate spacing of the motor

leads and allow easy connection of the starter cables. Starter cables will be either multicore or

single cables. Multicore cables would be 1 x 3 core 400 m2 x LPE/SWA/PVC plus 1 x 4 core

400 m2 XLPE/SWA/PVC (one core for earth). Single cables would be 6 x 300 m 2 single XLPE/

PVC cables plus one earth. Connections shall be adequately spaced apart and sharp corners

should be avoided. Non-ferrous gland plates shall be provided. Clearances between phases

and ground shall be to IEC 60034 standards.

Testing -The motor rotor and stator assemblies shall be manufactured so that the air gap

varies no more than plus or minus ten (10) per cent of nominal in all radial directions.

Performance testing in accordance with BS4999 Pt 143 shall be carried out using a dummy

shaft for the rotor on a dedicated test rig to ensure compliance with specifications. Test

reports shall be certified, one copy of which shall be faxed to Quality Department, Gardner

Denver Belliss & Morcom on completion of test, two other copies shall be sent with the motor.

3.3 Handling and Unpacking

a ) 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

WH29H3N


37/113

PET Compressor

Compressor Slinging Diagram (Typical)

WH29H3NPET C


38/113

PET Compressor

c ) Lifting Instructions

Because the type of lifting equipment for each installation will be different the followinginstructions 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.:

i. Establish the actual weight of the load.

ii. Check whether the lift will be a straight lift, or will an angle rig be needed. Thesefactors will affect the lifting capacity required.

iii. The slings must be free of kinks, knots, broken strands or loose connections etc,and meet the regulation requirements.

iv. Check the clearance available to make sure the lift can be attempted safely.

v. To prevent damage to the machine's finish or the edges of the machine fromcutting into the slings, use proper blocking and padding.

2. When involved in the lifting of heavy loads, we suggest you protect yourself by wearingapproved protective gear such as: safety helmets, steel toe cap safety shoes, gloves,eye protection, etc.

3. Prepare the installation area before moving the machine.

4. Refer to the machine installation drawings and note the location of the machine supportpoints. Review all machine installation requirements carefully before positioning themachine.

WH29H3NPET C


39/113

PET Compressor

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

DO NOTapply load tension to the slings if the compressor is held to the floor.

b ) 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 holdingdown bolt holes in the anti-vibration mounting plate.

4. Remove the compressor and attached mounts and drill the floor for appropriate sizeholes 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 diameterto the holes in the mounting plate. Use of these will eliminate the need to move thecompressor to drill the floor holes. The appropriate instructions supplied with the boltsshould be followed precisely.

6. Finally, check the bolts holding the compressor onto the anti-vibration mountings and


40/113



41/113

PET Compressor

20. Fill slowly and carefully (to avoid trapping air) in the cooling water spaces of thecompressor - 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 inassociation with any other water-cooled ancillary items in the overall cooling watersystem of the installation.

c ) 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.

d ) Motor Rotation Check

CAUTION!

BEFORE USING THE INSULATION TESTER DISCONNECT THE

SUPPLY LEADS AT THE MOTOR TERMINALS SO THAT ONLYTHE MOTOR WINDINGS ARE TESTED. THIS WILL AVOID THE

POSSIBILITY OF THE TEST INSTRUMENT POTENTIAL

DESTROYING ANY ELECTRONIC EQUIPMENT THAT MAY BE IN

ANCILLARY CIRCUITS.



42/113

PET Compressor

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 oilpressure is quickly established (this will be high with a cold machine) and observecompressor 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 andguides. This should be done using a thermometer fitted with a suitable surface probe.

All should be cool except the bottom end bearings, which can be a little warmer thanother bearings - also one side (the 'working face' side) of main guides may be slightlywarmer than the opposite side.

7. Refit the crankcase main doors and reconnect the compressor.

8. Run the compressor for a further 10 minutes and repeat checks as in step 6.

9. When satisfied that all is in order, restart the compressor. When the compressor hassettled on speed place the load control to the load condition whereupon the compressorwill commence compressing

WARNING!

TAKE CARE DURING EXAMINATION, AS SOME OF THE

PARTS WILL HAVE BECOME HEATED.


43/113



44/113

PET Compressor

Chapter 4 - Operating Instructions



45/113

PET Compressor

These instructions are designed to providing experienced operatives, who are fully conversant

with compressor operating techniques, with operational information for the Gardner Denver

Belliss & Morcom 'PET'range compressors.

The compressor is designed and built for continuous running and will provide long term

reliable operation if regular periodic checks and servicing are carried out in accordance with

the information provided within Chapter 5of this Instruction Manual.

NOTE: THE FOLLOWING OPERATING INFORMATION ASSUMES

THAT THE COMPRESSOR IS FITTED WITH A STANDARD

GARDNER DENVER BELLISS & MORCOM CONTROL SYSTEM.

HOWEVER, IF THE CONTROL EQUIPMENT IS OF DIFFERENT

MANUFACTURE, THE COMPRESSOR MUST BE OPERATED IN

ACCORDANCE WITH THE SUPPLEMENTARY OPERATINGINFORMATIONSUPPLIED WITH THE CONTROL SYSTEM.

CAUTION!PROLONGED UNLOADED RUNNING OF THE MACHINE

SHOULD BE AVOIDED NOT ONLY BECAUSE OF POWER

WASTAGE, BUT UNNECESSARY COMPONENT WEAR CAN

RESULT.



46/113

p

b ) Load Control System Functions

All of the suction valves in the compressor have actuators, which cause the valve plate to beheld off its seat whenever a pneumatic signal is applied. When the plate is held open no

compression can take place. If all suction valves are held open then the compressor is 'OFF

LOAD'. On removal of the pneumatic signal the plate returns to its seat and compression can

then recommence. The unloader is pushed back by the valve plate springs and the unloader

return spring. If only the upper set of suction valves are held open then the compressor is on

'HALF LOAD'.

Three-Step Load Control means that the compressor is either on:-1. FULL LOAD(compression taking place) - all suction valves being in service

or

2. HALF LOAD (compression taking place in bottom half of cylinder only) - lower set ofsuction valves only in service. or

3. OFF LOAD(no compression taking place) - all suction valves being held open.

4.2 Preparation for Starting

NOTE: THE FOLLOWING OPERATING INFORMATION ASSUMES

THAT THE COMPRESSOR IS FITTED WITH A STANDARD

GARDNER DENVER BELLISS & MORCOM CONTROL SYSTEM.

HOWEVER, IF THE CONTROL EQUIPMENT IS OF DIFFERENT



47/113

p

9. Ensure that the main air-isolating valve is OPEN.

4.3 Starting the Compressor

a ) Under Normal Conditions

Refer to the control panel manual for details of starting and operation.

b ) After An Emergency Stop

Rectify fault condition and restart.

4.4 Running

a ) Running Checks

1. Allow the compressor to run up to full speed and then close the small drain cocks.

2. Check the oil pressure. This will fall initially as the oil temperature rises, but shouldsteady at between 3.0 to 4.0 BarG even in a hot environment.

3. Check the cooling water is flowing at the visible outlet or flow indicator. On multi-compressor installations balance the flows in the parallel systems of the compressors(i l di i t l ) t i l t t t i b th id ll 11C



48/113

b ) Emergency Stopping

Pressing the 'EMERGENCY STOP' mushroom button stops the machine instantly in whatevermode of operation it is operating.

4.6 Fault Indications

The following is a list of indications of possible faults which could arise in service; periodic

surveillance of pressures and temperatures, etc, will establish the normally experienced levels

applicable to the site and load conditions.

Variation from these due to a fault arising may be slow to occur - the early effect of a fault (with

the robust reciprocating type machine) being, usually very gradual. It is IMPORTANT

therefore, to retain a simple daily record sheet of pressures and temperatures. Comparison

with previous readings will then warn if there is an untoward trend arising - when reference to

the following fault indication's list will indicate the probable cause and remedial action to take.

A copy of a typical log sheet is provided in the Appendices located at the end of this manual.

CAUTION!

THIS IS NOT RECOMMENDED FOR ROUTINE STOPPING AND

SHOULD ONLY BE USED IN THE CASE OF AN EMERGENCY

WHERE NORMAL STOPPING IS NOT POSSIBLE.



49/113

Low first stage delivery

pressure (high first stage

air delivery temperature).

1. Fouling of inlet filter. Renew filter elements.

2. Leaking or broken delivery valve

plate in first stage.Replace valve plate - examine seat for

damage.

3. Worn, broken or malfunctioning

piston rings in first stage.Renew rings - clean grooves.

High first stage delivery

pressure (normal or high

first stage delivery

temperature).

1. Leaking or broken suction valveplate in second stage.

Replace valve plate - examine seat fordamage.

2. Second stage suction valve

depressor sticking in "off-load"

position.

Examine, clean, and refit valve plate

depressor, also examine valve for

damage.


piston rings in third or second stage

cylinders.

Renew rings - clean grooves.

High first stage air

delivery temperature after

cooler.

1. Cooling water flow through first

stage intercooler restricted or

ceased by blockage.

Examine and clean intercooler tubes

(both on air and water sides).

First stage delivery


plate in second stage.Replace valve plate -examine seat for

damage.


piston rings in third stageRenew rings - clean grooves.

Table 4-1: Fault Finding

Fault Possible Cause Remedial Action



50/113

Second stage delivery

pressure relief valve

blowing.

1. Leaking or broken suction valve or

delivery valve plate in third stage.Replace valve plate examine seat for

damage.

2. Third stage suction valve depressor

sticking in "off-load" position.Remove, clean and refit depressor, also

examine valve for damage.

3. Second stage intercooler tubes

blocked on air side.Examine and clean air side of intercooler

tubes.

4. Relief valve defective. Repair or replace valve.

Low third stage delivery

pressure.

1. Demand of end using equipment

has overtaken capacity of

compressor.

If none of the previous faults are present,

i.e. compressor running normally, no

remedial action possible.

When demand reduces, the pressure will

rise to normal level (as set by the load

controller).

2. Low setting of load controller. Adjust to required pressure.

3. Malfunction of load controller. Repair/replace pressure controller.


plate in third stage.Replace valve plate examine seat for

damage.

2. Leaking or broken suction valve

plate in third stageReplace valve plate examine seat for

damage





51/113

High final air temperature

from aftercooler.

1. Cooling water flow through

aftercooler is restricted or ceased

by maladjustment of hand valves.

Check and adjust hand valve openings.

2. Aftercooler tubes partially blocked

on airside, or waterside of tubes is

fouled.

Examine and clean air and water sides of

tubes.

Low lubricating oil

pressure.

1. Crankcase oil level is low. Check oil level, add oil as required.

2. Air leakage into suction side of

pumping system.Check oil level. Check connecting unions

on suction pipe to pump.

3. Partially blocked oil pump suction

strainer in crankcase.Remove, clean and refit.

4. Oil relief valve set too low or valve

sticking open.Remove, check and reset.

5. Failure or wear of big end or small

end bearings.Renew bearing(s). Check crankshaft for

damage.

6. Partially blocked oil pump delivery

filter element.Replace element.

1. Compressor rotation incorrect (first

trial run, or after a rebuild).Change compressor rotation and

recheck.





52/113

NOTE:WATER EMITTED FROM THE TRAPS IS USUALLY IN THE

FORM OF A TRICKLE (INTERMITTENT OR STEADY) -

DEPENDING ON THE HUMIDITY OF THE AIR TAKEN IN BY THE

COMPRESSOR - OR NIL IN THE CASE OF VERY DRY

ATMOSPHERIC CONDITIONS.



53/113

Chapter 5 - Compressor Maintenance



54/113

5.1 Preventive Maintenance

This schedule of maintenance, in general terms, is a preventive maintenance guide andrunning service necessary for our range of reciprocating compressors. However, it does not

cover for any eventualities, which could occur from neglect or incorrect operation by the

customer or adverse environmental conditions.

Before carrying out any preventive maintenance work related to this equipment it is a

requirement that you read and work in accordance with the Safety Precautions given in

Chapter 2 - Safety Informationof this Instruction Manual. Also, for your own protection, be

sure to read and obey WARNINGand CAUTIONnotices and observe any special notes you

find in this Chapter and any associated literature.

When working on the compressors rotational parts you MUSTfit piston rod clamps to prevent

possible uncontrolled movement of the crankshaft and motion work. Refer to Maintenance

Procedure JOB No: 2 - Fit Piston Rod Clamps (page 5-10).

On plants with two or more compressors the opportunity should be taken during the early

weeks of running, following commissioning, to vary the service hours of the compressors so

that no two machines reach their maintenance interval at the same time. A gap of about 200hours between machine running times is recommended.

When 'running-in' a new compressor the crankcase oil MUSTbe renewed after the first 500

hours of operation and thereafter change in accordance with the intervals laid down in the

following maintenance schedule.

a ) Maintenance Schedule

http://../WH35H3N/WH35H3Nchap2.pdfhttp://../WH35H3N/WH35H3Nchap2.pdf


55/113

b ) Each Day or Shift

A shutdown of the compressor is not normally required for a Shift inspection.

Any aspect of the Shift inspection requiring further attention MUSTbe reported for action as

required.

c ) Monthly Inspection

Tasks Supplementary InformationCheck all temperature and pressure gauge

readings are normal.Report immediately any abnormality.

Check operation of moisture trap drains.Moisture shoud be regularly draining from the base of

the drain trap.

Check for undue noise, oil leakage, vibration

or heat.Report immediately any abnormality.

Ensure that load control equipment isoperating correctly.

Check that the compressor loads and unloads inresponse to demand by the air supply system.

Test protection circuits annunciator lamps.

All lamps MUSTilluminate

The 'Test' push-button is normally located on the

compressor control panel. If a lamp fails, renew the

bulb. If the new bulb does not illuminate report failure to

the Supervisor.

Check the crankcase oil level. Oil level

should be halfway up the window nut.

Use the breather aperture in the top of the crankcase to

top-up the oil. Refer to the table of lubricants for oil

type.

Where vee belts are fitted check tension

and adjust if necessary.

Refer to drive belt manufacturers instructions for details

of tensioning



56/113

d ) Six Monthly Service

The compressor is required to be shutdown for two days to perform this service schedule.Tasks Supplementary Information

Carry out a running examination to ensure

satisfactory operation of all compressor and ancillary

equipment.

Record all temperatures, pressures and hours run on

compressor log sheet. A copy of this form is provided in

Appendices located at the end of this manual. Check

cooling water flow rate (If flow recorder is fitted).

Check the cleanliness and ensure correct operation

of drain traps on compressor and ancillary

equipment where applicable.

Strip and clean drains and renew worn or damaged

parts, as required.

Check all external bolts and nuts on the compressor

including the holding down nuts for tightness.

Re-tighten or renew any missing nuts and bolts. Tighten

nuts to appropriate torque.

Visually examine (through the valve pockets) the

general surface condition of cylinder bores for

evidence of ring wear or scoring.

Replace worn or damaged parts, as required

Check valve unloaders, actuators & interconnecting

small bore pipework for defects.

Clean and service as necessary. Replace worn or

damaged parts as required.

Examine piston rods along gland travel to ensure no

scoring is present.

Clean and service as necessary. Renew worn or


Check that inlet filter is clean Clean and service as necessary.

Check that inter and aftercooler moisture drains are

operational and that the diffusers on the blowdown

valves are clear and clean..

Clean and service as necessary

Check one suction and one delivery valve from each

stage for cleanliness or fouling.





57/113

e ) Annual Service - (or as stipulated by local regulations)

The compressor is required to be shutdown for five days to perform this service schedule. AllSix Monthly tasks are to be undertaken as part of this schedule.

A t f th A l i i i f th tt ti MUST b t d f ti

Tasks Supplementary Information

Remove all air valves and replace with factory

refurbished units.

Where possible use factory re-conditioned valve units.

Where this is not possible. all valves re-conditioned on

site must be leak tested before re-fitting.

Renew crankcase oil and delivery filter element. Refer to table of lubricants for oil type and quantity.

Inspect connecting rod bottom end shells, crankpin,

top end bearing and gudgeon pin. Check motion work

clearances.



Withdraw pistons and piston rods and examine wear.

Gauge cylinder bores and piston rods for wear and

record readings.

Renew piston rings, piston rod packings, and piston rod

scrapers.

Check condition of water jacket spacers for fouling

from lime deposits.Report condition.

Check cleanliness of motor ventilation fan and that air

flow paths are clean. Carry out an insulation

resistance check on motor windings and record

readings.



Check all system protection devices and circuits for

correct operation.

Use a calibrated test rig to test the protection devices.

Alternatively the devices can be tested by simulation of

fault conditions at the machine.



58/113

5.2 Approved Lubricants

Lubricant Supplementary InformationCrankcase Oil Recommended Lubricant SAE 30 oil (ISO VG 100)

(Ambient temperature 0oC to 45oC)

Approved Brands:-

BP Vanellus M30

Esso Essolube HDX 30

Mobil Delvac 1330

Shell Rimula X30

Alternatively:- The oil MUST be a good quality mineral oil having a flash point

(open test) of not less than 210oC and within a viscosity range (Centistokes) of

110 at 40oC to 12.5 at 100oC, the oil should also contain rust and oxidation

inhibitors and anti-foam additives.

If the site is particularly hot (over 45oC) then use an SAE 40 oil (ISO VG 150).

Consult with Gardner Denver Belliss & Morcom for advice on the correct oil for

use in high ambient temperature locations.



59/113

5.3 Maintenance Instructions

The following procedures are intended for the use of the technician responsible for themaintenance of the compressor. It is essential that any necessary adjustments, servicing or

overhaul work should only be carried out by competent persons who are familiar with the

compressor installation and who have the appropriate authority (Permit to Work). To avoid

possible warranty invalidation the following instructions should be read before attempting to

maintain the machine.

WARNING !

WHEN WORKING ON COMPRESSOR ROTATIONAL PARTS YOU

MUST FIT PISTON ROD CLAMPS TO PREVENT POSSIBLE

UNCONTROLLED MOVEMENT OF THE CRANKSHAFT AND

MOTION WORK. THIS COULD RESULT IN INJURY OR LOSS OF

LIFE.

REFER TO JOB NO. 002



60/113

JOB No: 1 - Crankcase Oil Change

1. Isolate mains power and display appropriate warning signs.

2. Remove the crankcase doors, taking care not to damage the oil seals.

3. Wipe any excess oil off the doors using an industrial cleaning fluid and a lint free cloth.Place the cover in a clean location to avoid oil contamination when refitting.

4. Empty the oil sump using suitable equipment and clean out the crankcase sump (usinga lint-free cloth to avoid fouling of the oil strainer)

List of Special Tools

27mm (1-1/16) Spanner (no more than 10 mm thick) 1

List of Consumables

Crankcase Oil (see page 5-6 for reccommended oils) A/R

Industrial cleaning fluid (White Spirit) & lint free cloth A/R

WARNING!

TO AVOID SCALDING FROM HOT OIL, ALLOW THE

COMPRESSOR TO COOL DOWN BEFORE BEGINNING WORK.



61/113

Illustration 5-1 : Lubrication System

Oil Cooler

Oil SuctionHose

Cooling WaterInlet

Oil Pump

Oil Filter

Lub. Oil to CoolerDelivery pipe

Lub. Oil to CoolerReturn Pipe

Oil LevelSight Glass

Cooling WaterOutlet

Lub. Oil PressureBy-pass Pipe

Lub. Oil PressureRelief Valve



62/113

JOB No: 2 - Fit Piston Rod Clamps

1. Before starting this operation, carry out the following safety steps :

i. Isolate mains power and display appropriate warning signs.

ii. Ensure that all pressure is vented from the compressor.

iii. Carefully open the vent valves on the third stage cylinder to check de-pressurisinghas been completed successfully.

iv. Ensure that the compressor is isolated from the delivery system and that thecompressor is positively isolated from the delivery non-return valve.

v. Vent air pressure from the unloader system.

vi. Post signs instructing personnel that the machine MUST NOTbe used.

2. Remove the distance piece access covers from the line of motion works NOTbeingworked on. Wipe any excess oil off the covers using an industrial cleaning fluid and a lintfree cloth. Place the cover in a clean location to avoid oil contamination.

3. Mark the position of the oil shedder on the piston rod and remove shedder.

4 Loosely assemble the piston rod clamps onto the piston rod

LIST OF SPECIAL TOOLS

Piston Rod Clamps 1 set

LIST OF CONSUMABLES




63/113

JOB No: 3 - Cylinder Top Covers - Remove and Re-fit

a ) To Remove








2. Isolate and drain the cooling water from the compressor cylinders.


Lifting Eye-Bolt 1 set

Slings, Lifting Equipment A/R

LIST OF CONSUMABLES




64/113

4. Attach a suitable sling to the eye-bolts, and using suitable overhead lifting equipment,raise and position the top cover over the cylinder.

5. Slowly lower and guide the top cover onto the cylinder, ensuring the correct positioningof the cooling water and gas pockets.

6. When in position, remove the sling and lightly secure the top cover to the cylinder withthe fixing nuts.

7. Tighten the cylinder cover nuts (centre nuts first), tighten the nuts down evenly andprogressively. Nuts to be torque tightened to the appropriate torque figure. Refer toChapter 1 Section 1.1.3.

8. Remove the eye-bolts from the top cover and refit all pipes.

9. Secure the supply lines to the cylinder top cover with their fasteners.

10. Re-establish water and electrical supplies to the compressor.

11. Bleed off any trapped air in the cooling system using the plugs in the cylinder waterjacket.

12. Test run the compressor on clean, dry air or nitrogen and check for correct operationand freedom from leaks around any of the disturbed gaskets.



65/113

JOB No: 4 - Piston rings - Remove and Re-fit

a ) To Remove

To remove the piston rings, the piston assembly must be first removed from the cylinder.

Piston removal procedure is detailed as part of Job No.013 Piston Rod - Remove/Refit.

b ) Examination

Piston Pressure Rings- For piston pressure ring dimensions refer to Chapter 1 Technical

Data. The pressure rings MUSTbe replaced with new ones when the radial thickness at any

point has worn to 65% or less of the original thickness.

Piston Bearer Rings- For piston bearer ring dimensions refer to Chapter 1 Technical Data.

The bearer rings MUSTbe replaced by new ones, when the standout at any point has worn to

0.5mm or less.


Piston-rod Bullet 1 set

LIST OF CONSUMABLES



66/113



67/113

Illustration 5-3 : Piston Assembly 1stStage

Illustration 5-4 : Piston assembly 2nd Stage



68/113

Illustration 5-5 : Piston Assembly 3rd Stage



69/113

JOB No: 5 - Piston/Cylinder End (Bumping) Clearances

There are two ways of measuring the piston Top-Dead-Centre (TDC) clearance: Method 1is

used when the cylinder top covers are removed and Method 2is by removing the valves and

checking the clearance through the valve pockets. The Bottom-Dead-Centre (BDC) clearance

is checked using Method 2.

The third stage cylinder line can only be checked using Method 2.

Illustration 5-6 : Piston features

LIST OF CONSUMABLESSealing Gasket (between 0.8mm - 1.0mm thick) A/R




70/113

a ) Method 1

1. Remove the cylinder top cover refer to Job No.003.

2. Place a sealing gasket of between 0.8mm - 1.0mm on to the cylinder mating face.

3. Place the machined straight-edge across the top of the gasket on the cylinder.

4. Bar over the compressor to place the piston exactly at TDC.

5. Measure the clearance between the straight edge and the piston crown. Ensure that thestraight edge is held firmly against the gasket when measuring clearance. record thewith a feeler (thickness) gauge. The required clearances are detailed (See CrankaseComponent Clearances on page 1-7.)If the clearances are out side of the tolerance

band the clearance MUSTbe adjusted (see later in this procedure).

b ) Method 2

1. Remove either a suction or delivery valve from a top cylinder pocket (if measuring TDCclearance) or a bottom cylinder pocket (if measuring BDC clearance).

2. With the piston exactly at TDC or BDC, insert a feeler gauge through the valve pocketand measure the clearance. Record the end ("bumping") clearances with the piston at

the top (Top-Dead-Centre) and bottom (Bottom-Dead-Centre) of its stroke. Theclearances are detailed in . If the clearances are outside of the tolerance band theclearance MUSTbe adjusted (see later in this procedure).

CAUTION

FEELER GAUGES MUST NOT BE INSERTED INTO THE VALVE

POCKET WHILST TURNING THE MACHINE OVER BECAUSE IF

http://../WH35H3N/WH35H3Nchap1.pdfhttp://../WH35H3N/WH35H3Nchap1.pdfhttp://../WH35H3N/WH35H3Nchap1.pdfhttp://../WH35H3N/WH35H3Nchap1.pdf


71/113

8. Recheck that the piston rod slots are correctly aligned for clearance of the piston rodsecuring pin.

9. Fit a new locking plate to the securing pin before fitting and fully tighten the pin.10. Bend over the locking plate tab to prevent the securing pin from rotating.

11. Inspect the crosshead access cover gasket. Renew if necessary.

12. Refit the access cover.



72/113

JOB No: 6 - Packing Gland Assembly - Remove and Re-fit

Due to their construction, these packing glands can only be satisfactorily examined and

repaired when they are removed from the compressor and disassembled on a suitable

workbench.








a ) To Remove Packing Wearing parts

1. Fit piston rod clamps to prevent possible uncontrolled movement of the crankshaft andmotion works. Refer to Job No:2 (Page 5-10)

2 Mark the position of the oil shedder on the rod surface and remove shedder with its two

LIST OF CONSUMABLESIndustrial cleaning fluid (White Spirit) & lint free cloth A/R



73/113

b ) To Refit Packing Assemblies

If the piston rod is out of the compressor, the gland can be assembled on the work-bench,

then fitted into place as a finished unit. If the rod is in place, the rings and their springs are

assembled around the rod by working through the distance piece apertures.

1. Check the piston rod surface for wearing or any sign of scoring. If evidence of wearingor scoring is heavy the piston rod should be replaced.

2. Assemble each ring onto the piston rod with its garter spring.

3. Fit the rings as pairs into their respective containers (ensure peg is pointing upwards).

4. Slide each container assembly up the piston rod in turn, finally clamping the completedgland assembly with the tie rod nuts.Refit and tighten the packing nuts and secure thegland assembly to the cylinder bottom.

5. Refit the oil shedder to the piston rod in the position marked during removal and securewith its clamping screws.

6. Remove piston rod clamps.

7. Inspect the crosshead access cover gasket. Renew if necessary.

CAUTION!

THE RINGS AND GLANDS REFITTED COMPLETELY WITHOUT

OIL (THE COMPRESSOR BEING AN OIL-FREE CYLINDER

MACHINE) - ON NO ACCOUNT INTRODUCE OIL OR GREASE

INTO THE GLAND. IF REFITTING "USED" RINGS FIRST ENSURE

THAT THERE IS NO DIRT OR GRIT EMBEDDED



74/113

Illustration 5-7 : Stage Gland Packing

Packing Gland in position

Packing Gland tie nuts

Securing Nuts

1st and 2nd Stage Packing Assembly



75/113

JOB No: 7 - PACKING GLAND ASSEMBLY - OVERHAUL

Due to their construction, these packing glands can only be satisfactorily examined and

repaired when they are removed from the compressor and disassembled on a suitable

workbench.

a ) To Disassemble

1. Remove the nuts from the small diameter gland tie studs and separate and disassemblethe containers. As each container ring is lifted off the assembly, take meticulous care ofthe precision ground and lapped faces between the containers and the plates.

2. Observe carefully that the ring containers and the plates between them are staggeredsequentially, with number 1 being the top container ring.

3 Observe that the tie studs are unequally spaced to ensure the correct orientation of the


Wear Check Tool 1

Thread Guard Cap 1

LIST OF CONSUMABLES




76/113

c ) To Reassemble

Scrupulous cleanliness of all parts is required on assembly, particularly of the lapped faces

between the containers and plates.

1. Identify and layout the gland components in sequential order in preparation forreassembly.

2. Place piston rod/piston assembly onto a clean work-bench resting on the piston crownwith the piston rod pointing upwards so that the rod can be used as an assembly tool.

3. Thoroughly clean the rod surface and fit the thread guard cap to the rod end.

4. Thread the packing gland cover plate over the piston rod to rest on the piston.

5. Locate the lowest ring pair of the packing assembly onto the flange cover recess, firstthe ring with the peg pointing upwards, then the ring with the hole located over the peg.

6. Locate the tie studs (temporarily removed from the top container) in the holes in thecover to align subsequent containers.

7. Fit the 'O' rings into the grooves around around each tie stud. Great care must be takennot to knock or disturb these during later stages of assembly.

8. Progressively build up the gland assembly in the correct numbered sequence of theplates and containers refitting packing rings and O rings in their correct positions asnoted during dismantling.

9. When the top container ring is reached, very carefully withdraw the tie studs taking greatcare not to shake the assembly.

10. Firmly screw the tie studs back into their original positions in the top gland ring.

11. Carefully thread the tie rods back through the gland assembly until the top gland ringrests squarely onto the top container.

12 Whil t l i th bl fi l t t ti di l t f 'O' i



77/113

JOB No: 8 - Piston Rod Oil-Shedder - Remove and Re-fit

The piston rod oil shedder is clamped in halves to the piston rod by socket head screws. The

shedder is fitted so as to run clear of the packing gland and the scraper gland covers. If the

shedder becomes damaged renew as follows:

The oil shedder should only be fitted onto the piston rod when both the oil scraper gland and

packing gland are fully fitted in place.

Illustration 5-8 : Piston-rod Oil Shedder in situ.


Oil Shedder



78/113

b ) To Refit

1. Place the piston in BDC position and assemble the shedder onto the piston rod with thehollowed side placed downwards.

2. Position the shedder 2.5mm above the top face of the scraper gland and lightly butfirmly tighten the two screws.

3. Turn over the compressor to ensure that the oil shedder does not foul either the upperpacking gland or the lower scraper gland.

4. When adjustment is satisfactory, fully tighten the shedder clamping screws.

5. Refit the access cover to the cylinder distance piece.

6. Two small diameter washers of the required thickness placed either side on top of thescraper gland are helpful in setting the shedder position - remove the washersimmediately afterwards.



79/113

JOB No: 9 - Oil Scraper Gland - Remove and Re-fit

The support housings of the scraper glands fit directly on to the top of the guide for the

crossheads









Wear Check Tool 1

LIST OF CONSUMABLES




80/113

2. Lift the plate and slide the upper pair of scrapers up the rod.

3. Unhook the garter springs and remove the scraper ring segments.

4. Re-assemble and carefully store each ring of segments immediately upon removal.5. The segments are marked relative to each other, the lower ring pair having a peg and

locating hole arrangement for correct re-assembly. The rings can be re-used dependingupon condition.

6. Lift the container and slide the lower pair of scrapers up the rod.

7. Re-assemble and carefully store each ring of segments immediately upon removal.

b ) Oil Scraper Gland - Inspection

1. The oil scraper rings are checked for wear by re-assembly, with garter spring, squarelyaround the piston rod, or on the wear check tool and examining the butt clearances inthe case of ring W1 and W2.

2. When parts are new the butts of W1 and W2 are each 0.8mm (0.032") wide.

3. Discard the rings and their sealing rings when the butts reduce to 0.12mm (0.005") eachor a total of 0.36mm (0.015") or less, and replace with a new pair.

4. The segments of the sealing ring have angle cut contact faces - there are no buttclearances.

c ) To Refit

1. Ensure that the correct relationship is maintained between the rings.

2 There are oil drain slots cast in the bottom of the housing Should the housing need to



81/113

JOB No: 10 - Suction and Delivery Valves - Remove and Re-fit


i. Isolate mains power. Lock all isolators in the Off position and / or remove allfuses. Display appropriate warning signs.

ii. Ensure that all pressurised compartments are vented down to atmosphericpressure and that all pressure gauges read zero. Pressure venting must becarried out as slowly as possible in order to prevent freezing of the valve orpossible personnel injury.

iii. Ensure that the final delivery pipework vent valve has had its plug removed and isfully opened. Ensure that all pressure is dissipated and that the valve is left in anopen unplugged condition until all work is completed.

iv. Carefully open the vent valves on the third stage cylinder to check de-pressurisinghas been completed successfully.

v. Ensure that the compressor is isolated from the delivery system and that thecompressor is positively isolated from the delivery non-return valve.

vi. Vent air pressure from the unloader system.

vii. Post signs instructing personnel that the machine MUST NOTbe used.

LIST OF CONSUMABLES


Grinding Paste A/R



82/113

b ) To Refit

1. Ensure that there are no bruises or burrs on the valve seat or pocket seat. A lightgrinding-in operation may be needed, it is important to ensure that no grinding pasteenters the cylinder and that all is clean after completion.

2. The diametric clearance between the valve seat and the seating in the cylinder is small,therefore the valve has to be fitted very carefully to ensure that it fits squarely on to itsseat. It is essential that the valve is squarely fitted on its seat and metal to metal contactestablished.

3. Check that 'O' rings are in good condition and that their associate grooves are clean

before final assembly of valve cover/cage. Renew if necessary.4. Refit the valve cage and the valve cover.

5. Refit the cover securing bolts and tighten evenly and squarely to the correct torque

6. On third stage cylinder ensure that the locknut, castle-nut and split pin are correctly re-fitted

CAUTION!SERIOUS DAMAGE COULD RESULT FROM SUCTION VALVES

AND THEIR ASSOCIATED COMPONENTS, BEING FITTED IN

DELIVERY VALVE POCKETS OR VICE-VERSA. THEREFORE,

ENSURE VALVES ARE CORRECTLY IDENTIFIED WITH THEIR

POCKETS.

CAUTION!



83/113

Illustration 5-10 : 1st Stage Delivery Valve (Typical)



84/113

JOB No: 11 - Suction and Delivery Valves - Overhaul

Gardner Denver Belliss & Morcom are able to offer a valve exchange service, whereby re-

furbished valves are supplied in exchange for valves returned by customers. The refurbished

valves supplied by Gardner Denver Belliss & Morcom are factory reconditioned and all parts

are guaranteed . Use of this service may be more cost effective than stripping and cleaning

valves on customers own site. Please contact Gardner Denver Belliss & Morcom service

department for details.

a ) To Remove

1. Remove the suction delivery valve in accordance with JOB No: 10 -Suction andDelivery Valves - Remove and Re-fit on page 5-29

b ) To Inspect

LIST OF SPECIAL TOOLSValve Holding Tool 1

LIST OF CONSUMABLES




85/113

c ) To Overhaul

1. The valves have locating pins, which ensure that the various components are correctlyrelated radially. The pins are of differing diameters which ensures that the valve seat,valve plate, valve damper plates, and valve guard are correctly fitted, one to the other.

2. If new locating pins are fitted to an old seat it is essential that they are of the correct

sizes and positioned exactly as on original valve seats, with correct standout heightabove the valve seat top surface.

3. Lift Washers - when not of identical thickness - should be fitted with the thinner one nextto the valve seat (this thinner one is referred to as the lower lift washer).

4. Conical type springs are fitted with the large diameter end located in the holes in thevalve guard.

5 Torque the centre bolt nut to the correct value (see Chapter 1 - Technical Data and

CAUTION!CARE MUST BE TAKEN WHEN REASSEMBLING OVERHAULED

VALVE COMPONENTS. THE COMPONENTS MUST BE

ASSEMBLED CORRECTLY. AN INCORRECTLY ASSEMBLED

VALVE WILL QUICKLY DETERIORATE IN SERVICE AND

CONSEQUENTLY MAY DAMAGE OTHER PARTS OR AFFECT

THE COMPRESSOR PERFORMANCE. PARTICULAR CARE

MUST BE TAKEN WHEN ASSEMBLING VALVES TO ENSURETHAT THE SPRINGS REMAIN CORRECTLY IN THEIR

LOCATIONS.

http://../WH35H3N/WH35H3Nchap1.pdfhttp://../WH35H3N/WH35H3Nchap1.pdf


86/113

JOB No: 12 - Suction Valve Unloader Actuators - Remove and Refit








a ) To Remove

1. Disconnect the control air pipe from the actuator and cap open ends.

2. Remove the end fittings from the actuators and store carefully.

3. Slacken locknut and screw actuator out of top cover. Place the actuator onto a cleanwork surface.



8 U i th d l/ d d th t t ( i t th ti f th i dl t


87/113

8. Using the dowel/rod depress the actuator (against the action of the spindle returnspring) until it just contacts the unloader, but do not depress it.

9. While holding the dowel/rod in position, mark it accurately again in line with the actuatorcover plate top. Then release the dowel/rod (it will rise under the action of the actuatorspindle return spring).

10. Remove the dowel/rod and measure the distance between the marks. If it is NOTbetween 1.4mm and 1.6mm then adjust the actuator position, by screwing it in or, out ofthe cover plate, as required.

11. When the gap is set correctly, tighten the locknut to the correct torque.

12. When all the actuators on the compressor are correctly set, fit the end fittings to theactuators; reconnect the control air pipework to the actuators and to the associated ventvale and test the compressor for correct operation.


JOB N 13 Pi t d Pi t R d R d R fit


88/113

JOB No: 13 - Piston and Piston Rods - Remove and Re-fit








a ) To Remove

1. Remove the cylinder top cover as described in Chapter 5 - Cylinder Top Covers -Remove and Re-fit.

2. Remove the crosshead access cover and gasket from the crankcase.

3. Bar over the crankshaft to reveal the crosshead locknut and the piston rod securing pin.



Note : The piston nut is assembled using a very high torque Following


89/113

Note : The piston nut is assembled using a very high torque. Following

a number of hours service, the piston nut may seize in position.

If this is the case, it will be necessary to carefully drill and split

the piston nut. On re-assembly a new piston nut will be required.

7. Slacken the crosshead locknut.

8. Unscrew the piston rod from the crosshead - the loosened locknut should be held by aspanner to be unscrewed off the rod end simultaneously, and removed as the rod iswithdrawn.

9. Fit a lifting eye to the M12 tapping in the end of the piston rod. (In some cases, thistapping may be plugged)

10. Using suitable lifting equipment, carefully withdraw the piston and rod assembly fromthe cylinder.

11. If the packing gland is to be reused, great care must be taken as the threaded portion ofthe rod is lifted through the packing gland. If possible fit the piston rod thread protector.See illustration below.

b ) To Refit

Prior to refitting the piston rod, examine the rod. If it is found to be worn (evenly or tapered) or

scored then renew as necessary.

Illustration 5-12 : Fitting the Piston-rod thread guard (Bullet)


5 Refit the piston as described in JOB No: 4 Piston rings Remove and Re fit (page 5


90/113

5. Refit the piston as described in JOB No: 4 - Piston rings - Remove and Re-fit (page 5-13).

6. Check the piston bumping clearances as described in JOB No: 5 - Piston/Cylinder End(Bumping) Clearances (page 5-17).

7. Turn the compressor over a couple of times to ensure satisfactory operation.


JOB No: 14 Oil Filter Remove and Re fit


91/113

JOB No: 14 - Oil Filter - Remove and Re-fit

a ) To Remove

1. To open the filter body undo the bottom bolt (using a clean bucket to catch spilled oil),

the filter body and element draw off vertically downwards.2. Discard the old element and clean out the body.

3. When replacing the assembly (with a new filter pack) care should be taken that the sealring gasket at the to

Manual IOM Wh29H3N

Documents

Transcript of Manual IOM Wh29H3N