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JGP
Ariel JGP User Manual
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F
IGURE
2-5 P
ACKING
L
UBRICATION
A
ND
V
ENTING
F
OR
M
ODELS
: JGI, JGM, JGN, JGP
AND
JGQ
S
ECTION
2 - I
NSTALLATION
PAGE 2-14
9/08
Primary V
ent/Drain
Packing Lubrication
O-Ring Seal
Lubricating
Oil
Gas and Oil
Gas
Purge Gas
(Optional)
Secondary
V
ent
Optional Purge
Gas Connection
Section A-A
Section A-A
Piston Rod
Seal Gasket
45
47
Table of Contents
Default Chapter
5
Default Chapter
5
Table of Contents
5
Design Specifications & Data
12
Specifications
13
Opposed Throw - Reciprocating Weight Balancing
15
Product Information and Safety Plates
16
Important Safety & Data Information
17
Clearances
20
Piston Ring and Packing Ring Side Clearance, Inches (MM)
21
Fastener Tightening Torque
25
Tightening Torque Procedures
29
Ariel Bolting
31
Zone 1 Environment
31
Installation
33
The Skid or Package
33
Lifting the Compressor
33
Setting the Compressor
34
Leveling Limits for Compressors
35
Aligning Main Bearing Bores
35
Alignment - to Driver
38
Electrical Grounding
43
Pneumatically Actuated Unloaders & Clearance Devices
43
Vents and Drains
43
BICERA Type Crankcase Over-Pressure Relief Valves
44
Start up
47
General
47
Start up Check List
47
Warranty Notification - Installation List Data and Start up Check Lists for JG:A:M:N:P:Q:R:J:H:E:K:T:C:D Reciprocating Compressors
48
Maximum Allowable Working Pressure
56
Relief Valve Settings
57
Filling Sump & Priming a Main Oil Lube Oil System - before Starting
57
Filling the Sump
57
Priming - Main Lube Oil System
58
Compressor Prelube
58
Force Feed Lubricator Adjustment
58
Compressor Re-Application
58
Lubrication
59
General
59
Lubrication Functions
59
Lubricant Characteristics
60
Viscosity
60
Flash Point
61
Pour Point
61
Viscosity Index
61
Lubricant Base Stock
61
Petroleum-Based Lubricants (also Referred to as Mineral Oils)
61
Synthetic Lubricants
62
Lubricant Formulations
63
Compounded Cylinder Oils
63
Engine Oil
63
R&O Oil
63
Gear Oil
64
Used Engine Oil
64
Frame Oil System
65
Components
65
Oil Cooler
65
Oil Pump
65
Oil Strainer
65
Oil Filtration
66
Oil Temperature Control Valve
66
Compressor Prelube Pump
67
Oil Heaters
67
Lube Oil Analysis Sampling Point
68
Cold Starting
69
Dry Sump
70
Frame Oil Operating Conditions
71
Compressor Frame Lubricant
71
Oil Pressure
72
Oil Temperature
72
Oil Viscosity
72
Oil Maintenance
73
Oil Sampling
73
Oil System Cleanliness
73
Cylinder and Packing Lubrication
75
Common Oil Supply
75
Independent Force Feed Lubricator Systems
75
Independent Oil Supply
76
Force Feed Lubrication System Components
76
Gas Inlet Debris Screens to Maintain Lube Performance
76
Cylinder Oil Lubrication Examples
77
Injection Oil Inlet Filter
77
Oil Dilution
77
Under/Over Lube
77
Inadequate Lubrication Symptoms
78
Lubrication Quantity - Paper Test Method
78
Lubricator Cycle Time
78
Cycle Time Indication
79
Devices
79
Force Feed Lubrication System Monitoring
79
Minimum Requirements
79
Choosing a Lube System Monitor
80
Break-In Rate
83
Liquids in Gas
83
Lube Type & Rate Recommendations
84
Rate Calculation Notes
86
Water-Cooled Packing
88
Coolant System Requirements
89
Force Feed Lubrication System - Description
89
Blow-Out Fittings, Rupture Disks and Tubing
90
Force Feed Lubricator Adjustment
90
Description
92
Divider Valves
92
Divider Valve Block Assembly Instructions
93
Operation - (See Figure 4-13 and Figure 4-14)
93
Pressure Testing for Divider Valve By-Passing
96
Electronic Lubricator Fluid-Flow Monitor/No-Flow Timer Switch - Proflo PF1
97
Proflo PF1 Monitor Wiring Identification and Instructions for Electronic Indication
98
Downloading Proflo PF1 Data
99
Proflo PF1 Button Operation
99
Proflo PF1 Setup Alarm Time and Mode
100
Proflo PF1 Battery Replacement
101
Proflo PF1 Display Errors
102
Proflo PF1 Operation Notes
103
Proflo Normally Open and Normally Closed Definition
104
Proflo PF1 - Using Pulse Output and Alarm Circuit at same Time
105
Proflo PF1 - Using PLC to Calculate Oil Consumption
106
Electronic-Lubricator Digital No-Flow Timer Switch (DNFT)
107
Proflo PF1 Accessories Available
107
Protection of Electronics & the Compressor When Arc Welding
107
Replacing the (Field-Replaceable) Battery in the DNFT
108
Force Feed Lubrication System
109
Force Feed Lubrication System and Running Conditions
109
Oil Head at Lube Points
109
Force Feed Balance Valves
110
Running Conditions
110
Setting and Maintaining Balance Valves
110
System Design Considerations and Operating Parameters
110
Checking/Adjusting Balance Valves on Subsequent Start-Up
111
Frame Lubricating System - Description
112
Lube Oil Strainer
112
Lube Oil Strainer, Filter & Filter Installation Instructions
112
Lube Oil Filter
113
Oil Filter Element Installation for Cartridge Type Filters
113
Oil Filter Installation for Spin-On Type Filters
113
Description & Adjustment
115
Lube Oil Pressure Regulating Valve
115
Lube Oil Pump & Lube Oil Pressure
115
Low Oil Pressure Shutdown
116
General Introduction
117
Compressor Components
119
Maintenance
117
Positioning a Throw for Maintenance
119
Connecting Rod
120
Connecting Rod (Crank Pin) Bearing
120
Connecting Rod - Removal
122
Connecting Rod Bushing Replacement
123
Connecting Rod - Installation
124
Crosshead
127
Crosshead - Removal
127
Crosshead - Installation
129
Crankshaft
130
Main Bearings - Checking Clearances
130
Crankshaft - Removal
133
Oil Slinger - Removal
134
Oil Slinger - Installation
134
Chain Sprocket - Removal
134
Chain Sprocket - Installation
135
Fan Shaft Assembly Procedure
135
Main Bearings - Removal and Installation W/Crankshaft Removed
136
Main Bearings - Removal and Installation W/Crankshaft in Place
137
Crankshaft - Installation
138
Chain Drive System
139
Description
139
Chain Adjustment
140
Chain and Sprocket Replacement
140
Chain Idler Sprocket Replacement - (Eccentric Adjustment Cap)
141
Lube Oil Pump Chain Sprocket Replacement
141
Force Feed Lubricator Chain Sprocket Replacement
142
Piston and Rod
143
Piston and Rod - Removal
143
Piston and Rod Disassembly
144
Piston and Rod Reassembly
145
Piston and Rod - Installation
146
Piston Rod Run out
147
Piston Rings
148
Determining Ring Wear
148
Removal
148
Piston Rings - Installation
148
Wear Bands
148
Determining Wear Band Wear
149
Wear Band - Installation
149
Piston Rod Pressure Packing - Removal
149
Piston Rod Packing - Reassembly
150
Types of Piston Rod Packing Rings
151
Type "P" Pressure Breaker
151
Type "BTR" Single Acting Seal Set
152
Type "AL" Double Acting Seal Set
152
Type "BD" Double Acting Seal Set
152
Type "3RWS" Oil Wiper Set
153
Typical Arrangement of Piston Rod Packing Rings
153
Piston Rod Packing Ring Material
153
Water-Cooled Piston Rod Packing
154
Reassembly
154
Testing
154
Valves
155
Valves - Removal
155
Valves - Maintenance
156
Valves - Reassembly
157
Bolt Tightening for Valve Caps
158
VVCP - Head-End Variable Volume Clearance Pocket
159
VVCP - Disassembly
160
VVCP - Removal
160
VVCP - Adjustment
161
VVCP - Maintenance
161
Compressor Cylinder Re-Boring & Bore Restoration Guidelines
162
Ethylene Glycol Contamination
163
Technical Assistance
165
Recommended Maintenance Intervals
165
Daily
165
Monthly (in Addition to Daily Requirements)
166
Every 6 Months or 4000 Hours (Plus Daily/Monthly)
167
Yearly or 8000 Hours (Plus Daily/Monthly/6 Months)
167
Every 2 Years or 16,000 Hours (Plus Daily/Monthly/6 Months/Yearly)
168
Every 4 Years or 32,000 Hours (Plus Daily/Monthly/6 Months/1 & 2 Years)
168
Every 6 Years or 48,000 Hours (Plus Daily/Monthly/6 Months/1, 2 & 4 Years)
169
Trouble Shooting
169
Appendices
171
Ariel Tools
171
Ariel Furnished Tools
171
Ariel Tools - Purchased Separately from Authorized Dealer
173
Minimum Hand & Commercial Tools Required
173
Gas Analysis Common Abbreviations
177
Technical and Service Schools on Ariel Compressors
177
Ariel Customer Technical Bulletins
178
Vendor Literature
178
Ariel Contact Information
178
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Ariel JGP Specifications
General
Brand
Ariel
Model
JGP
Category
Air Compressor
Language
English
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