Hycomp Ambient - Initial Startup and Operation (Air Boosters and Gas Compressors)

37
should be monitored at least once every 6-8 hours.
After two days of operation, check the belt tension, oil
level and inspect for leaks.
On new and newly rebuilt units, the valve hold-down
screws, valve cover bolts and cylinder head bolts must
be re-torqued after 8 and 36 hours of running time.
Also check all mounting bolts, fl ywheel bolts, etc. The
standard two day check period should be used after this
initial run-time. Units run in extreme environments and
air temperature ranges may require special attention.
Expansion and contraction of parts due to the unit
warming up from lower temperatures may cause bolts
and screws to loosen at an accelerated rate.
INITIAL STARTUP AND
OPERATION (AIR BOOSTERS AND
GAS COMPRESSORS)
Air Boosters - these are compressors that compress
air that is taken from a source other than the ambient
air. Generally the inlet air source is at an elevated
pressure, but vacuum applications can also be
accomplished The inlet air is usually taken from
customer’s existing plant air system.
Gas Compressors - These are compressors pumping
any gas other than air.
All air boosters and gas compressors are broken in
and tested at the factory prior to shipment. In most
cases, it is not necessary to perform any special
start-up procedures on a new unit. Occasionally it
may need an extended amount of ‘break-in’ time to
seat the piston rings and create proper wear patterns.
Units that have been in storage for an extended
length of time may require special attention. Refer to
sections in this manual on Inspection After Extended
Storate, and Compressor Storage, or contact the local
representative or the factory.
With the pre-start-up checklist completed and satisfi ed,
turn the compressor on briefl y (1-2 seconds) to check
the direction of rotation. Be sure it agrees with the
rotation arrow embossed on the compressor sheave
(counterclockwise when viewed from the fl ywheel side
of the compressor). If the compressor is not turning in
the proper direction, it will not achieve oil pressure and
will shut down. Fix the problem before re-starting.
Start the compressor. Watch and listen for excessive
vibration and strange noises. If either exist, stop the
compressor immediately.
Watch the oil pressure gauge to be sure the oil
pressure is adequate. Oil pressure should rise to
working pressure within 10-15 seconds. If there is a
question about oil pressure, stop the compressor and
investigate. Refer to the Section titled “Maintenance
and Troubleshooting” for assistance if operation is not
normal.
Check the pressure gauges or system pressure
gauges for proper readings. If inadequate or excessive
pressure conditions occur shutdown the compressor.
Design conditions must be met before the compressor
will operate properly
Observe the compressor operation closely for the fi rst
hour of operation and then frequently (every 1/2 hour)
for the next seven hours. As the compressor reaches
normal operating conditions, temperature distortion
may cause changes in the operating parameters,
excessive vibration or previously unnoticed noises.
THIS IS NOT NORMAL. Shutdown the compressor
and investigate the problem.
After the fi rst eight hours of operation, the compressor
should be monitored at least once every 6-8 hours.
After two days of operation, check the belt tension, oil
level and inspect for leaks.
Test each shutdown device, unloader device, dump
valve and safety valve. Record the actual setpoints
and adjust as necessary.
On new and newly rebuilt units, the valve hold-down
screws, valve cover bolts and cylinder head bolts must
be re-torqued after 8 and 36 hours of running time.
Also check all mounting bolts, fl ywheel bolts, etc. The
standard two day check period should be used after this
initial run-time. Units run in extreme environments and
air temperature ranges may require special attention.
Expansion and contraction of parts due to the unit
warming up from lower temperatures may cause bolts
and screws to loosen at an accelerated rate.
Gas packings require a period of run-time to seat in, as
do piston rings depending upon running conditions. All
Hycomp compressors have been tested at the factory
for a minimum of four hours, but more time may be
needed to fully break in the packings and rings into their
wear patterns. When gas packings are pressurized
under static (unloaded/idle) conditions there will be an
audible minor leakage sound.
At initial start-up, and any time after replacement of
the packings and/or rings, the compressor must be
closely monitored for leakage past the packings. If
leakage occurs in amounts beyond safe limits, then the
compressor must be broken in with a gas that can be
released to the local atmosphere like air, or nitrogen if
it acceptable to release it locally.
If a break-in period is required, the compressor must