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KIRLOSKAR KC4 User Manual

KIRLOSKAR KC4
58 pages
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Kirloskar KC Series Refrigeration Compressors
Instruction and
Operation Manual
Versions:
Single Stage : KC2, KC3, KC4, KC6, KC9, KC12
Two Stage : KC21, KC31, KC42, KC51, KC63, KC72, KC84,
KC93 & KC102
KIRLOSKAR
KIRLOSKAR PNEUMATIC CO. LTD.
Kirloskar Refrigeration
INDIAN REGISTER
©
OF SHIPPING 1993
MGMT. SYS.
RvA C 071
ISO 9001 : 2000

Questions and Answers:

KIRLOSKAR KC4 Specifications

General IconGeneral
BrandKIRLOSKAR
ModelKC4
CategoryAir Compressor
LanguageEnglish

Summary

Safety Guidelines

Do's and Do Not's

Essential guidelines for safe operation, maintenance, and handling of the compressor.

Handling and Storage

Lifting and Handling Guidelines

Proper planning and precautions for lifting and handling the compressor to avoid damage.

Lifting Slings and Shackles Selection Guideline

Guideline for selecting appropriate lifting slings and shackles for material handling.

Compressor Preservation

Pre-Operation Checks and Procedures

Startup Checks and Priming

Checks and priming procedures before starting the compressor and during initial runs.

Compressor Operation and Loading

Guidelines for compressor operation and cylinder loading for single and two-stage units.

Mandatory Maintenance Schedule

Schedule for oil, filter, and strainer checks after initial run and subsequent periods.

Technical Data and Overall Dimensions

Constructional Details

Compressor Component Details

Safety Valve Function

Details on the safety valve, its function, and the importance of its proper operation.

General Operating Instructions

Compressor Operation

Detailed steps for operating the compressor, including no-load starting and bringing cylinders on load.

Liquid Stroke Hazards

Explanation of liquid stroke, its potential for damage, and protective devices.

Safety Rules: Ammonia

Precautions related to ammonia handling, storage, and potential health hazards.

Operation Procedures and Safety

Safety Rules: Freon

Safety precautions for Freon, including its characteristics and leak detection.

Plant Operation Procedures

Leak Test Procedure

Method for testing the plant's soundness using gas pressure, typically air or nitrogen.

Evacuation for Freon Plants

Detailed steps for evacuating Freon systems using a compressor and vacuum pump.

Evacuation for Ammonia Plants

Procedure for evacuating ammonia plants using only the compressor.

System Charging and Purging

Refrigerant Charging

Steps for charging the system with refrigerant after leak testing and evacuation.

Compressor Starting Procedure

Step-by-step guide for starting the compressor, including initial oil pickup and operation.

Capacity Control System: Single Stage

Part Load Operation Limits: Single Stage

Advisories on operating single-stage compressors at minimum capacity steps and discharge temperature limits.

Operating Instructions and Capacity Control: Two Stage

Starting Two Stage Compressors

Careful procedure for starting and loading two-stage compressors to avoid temperature/pressure issues.

Two Stage Operation Steps

Sequence of operations for starting and increasing capacity, considering evaporation and condensing temperatures.

Capacity Control Limits and Examples

Limits of Operation

Guidelines on using capacity control steps for pull-down and minimum load requirements.

Determining Capacity Control Limits

Methodology for determining minimum capacity steps for reduced heat loads and avoiding operational issues.

Parallel Operation of Compressors

Periodical Maintenance and Schedule

Periodic Inspection and Component Maintenance

Guidelines for periodic inspection and maintenance of valves, piston rings, and bearings.

Compressor Maintenance Procedures

Lubrication Instructions

Importance of lubrication records, oil renewal, topping up procedures, and oil pressure checks.

Maintenance Schedule

Accessories and Controls

Pressure Switches (Pressostats)

Function and importance of pressure switches for safety and operational control.

Oil Pressure Differential Pressostat

Protection provided by the oil pressure differential pressostat against low oil pressure.

Trouble Shooting Chart

Pressure Issues (Suction/Discharge)

Troubleshooting high/low suction and discharge pressure issues.

Oil System Issues

Troubleshooting high/low oil pressure and high oil consumption.

Operational and Mechanical Issues

Troubleshooting liquid stroke, pressure difference, loading/unloading malfunctions.

Safety Valve and Shaft Seal Issues

Troubleshooting warm HP safety valve side and shaft seal leakage.

Recommended Spares

Illustrated Spare Parts List

Stop Valve Assembly and Pressure Components

Precautions to Prevent Failures

Source of Entry for Failures

Identification of common sources of system dirt that cause compressor failures.

Prevention of System Dirt Entry

Methods to avoid dirt entry, including flushing systems and using cloth bags in strainers.

Compressor Prevention Measures

Steps to take before first start and during initial runs to prevent compressor damage.

Restart Procedures and Precautions

Guidelines for restarting the compressor, using new oil, and checking pressure settings.

Important Installation Checks

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