Corken 91, 491, 291, F91, F291 Installation, Operation & Maintenance Manual

...

ORIGINAL INSTRUCTIONS IE101K

Installation, Operation & Maintenance Manual

Plain Style Compressors for Liquid Transfer-Vapor Recovery

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. (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.

Mo de l 4 91-107

Solutions beyond products...

Warning

Install, use and maintain this equipment according to Corken’s instructions and all applicable federal, state, local laws and codes. Periodic inspection and maintenance is essential.

Corken One Year Warranty

CORKEN, INC. warrants that its products will be free from defects in material and workmanship for a period of one year from date of installation, provided that the warranty shall not extend beyond twenty-four (24) months from the date of shipment from CORKEN. If a warranty dispute occurs, the DISTRIBUTOR may be required to provide CORKEN with proof of date of sale. The minimum requirement would be a copy of the DISTRIBUTOR’S invoice to the customer.

CORKEN products which fail within the warrant period due to defects in material or workmanship will be repaired or replaced at CORKEN’s option, when returned, freight prepaid to CORKEN, INC., 3805 N.W. 36th St., Oklahoma City, Oklahoma 73112.

Parts subject to wear or abuse, such as mechanical seals, blades, piston rings, valves and packing, and other parts showing signs of abuse, neglect or failure to be properly maintained 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 the 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. Experienced, trained personnel in compliance with governmental and industrial safety standards should handle such substances.

Important notes relating to the European Union (EU) Machinery Directive

Pumps delivered without electric motors are not considered as machines in the EU Machinery Directive. These pumps will be delivered with a Declaration of Incorporation. The fabricator of the machinery must assure and declare full compliance with this Directive before the machine in which the pump will be incorporated, or of which it is a part, is put into service.

Contacting the Factory

Before you contact the factory, note the model number and serial number of your pump. The serial number directs us to a file containing all information on material specifications and test data applying to your specific pump. When ordering parts, the Corken service manual or Operations, Installation and Maintenance (IOM) manual should be consulted for the proper part numbers. ALWAYS INCLUDE THE MODEL NUMBER AND SERIAL NUMBER WHEN ORDERING PARTS.

The model and serial numbers are shown on the nameplate of the unit. Record this information for future reference.

Model No.

Serial No.

Date Purchased

Date Installed

Purchased From

Installed By

Table of Contents

Chapter 1—Introduction ........................................................................4

1.1 Liquid Transfer By Vapor Differential Pressure ...................................................5

1.2 Residual Vapor Recovery ....................................................................5

1.3 Compressor Construction Features ...........................................................6

Chapter 2—Installing Your Corken Compressor ....................................................8

2.1 Location .................................................................................8

2.2 Foundation ...............................................................................8

2.3 Piping ...................................................................................8

2.4 Liquid Traps .............................................................................11

2.5 Driver Installation / Flywheels ...............................................................12

2.6. Crankcase Lubrication ....................................................................12

2.7 Relief Valves .............................................................................14

2.8 Truck Mounted Compressors ...............................................................15

2.9 Shutdown/Alarm Devices ...................................................................15

Chapter 3—Starting Up Your Corken Compressor .................................................16

3.1 Inspection After Extended Storage ...........................................................16

3.2 Flywheel and V-belt Alignment ..............................................................16

3.3 Crankcase Oil Pressure Adjustment ..........................................................16

3.4 Startup Check List ........................................................................17

Chapter 4—Routine Maintenance Chart .........................................................18

Chapter 5—Routine Service and Repair Procedures ...............................................18

5.1 V alve s ..................................................................................18

5.2 Heads ..................................................................................20

5.3 Piston Rings and Piston Ring Expanders ......................................................20

5.4 Pistons .................................................................................21

5.5 Piston Rod Packing Adjustment .............................................................22

5.6 Cylinder and Packing Replacement ..........................................................22

5.7 Bearing Replacement for Crankcase and Connecting Rod ........................................25

5.7.1 Wrist Pin Bushing Replacement ..........................................................25

5.7.2 Replacing Connecting Rod Bearings ......................................................25

5.7.3 Replacing Crankcase Roller Bearings .....................................................25

5.8 Oil Pump Inspection ......................................................................26

Chapter 6—Extended Storage Procedures .......................................................27

6.1 Repair Kits ..............................................................................27

6.2 Gasket Sets .............................................................................28

Appendices

A. Model Number Identification Code and Available Options ..........................................30

B. Specifications ............................................................................32

C. Compressor Selection ......................................................................38

D. Outline Dimensions ........................................................................42

E. Parts Details .............................................................................58

Model 91 and F91 .........................................................................58

Model 291 and F291 .......................................................................66

Model 491 and F491 .......................................................................74

Model 691 and F691 .......................................................................82

Model D891 and FD891 ....................................................................90

F. Troubleshooting ...........................................................................98

Chapter 1—Introduction

Connections:

Available in threaded NPT or Class 300 RF flanges.

High-efficiency valves:

Valves are quiet and highly durable. Special suction valves tolerating small amounts of condensate are available.

O-ring seals:

Easy to install O-ring seals head and cylinder.

Ductile iron construction:

Cylinder and head are made of ductile iron for maximum thermal shock endurance.

Self-lubricating PTFE piston rings:

State-of-the-art piston ring designs to provide the most cost-effective operation of compressors for non-lube service. The step-cut design provides higher efficiencies during the entire life of the piston ring.

Positively locked piston:

Simple piston design allows end clearance to be precisely set to provide maximum efficiency and long life.

Piston rod seals:

Seals constructed of PTFE incorporating special fillers to maximize leakage control. Spring loaded seal design self adjusts to compensate for normal wear.

Nitrotec ®1 coated piston rods:

Impregnated nitride coating provides superior corrosion and wear resistance.

Cast-iron crosshead:

Durable cast-iron crossheads provide superior resistance to corrosion and galling.

Pressure-lubricated crankcase with filter:

Self-reversing oil pump ensures proper lubrication regardless of directional rotation to main and connecting rod bearings. Standard 10-micron filter ensures long-lasting bearing life (not available on Model 91).

Registered trademark of TTI Group Ltd.

Construction Details—Model F291 Compressor

1.1 Liquid Transfer By Vapor Differential Pressure

Corken LPG/NH3 compressors are designed to transfer liquefied gases such as butane/propane mixtures (liquefied petroleum gas or LPG) and Anhydrous Ammonia (NH3) from one tank to another. Liquefied gases such as LPG and NH3 are stored in closed containers where both the liquid and vapor phases are present.

Figure 1.1A: Typical nameplate

(also serves as the packing adjusting screw cover)

There is a piping connection between the vapor sections of the storage tank and the tank being unloaded, and there is a similar connection between the liquid sections of the two tanks. If the connections are opened, the liquid will seek its own level and then flow will stop; however, by creating a pressure in the tank being unloaded which is high enough to overcome pipe friction and any static elevation difference between the tanks, all the liquid will be forced into the storage tank (see figure 1.1B). The

gas compressor accomplishes this by withdrawing vapors from the storage tank, compressing them and then discharging into the tank being unloaded. This procedure slightly decreases the storage tank pressure and increases the pressure in the other tank, thereby causing the liquid to flow.

The process of compressing the gas also increases the temperature, which aids in increasing the pressure in the tank being unloaded.

1.2 Residual Vapor Recovery

The principle of residual vapor recovery is just the opposite of liquid transfer. After the liquid has been transferred, the four-way control valve (or alternate valve manifolding) is reversed so that the vapors are drawn from the tank just unloaded and discharged into the receiving tank. Always discharge the recovered vapors into the liquid section of the receiving tank. This will allow the hot, compressed vapors to condense, preventing an undesirable increase in tank pressure (see figure 1.2A).

Residual vapor recovery is an essential part of the value of a compressor. There is an economical limit to the amount of vapors that should be recovered, however.

When the cost of operation equals the price of the product being recovered, the operation should be stopped. For most cases in LP-Gas and Anhydrous Ammonia services, this point is reached in the summer when the compressor inlet pressure is 40 to 50 psig

Compressor increases pressure in tank car by adding vapor

Pressure difference between tanks causes liquid to flow out of the tank car into the storage tank

Four Way Valve Position 1

Vapor Line

Compressor reduces pressure in storage tank by removing vapor

Liquid Line

Figure 1.1B: Liquid transfer by vapor differential pressure.

Vapor Line

Liquid line is valved closed during vapor recovery.

Removing vapor from tank causes liquid heel to boil into vapor

Four Way Valve Position 2

Liquid Line

Figure 1.2A: Residual vapor recovery.

(3.8 to 4.5 bars). A good rule of thumb is not to operate beyond the point at which the inlet pressure is onefourth the discharge pressure. Some liquids are so expensive that further recovery may be profitable, but care should be taken that the ratio of absolute discharge pressure to absolute inlet pressure never exceeds 7 to

1. Further excavation of very high value products would require a Corken two-stage gas compressor.

Vapor Line

Vapor is bubbled through liquid to help cool and recondense it

Invariably, there is some liquid remaining in the tank after the liquid transfer operation. This liquid “heel” must be vaporized before it can be recovered, so do not expect the pressure to drop immediately. Actually, more vapor will be recovered during the first few minutes while this liquid is being vaporized than during the same period of time later in the operation. Remember that more than half of the economically recoverable product is usually recovered during the first hour of operation on properly sized equipment.

1.3 Compressor Construction Features

The Corken liquid transfer-vapor recovery compressor is a vertical single-stage, single-acting reciprocating compressor designed to handle flammable gases like LPG and toxic gases such as ammonia. Corken compressors can handle these potentially dangerous gases because the LPG/NH3 is confined in the compression chamber and isolated from the crankcase and the atmosphere. A typical liquid transfer-vapor recovery compressor package is shown in figure 1.3A.

Figure 1.3A: 107-style compressor mounting.

Corken gas compressors are mounted on oil lubricated crankcases remaining at atmospheric pressure. Crankshafts are supported by heavy-duty roller bearings and the connecting rods ride the crankshaft on journal bearings. With the exception of the small size model 91 compressor, all compressor crankcases are lubricated by an automotive type oil pressure system. An automatically reversible gear

type oil pump circulates oil through passages in the crankshaft and connection rod to lubricate the journal bearings and wrist pins (see figure 1.3B). Sturdy iron crossheads transmit reciprocating motion to the piston.

Corken’s automatically reversible oil pump design allows the machine to function smoothly in either direction of rotation.

Corken compressors use iron pistons locked to the piston rod. The standard piston ring material is a glass-filled PTFE polymer specially formulated for non-lubricated services. Piston ring expanders are placed behind the rings to ensure that the piston rings seal tightly against the cylinder wall.

Figure 1.3C: Compressor sealing system

Suction Valve

Spec 3

Gasket

Figure 1.3B: Pressure lubrication system (not available on Model 91).

Piston rod packing is used to seal the gas in the compression chamber and prevent crankcase oil from entering the compressor cylinder. The packing consists of several PTFE V-rings sandwiched between a male and female packing ring and held in place by a spring (see figure 1.3C).

The typical Corken compressor valve consists of a seat, bumper, one or more spring/s and one or more valve/s discs or plates as shown in figure 1.3D. Special heattreated alloys are utilized to prolong life of the valve in punishing non-lubricated services. The valve opens whenever the pressure on the seat side exceeds the pressure on the spring side.

Adjusting screw

Relief ball spring

Relief ball

Suction valve seat

Valve plate

Spacers Washer

Valve spring

Suction valve post

Suction valve bumper

Valve gasket

Figure 1.3D: Compressor sealing system

Discharge Valve

All Specs

Gasket

Bolt

Discharge valve bumper

Valve spring

Washer

Spacers

Valve plate

Discharge valve seat

Valve gasket

Chapter 2—Installing Your Corken Compressor

2.1 Location

NOTE: Compressor must be installed in a well ventilated area.

Corken compressors are designed and manufactured for outdoor duty. For applications where the compressor will be subjected to extreme conditions for extended periods such as corrosive environments, arctic conditions, etc., consult Corken. Check local safety regulations and building codes to assure installation will meet local safety standards.

Corken compressors handling toxic or flammable gases such as LPG/NH3 should be located outdoors. A minimum of 18 inches (457.2 mm) clearance between the compressor and the nearest wall is advised to make it accessible from all sides and to provide unrestricted air flow for adequate cooling.

NOISE. Corken vertical compressors sizes model 91 through 891 should not exceed an 85 DBA noise level at a distance of one meter (3.3 ft.) when properly installed.

After leveling and bolting down baseplate and/or skid, the volume beneath the channel iron baseplate must be grouted to prevent flexing of the top portion of the baseplate and the “J” bolt that extends beyond the foundation. The grout also improves the dampening capabilities of the foundation by creating a solid interface between the compressor and foundation.

See ED410: Compressor Foundation Design for more information.

2.3 Piping

Proper piping design and installation is as important as the foundation is to smooth operation of the compressor. Improper piping installation will result in undesirable transmission of compressor vibration to the piping.

DO NOT SUPPORT PIPING WITH THE COMPRESSOR. Unsupported piping is the most frequent cause of vibration of the pipe. The best method to minimize transmission of vibration from the compressor to the piping is to use flexible connectors (see figure 2.3A).

Flexible

connections

Flexible

connections

2.2 Foundation

Proper foundations are essential for a smooth running compression system. The concrete slab should be at least 8 inches thick with a 2 inch skirt around the circumference of the baseplate. The total mass of the foundation should be approximately twice the weight of the compressor system (compressor, baseplate, motor, etc.). For Models 91, 291, 491, and 691, the baseplate should be secured to the foundation using 1/2" diameter x 12" long “J” bolts. Use 3/4" x 12" anchor bolts for 891.

NOTE: Be sure to use all anchor holes.

Hex nut

2" minimum all sides

8" minimum

NOTE: Locate “J” bolts per compressor outline dimension drawings.

Figure 2.2A: Recommended foundation details for Corken

Washer

compressors 91–691.

Compressor baseplate

Grout beneath base

Concrete foundation with reinforcements should be used on all models

1/2" “J” bolts 12" long

Pipe

support

Grouted

baseplate

Baseplate should

be a maximum

of 4" high

Ground level

Figure 2.3A: On –107 mountings, the flexible connectors should be

located near the four way valve.

Concrete

foundation

Pipe

support

Pipe must be adequately sized to prevent excessive pressure drop between the suction source and the compressor as well as between the compressor and the final discharge point. In most cases, piping should be at least the same diameter as the suction nozzle on the compressor. Typically, LPG/NH3 liquid transfer systems should be designed to limit pressure drops to 20 psi (1.4 bar). Appendix C shows recommended pipe sizes for each compressor for typical LPG/NH3 installations.

Care must be taken if a restrictive device such as a valve, pressure regulator, or back-check valve is to be installed in the compressor’s suction line. The suction line volume between the restrictive device and the compressor suction nozzle must be at least ten times the swept cylinder volume. See Appendix B for details on cylinder and stroke.

Vapor line to

D A C

rail car

(inbound bulk

transport)

Hydrostatic relief valve

Back check valve

Relief valve

4-Way valve

Bury or

insulate in

cold climate

areas

Vapor line to truck

trailer or tank

(local transport)

Vapor line to gas phase

4-way Valve Operation

E B

4-Way Valve

Position 1

in storage tank

4-Way Valve

Position 2

Vapor line to liquid phase

in storage tank

Service to Perform

1. Unload tank car into storage tank

2. Recover vapors from tank car into storage tank

3. Unload transport or truck into storage tank

4. Recover vapors from transport or truck into storage tank

5. Load truck or field tank from storage tank

6. Load truck or field tank from tank car

7. Equalize between tank car and storage tank without using vapor pump

8. Equalize between truck or field tank and storage tank without using vapor pump

Valve Position

4-way A B C D E

Position

Open Open Close Close Close

One

Close Open Open Close Close

Two

Open Close Close Close Open

One

Close Close Open Close Open

Two

Open Close Close Close Open

Two

Close Open Close Open Close

One

— Open Open Close Open Open

— Open Close Close Open Close

107 style compressors are usually connected using a fivevalve (figure 2.3B) or three-valve manifold (figure 2.3C). The five-valve manifold allows the storage tank to be both loaded and unloaded. The three-valve manifold only allows the storage tank to be loaded. Adequate sizing of the liquid and vapor lines is essential to limit the pressure drop in the system to a reasonable level (20 psi or less).

The line size helps determine the plant capacity almost as much as the size of the compressor, and liquid line sizes are a bigger factor than vapor lines. If the pressure gauges on the head indicate more than a 15 to 20 psi (1.0 to 1.4 bars) differential between the inlet and outlet pressures, the line sizes may be too small or there is too much piping restriction. The less restriction in the piping, the better the flow. Appendix C shows recommended pipe sizes for typical LPG/NH3 compressor installation.

Figure 2.3B: Five valve manifold piping system.

A tank car unloading riser should have two liquid hoses connected to the car liquid valves. If only one liquid hose is used, the transfer rate will be slower and there is a good possibility that the car’s excess flow valve may close.

Since the heat of compression plays an important part in rapid liquid transfer, the vapor line from the compressor to the tank car or other unloading container should be buried or insulated to prevent the loss of heat and the compressor should be located as near as possible to the tank being emptied. In extremely cold climates, if the line from the storage tank to the compressor is over 15 feet (4.6 meters) long, it should be insulated to lessen the possibility of vapors condensing as they flow to the compressor. The vapor recovery discharge line should not be insulated. Placing the compressor as close as possible to the tank

Hydrostatic releif valve

A C

Vapor line rail car

(in-bound

bulk transfer)

Bury or insulate in cold climate areas

Vapor line to gas phase in storage

4-way Valve Operation

Back check valve

Vapor line to liquid

phase in storage

4-Way valve

Relief valve

being unloaded will minimize heat loss from the discharge line for the best liquid transfer rate.

Unloading stationary tanks with a compressor is quite practical. Delivery trucks and other large containers can be filled rapidly if the vapor system of the tank to be filled will permit fast vapor withdrawal, and if the liquid piping system is large enough. Many older trucks (and some new ones) are not originally equipped with vapor excess flow valves large enough to do a good job and these should be replaced by a suitable size valve. The liquid discharge should be connected to the tank truck pump inlet line rather than the often oversized filler valve connection in the tank head.

4-Way Valve

Position 1

Service to Perform

1. Unload tank car into storage tank

2. Recover vapors from

4-Way Valve

Position 2

Figure 2.3C: Three valve manifold piping system.

tank car into storage tank

(see section 2.4). It is of equal importance to protect the discharge of the compressor from liquid. This may be done by installing a check valve on the discharge and designing the piping so liquid cannot gravity-drain back into the compressor. Make sure to install a check valve on vapor lines discharging to the liquid space of the tank.

All piping must be in accordance with the laws and codes governing the service. In the United States, the following codes apply:

For LP-Gas — The National Fire Protection Association Pamphlet No. 58, Standard for the Storage and Handling of Liquefied Petroleum Gases.

Valve Position

4-way A B C

Position

One

Position

Two

Open Open Close

Close Open Open

It is of extreme importance to prevent the entry of liquid into the compressor. The inlet of the compressor should be protected from liquid entry by a liquid trap

For Ammonia — The American National Standards Institute, Inc., K61.1-1999, Storage and Handling of Anhydrous Ammonia.

Install, use and maintain this equipment according to Corken instructions and all applicable federal, state, and local laws and previously mentioned codes.

2.4 Liquid Traps

Compressors are designed to pressurize gas, not to pump liquids. The entry of even a small amount of liquid into the compressor will result in serious damage to the compressor.

On liquefied gas applications, a liquid trap must be used to prevent the entry of liquid into the compressor.

109 and 107 compressor mountings (see Appendix D for details on standard Corken compressor mountings).

When the compressor will not be under more-or-less constant observation an automatic trap is recommended. The automatic trap replaces the float with electrical float switches. If the liquid level should rise too high, the level switch will open and disconnect the power to the motor starter, stopping the compressor. This design ensures the machine will be protected even when it is not under close observation and is standard in the 109A and 107A mounting configurations.

Corken offers three types of liquid traps for removal of liquids in the gas stream (see figure 2.4A). The simplest is a mechanical float trap. As the liquid enters the trap the gas velocity is greatly reduced, which allows the liquid to drop out. If the liquid level rises above the inlet, the float will plug the compressor suction. The compressor creates a vacuum in the inlet piping and continues to operate until the operator manually shuts it down. The trap must be drained and the vacuum-breaker valve opened before restarting the compressor, to allow the float to drop back. This type of trap is only appropriate for use where the operator keeps the compressor under fairly close observation. This trap is provided with the

Corken’s most sophisticated trap provides the most thorough liquid separation. This trap is larger and is ASME code stamped. It contains two level switches, one for alarm and one for shutdown. In some cases the alarm switch is used to activate a dump valve (not included with trap) or sound an alarm for the trap to be manually drained by the operator. This trap also contains a mist pad. A mist pad is a mesh of interwoven wire to catch fine liquid mists. The ASME code trap is standard in the 109B and 107B mounting configurations.

A typical wiring diagram for the liquid level switch is shown in figure 2.4B.

Standard Liquid Trap Automatic Liquid Trap ASME Automatic Liquid Trap

Standard liquid trap with mechanical float assembly and drain valve.

Sizes: • 1-1/4" x 1-1/4" NPT

• 1-1/4" x 1-1/2" NPT

Automatic liquid trap, with one NEMA 7 liquid-level switch for compressor shutdown and drain valve.

Sizes: • 1-1/4" x 1-1/4" NPT

• 1-1/4" x 1-1/2" NPT

Figure 2.4A: Liquid traps.

Class 300 RF flange code-stamped automatic liquid trap with two NEMA 7 liquidlevel switches for compressor shutdown and alarm. Equipped with relief valve, pressure gauge, demister pad, and drain valve.

Sizes: • 1-1/2" x 1-1/2" NPT

• 2" x 2" Class 300 RF flange

Typical Float Switch Wiring Diagram

1 = Common, black 2 = Normally closed, blue 3 = Normally open, red

Figure 2.4B: Typical float switch wiring diagram.

NOTE: The level switch MUST be removed from the trap before grounding any welding devices to the trap or associated piping! Failure to do so will damage the switch contacts.

If your compressor is equipped with a liquid trap of other than Corken manufacture, make sure it is of adequate size to thoroughly remove any liquid present in the suction stream.

2.5 Driver Installation / Flywheels

Corken vertical compressors may be driven by either electric motors or combustion engines (gasoline, diesel, natural gas, etc.). Corken compressors are usually V-belt driven but they are also suitable for direct drive applications as well. Direct drive applications require an extended crankshaft to allow the attachment of a rigid metal coupling.

Note: Flexible couplings are not suitable for reciprocating compressors. Never operate a reciprocating compressor without a flywheel.

Drivers should be selected so the compressor operates between 350 to 825 RPM. The unit must not be operated without the flywheel or severe torsional imbalances will result that could cause vibration and high horsepower requirement. The flywheel should never be replaced by another pulley unless it has a higher WK 2 value than the flywheel.

A humid climate can cause problems, particularly in explosion proof motors. The normal breathing of the motor, and alternating between being warm when running and being cool when stopped, can cause moist air to be drawn into the motor. This moist air will condense, and may eventually add enough water inside the motor to cause it to fail. To prevent this, make a practice of running the motor at least once a week on a bright, dry day for an hour or so without the V-belts. In this period of time the motor will heat up and vaporize the condensed moisture, driving it from the motor. No motor manufacturer will guarantee their explosion proof or totally enclosed (TEFC) motor against damage from moisture.

For installation with engine drivers, thoroughly review instructions from the engine manufacturer to assure the unit is properly installed.

2.6. Crankcase Lubrication

Non-detergent oil is recommended for Corken vertical compressors. Detergent oils tend to keep wear particles and debris suspended in the oil, whereas non-detergent oils let them settle in the bottom of the crankcase. When non-detergent oils are not available, detergent oils may usually be successfully substituted, although compressors handling ammonia, amine, or imine gases are notable exceptions. These gases react with the detergent and cause the crankcase oil to become corrosive and contaminated. Figures 2.6A and 2.6B show recommended oil viscosities and crankcase capacities.

Acceptable Crankcase Oil Products

for Corken Compressors

Constant Weight - Non-Detergent - R&O Inhibited

Oil product ISO VI SAE Ambient Temp.

Exxon

100 95 30 65° – 100° F

TERESSTIC

Mobil

RARUS 427 Reciprocating Compressor Oil DTE Oil Heavy Medium 68 95 20+ 45° – 70° F Dectol R&O Oil 46 95 20 35° – 50° F

Conoco

Dectol R&O Oil

Texaco

Regal R&O Oil

Sun

SunVis 900 Oil

Compressor

Model

91 0.9 0.8

291 1.5 1.4

491 3.0 2.8

691/891 7.0 6.6

Synthetic lubricants are generally not necessary. Please consult your lubricate supplier if you are considering the use of synthetic oil. To add oil, remove the name plate and pour through the opening.

General Notes on Crankcase Oil

Corken gas compressors are used for a wide variety of gases in a multitude of operating conditions. They are used in all areas of the world from hot dusty deserts, to humid coastal areas, to cold arctic climates. No single crankcase oil or maintenance schedule is right for every compressor installation. Availability of brands and grades

68 95 20+ 45° – 70° F 46 95 20 35° – 50° F

100 95 30 65° – 100° F

100 98 30 65° – 100° F

68 97 20+ 45° – 70° F 46 99 20 35° – 50° F

100 92 30 65° – 100° F

68 97 20+ 45° – 70° F 46 102 20 35° – 50° F

100 100 30 65° – 100° F

68 100 20+ 45° – 70° F 46 100 20 35° – 50° F

Figure 2.6A: Oil selection chart.

Approximate

Quarts

Figure 2.6B: Oil capacity chart.

Capacity Liters

of oil varies from one location to another. These factors can make it challenging for a Corken compressor user to select a suitable crankcase oil.

It is safe to say that purchasing a quality crankcase oil, and changing it regularly, is significantly less costly than the repair bill and downtime associated with a lubrication failure in any gas compressor. Given the relatively small volume of oil used in the crankcase of a Corken compressor, and the critical nature of the services where these compressors are typically used, selecting the appropriate high-quality oil is the most economical choice. It will help ensure the dependability and longevity of the compressor.

Oils to Avoid

Selecting a crankcase oil based on low price or easy availability is seldom the most economic decision. Following are oils to avoid.

• Do not use engine/motor oil with an API Service SA through SH.

• Do not use any oil with a viscosity index below 95.

Viscosity Index

Viscosity Index (VI) is a measure of how much the oil’s viscosity changes as its temperature changes. A low viscosity index is an indication that the viscosity changes more as the temperature changes. A high viscosity reflects a more stable viscosity, and is generally preferred for Corken compressors.

Oil with a low viscosity index tends to thin out as the oil temperature increases. This can cause lubrication failure as well as unstable oil pressure. The minimum Viscosity Index for oils used in Corken compressors is 95 (VI is a unit-less number). This is particularly important when operating at high or low temperature extremes, or at a variety of ambient temperatures (seasonal changes).

Pour Point

The pour point of an oil is the lowest temperature at which the oil flows. At temperatures below the pour point, the oil is very thick and can’t freely flow to the compressor’s bearings and other wear surfaces, or even to the compressor’s oil pump.

• Do not use any oil with a pour point less than 15ºF (8ºC) lower than the anticipated minimum ambient temperature (unless a crankcase oil heater is used).

See below for additional detail on each of these parameters.

Industrial Oils

Corken recommends using industrial oils (rather than engine oil or “motor oil”). Industrial oils have additives specifically selected and blended for specific purposes. Many are designed specifically for the conditions inherent in compressor crankcases. Such industrial oils are required for Corken compressors operating in continuous duty or heavily loaded applications.

Industrial oils do not receive an API service designation like an engine oil does.

Critical Oil Characteristics

Viscosity

The viscosity of a crankcase oil is a measure of its resistance to flow. Viscosity is the most important physical property of lubricating oil. Oils with higher viscosity (ISO 100 and ISO 150) are thicker and are used for higher ambient temperatures. Oils with lower viscosity (ISO 68, ISO 46, and ISO 32) are thinner and are used at lower ambient temperatures. However, oils with a high viscosity index (see below) can be used at wider ambient temperature range compared to oils with a lower viscosity index.

In low ambient temperature operation, the oil’s pour point is critical. An oil should have a pour point at least 15ºF (8ºC) below the lowest expected ambient temperature. For example, if the minimum ambient temperature is expected to be 0ºF (-18ºC), the pour point must be no higher than -15ºF (-26ºC).

Do not assume the pour point of an oil is low enough. Consult the oil’s technical data sheet. Many oils have a pour point around 0 to 10ºF (-18 to -12ºC) which is too high for low ambient temperatures. Synthetic oils often have a lower pour point than conventional oils.

Engine Oils (Motor Oils)

Engine oils are formulated for use in internal combustion engines and contain additives that specifically counter the contaminants created by the combustion of fuel (soot, CO2, water, etc.). A gas compressor crankcase is a different environment than an engine crankcase. Thus, engine oils are not necessarily the best oils to use in a gas compressor. They are by far the most readily available oils.

If a suitable industrial oil is not available, engine oils can be used in Corken compressors used in intermittent service. Heavily loaded compressors or those in continuous duty service should always use high quality industrial oil. If engine oil is used, it is critical that the engine oil have an adequate API Service Grade.

API Service

The American Petroleum Institute (API) grades motor oils (oils designed for use in engines in cars and trucks) with a two letter classification. Oils with API grades “SA” through “SH” are obsolete and should never be used in modern engines or gas compressors. Unfortunately, motor oils with an “SA” and “SB” ratings are still readily available at parts stores, service stations, and other retail outlets at low prices. These are low quality oils and should NEVER be used in Corken compressors. If motor

oil is used in a Corken compressor, it should have an API Service of SJ or better. Multigrade motor oils such

as 10W-40 tend to have a higher viscosity index.

Service classification

S=gasoline engine

C=diesel engine

API (American

Petroleum Institute)

Quality rating

SAE

• Oil dilution caused by condensation or other liquids in the gas stream (see below)

• Change in viscosity for any reason (various oil additives can break down over time)

• Changing ambient temperature may cause the need for a different viscosity

The oil should be changed as often as necessary to maintain clean, undiluted oil. Each time the oil is changed, the oil filter (Corken part number 4225) should also be changed.

Ammonia Services

Never use a detergent oil in a compressor in ammonia service. Ammonia will react with the detergent and cause lubrication failure.

Oils that can be used in ammonia compressors:

• Royal Purple: Uni-Temp

• Phillips 66: Ammonia Compressor Oil

Example of API “Donut” symbol used on motor oil.

Oil suppliers post product data sheets on line that contain various physical properties of the oil , and the API Service classification. If there is any doubt, do not

use the oil.

Oil Change Intervals

Oil change intervals can vary significantly depending on local environmental conditions, the gas being compressed, and the oil being used. Unless there are factors that shorten the life of the oil, the following recommendations apply:

Conventional oil: 2200 hours or 6 months – whichever

Synthetic oil: 6000 - 8000 hours* or one year –

*Oil change intervals in this range should be confirmed via oil analysis.

5W-30

comes first

whichever comes first

• Chevron: Capella P68

Crankcase Oil Heater Option

Corken offers a crankcase oil heater as an option on all models except the small model 91. This heater is available in 110V and 220V versions and is rated for Class 1, Division 1 and 2, Group B, C, D service. The heater includes a thermostat set at 70°F (21.1°C).

If a crankcase heater is desired, it is best to order the heater with the compressor (crankcase specification “MH”). The mounting hole for the heater is not drilled unless the heater is ordered with the compressor. It is also possible to order the compressor with the hole drilled (1" NPT), but without the heater (crankcase specification “MR”). With this option, a customer can supply their own heater.

2.7 Relief Valves

An appropriate relief valve must be installed at the compressor discharge. On Corken 107-style mounted units a relief valve should be fitted in the piping between the compressor discharge and the four-way valve (see figure 1.3A). Relief valves should be made of a material compatible with the gas being compressed. Local codes and regulations should be checked for specific relief valve requirements. Also, relief valves may be required at other points in the compressor’s system piping.

Factors that shorten the life of the oil:

• Dirty or dusty environmental conditions that cause the oil to become dirty or discolored

2.8 Truck Mounted Compressors

Corken compressors may be mounted on trucks to perform liquid transfer operations as described in section 1.1. The compressor should be mounted so the inspection plate is accessible for packing adjustment. The compressor must be protected against liquid as explained in section 2.4 and a relief valve must be installed in the discharge piping before the first downstream shutoff valve.

Three types of mountings are typically used. The inside mounting (figure 2.8A) drives the compressor directly off the PTO shaft. The PTO must be selected to drive the compressor between 400 and 800 RPM. An extended compressor crankshaft is required so the U-joint yoke may connect to the compressor without removing the flywheel. Do not operate the compressor without a flywheel. Use a U-joint with a splined joint and make sure the connections are parallel and in line. The U-joint angle should be less than 15 degrees (see figure 2.8B). Always use an even number of U-joints.

Figure 2.8C: Outside transport mounting

Figure 2.8D: Top transport mounting.

2.9 Shutdown/Alarm Devices

For many applications, shutdown/alarm switches will provide worthwhile protection that may prevent serious damage to your compressor system. All electronic devices should be selected to meet local code requirements. Shutdown/alarm devices typically used on Corken compressors are as follows:

Figure 2.8A: Inside transport mounting.

Figure 2.8B: U-joint drive for compressor.

Depending on the truck design, the compressor may be outside or top mounted as shown in figures 2.8C and

2.8D to be V-belt driven. Power is transmitted through a U-joint drive shaft, jackshaft with two pillow block bearings, V-belt sheave and V-belts. An idle pulley may be used under the truck frame.

1. Low Oil Pressure Switch: Shuts down the unit if crankcase oil pressure falls below 12 psi due to oil pump failure or low oil level in crankcase. The switch or the compressor controller must have a 30 second delay on startup which allows the compressor to build oil pressure in the crankcase.

2. High Discharge Temperature Switch: This switch is strongly recommended for all applications. Both the High Discharge Temperature switch (HDT) and compressor have an operating pressure range. It is preferable that the switch set point be midpoint in its range and 30°F (-1°C) above the normal discharge temperature, but below the maximum design temperature for the compressor of 350°F (176.7°C).

3. Low Suction Pressure Switch: Shuts down the unit if inlet pressure is not within the preset limit (set point). In some cases, it is important not to pull a vacuum because of the potential of pulling oil from the crankcase into the gas stream.

4. High Discharge Pressure Switch: Shuts down the unit if the outlet pressure reaches a preset limit (set point). Both the switch and the compressor have an operating range. The set point of the pressure switch should be as follows:

Greater than the normal operating pressure for the compressor.

Less than 90% of the relief valve set point pressure.

Less than the maximum operating pressure of the compressor.

Midpoint of the pressure switch range.

5. Vibration Switch: Shuts down the unit if vibration becomes excessive. Recommended for units mounted to a portable skid.

Chapter 3—Starting Up Your Corken Compressor

NOTE: Before initial startup of the compressor be sure the principal of using a compressor for liquid transfer by vapor differential pressure is understood (see section 1.1). Read this entire chapter, then proceed with the startup checklist.

bushing and three bolts (refer to figure 3.2A). These bolts should be tightened in an even and progressive manner until torqued as specified below. There must be a gap between the bushing flange and the flywheel when installation is complete. Always check the flywheel runout before startup and readjust if it exceeds the value listed in Appendix B.

Hub Size

Diameter

in. (cm)

SF 4.625 (11.7) 12-18 (1.7–2.5) 22 (3.1)

E 6.0 (15.2) 30-36 (4.1–4.9) 22 (3.1)

J 7.25 (18.4) 75-81 (10.3 –11.1) 10 9 (15.1)

Bolt Torque

Ft-lb (kg-meter)

Set Screw

Torque Ft-lb

(kg-meter)

3.1 Inspection After

Extended Storage

If your compressor has been out of service for a long period of time, you should verify the cylinder bore and valve areas are free of rust and other debris (see chapter 5 of this IOM manual for valve and/or cylinder head removal instructions).

Drain the oil from the crankcase and remove the nameplate and crankcase inspection plate. Inspect the running gear for signs of rust and clean or replace parts as necessary. Replace the crankcase inspection plate and fill crankcase with the appropriate lubricant. Squirt oil on the crossheads and rotate the crankshaft by hand to ensure that all bearing surfaces are coated with oil.

Rotate unit manually to ensure running gear functions properly. Replace nameplate and proceed with startup.

3.2 Flywheel and V-belt Alignment

Before working on the drive assembly, be sure that the electric power is disconnected. When mounting new belts, always make sure the driver and compressor are close enough together to avoid forcing.

Improper belt tension and sheave alignment can cause vibration, excessive belt wear and premature bearing failures. Before operating your compressor, check alignment of the V-grooves of the compressor flywheel and driver sheave. Visual inspection often will indicate if the belts are properly aligned, but use of a square is the best method.

The flywheel is mounted on the shaft via a split, tapered

Figure 3.2A: Flywheel installation.

Tighten the belts until they are taut, but not extremely tight. Consult your V-belt supplier for specific tension recommendations. Belts that are too tight may cause premature bearing failure. Refer to figure 3.2B.

Figure 3.2B: Belt tension.

3.3 Crankcase Oil Pressure Adjustment

Corken compressor models 291 through 891 are equipped with an automatically reversible gear type oil pump (if your compressor is the splash lubricated Model

91, proceed to section 3.4). It is essential to ensure the pumping system is primed and the oil pressure is properly adjusted in order to assure smooth operation.

5. Check all mounting shims, cylinder and piping supports to ensure that no undue twisting forces exist on the compressor.

Before starting your compressor, check and fill the crankcase with the proper quantity of lubricating oil. (Refer to section 2.6)

When the compressor is first started, observe the crankcase oil pressure gauge. If the gauge fails to indicate pressure within 30 seconds, stop the machine and loosen the oil filter. Restart the compressor and run until oil comes out and tighten the filter.

The oil pressure should be about 20 psi (1.4 bars) minimum for normal service. If the discharge pressure is above 200 psi (13.8 bars) the oil pressure must be maintained at a minimum of 25 psi (1.7 bars). A springloaded relief valve mounted on the bearing housing opposite the flywheel regulates the oil pressure. As shown in figure 3.3A, turn the adjusting screw clockwise to increase the oil pressure and counterclockwise to lower it. Be sure to loosen the adjusting screw locknut before trying to turn the screw and tighten it after making any adjustment.

6. Verify that strainer elements are in place and clean.

7. Verify that cylinder bore and valve areas are clean.

8. Check V-belt tension and alignment. Check drive alignment on direct drive units.

9. Rotate unit by hand. Check flywheel for wobble or play.

10. Check crankcase oil level.

11. Drain all liquid traps, separators, etc.

12. Verify proper electrical supply to motor and panel.

13. Check that all gauges are at zero level reading.

14. Test piping system for leaks.

15. Purge unit of air before pressurizing with gas.

16. Carefully check for any loose connections or bolts.

17. Remove all stray objects (rags, tools, etc.) from vicinity of unit.

Oil Pressure

Adjusting

Screw

Lock Nut

Oil Pump Cover

Oil Level Bayonet

Oil Pressure Gauge

Figure 3.3A: Oil pressure adjustment.

3.4 Startup Check List

Please verify all of the items on this list before starting your compressor! Failure to do so may result in a costly (or dangerous) mistake.

Before Starting the Compressor

1. Become familiar with the function of all piping associated with the compressor. Know each line’s use!

2. Verify that actual operating conditions will match the anticipated conditions.

18. Verify that all valves are open or closed as required.

19. Double-check all of the above.

After Starting Compressor

1. Verify and note proper oil pressure. Shut down and correct any problem immediately.

2. Observe noise and vibration levels. Correct immediately if excessive.

3. Verify proper compressor speed.

4. Examine entire system for gas, oil or water levels.

5. Note rotation direction.

6. Check start-up voltage drop, running amperage and voltage at motor junction box (not at the starter).

7. Test each shutdown device and record set points.

8. Test all relief valves.

9. Check and record all temperatures, pressures and volumes after 30 minutes and 1 hour.

3. Ensure that line pressures are within cylinder pressure ratings.

4. Clean out all piping.

10. After 1 hour running time, tighten all head bolts, valve holddown bolts, and baseplate bolts. See Appendix B for torque values.

Chapter 4—Routine Maintenance Chart

Item to Check Daily Weekly Monthly

Six

Months

Yearly

Crankcase oil pressure

Compressor discharge pressure

Overall visual check

Crankcase oil level

Drain liquid from accumulation points

1 1

Drain distance pieces

Clean cooling surfaces on compressor and intercooler (if any)

Lubricator supply tank level (if any)

Check belts for correct tension

Inspect valve assemblies

Lubricate motor bearings in accordance with manufacturers’ recommendations

Inspect motor starter contact points

Inspect piston rings

Change oil every 2,200 hours of op eration or every 6 months, whichever occurs fir st. If the oil is unusually dirty, change it as often as needed to maintain a clean oil condition. Change replaceme nt filter 4225 with every oil change.

Liquid traps should be drained prior to startup.

Piston ring life varie s greatly, depending on application, gas, and operating pre ssures. Consult factory for additional re commendations for your specific application.

Chapter 5—Routine Service and Repair Procedures

CAUTION: Always relieve pressure in the unit

before attempting any repairs. After repair, the unit should be pressure tested and checked for leaks at all joints and sealing surfaces.

If routine maintenance is performed as listed in chapter 4, repair service on your Corken gas compressor is generally limited to replacing valves or piston rings. When it comes time to order replacement parts, be sure to consult the part details appendix in the back of this Installation, Operation & Maintenance (IOM) manual for a complete list of part numbers and descriptions.

5.1 Valves

Test the compressor valves by closing the inlet piping valves while the unit is running; however, do not allow the machine to operate in this way very long. If the inlet pressure gauge does not drop to zero almost immediately, one or more of the valves is probably either damaged or dirty. It is possible, of course, that the pressure gauge itself is faulty.

Inspect valves for breakage, corrosion, debris, and

scratches on the valve disc. In many cases, valves may simply be cleaned and reinstalled. If the valves show any damage, they should be repaired or replaced. Replacement is usually preferable, although individual parts are available. If valve discs are replaced, seats should also be lapped until they are perfectly smooth. A maximum of .005 inch can be removed during the lapping process. If more than .005 inch must be removed to achieve a smooth surface, the valve should be discarded. If discs are replaced without relapping the seat, rapid wear and leakage may occur.

Each suction and/or discharge valve assembly is easily removed as a unit for inspection. If any part of the valve assembly is broken, the valve assembly should be replaced. See valve assembly parts details in the appendices for a complete list of part numbers and descriptions.

If a valve is leaking due to dirt or any other foreign material that keeps the valve plate and seat from sealing, the valve may be cleaned and reused. New gaskets and/ or O-rings should be used to assure a good seal.

The valve holddown assemblies and valve assemblies on the following pages show the various specifications used on models 91, 291, 491, 691 and 891 compressors. Since more than one suction valve arrangement is available for each model of compressor, it is necessary to know your complete model number so you can identify the valve

type specification number (see examples listed below). In most cases for liquid transfer and/or vapor recovery compressors, the valve type will be spec 3 or 3P.

Model number 491AM 3 FBANSNN

Valve type = spec 3

Model number 691AM 3P FBANSNN

Valve type = spec 3P

Valve Inspection and/or Replacement for Models 91 and 291 Compressors

Before removing and inspecting the valves, begin by depressurizing and purging (if necessary) the unit.

Disassembly

1. Unscrew the valve cap and remove O-ring.

2. With the special wrench supplied with your compressor at time of purchase, remove the holddown screw.

Valve Holddown Assemblies: Depending on your model of compressor, the valve holddown assembly has all or a combination of the following:

1. Valve cap / cover

2. Valve cap O-ring

3. Holddown screw

4. Valve cover plate

5. Valve cover plate bolts

6. Valve cover plate O-ring

7. Valve spacer (model 491 only)

8. Valve cage

9. Valve assembly

10. Va lve ga sket

Valve Assemblies: Depending on your valve specification, the valve assembly has all or a combination of the following:

1. G asket

2. Adjusting screw

3. Relief ball spring

4. Relief ball

5. Valve seat

6. Valve plate

7. Spacers

8. Washer

9. Valve spring

10. Suction valve post

3. After the holddown screw has been removed, the valve assembly and valve gasket can be lifted out.

4. Carefully inspect for dirt or broken/damaged parts.

5. Inspect valves for breakage, corrosion, debris and scratches on the valve disc or plate. In many cases, valves may simply be cleaned and reinstalled. If the valves show any damage, they should be repaired or replaced. Replacement is usually preferable although repair parts are available. If valve plates are replaced, seats should also be lapped until they are perfectly smooth. If more than .005 in. must be removed to achieve a smooth surface, the valve should be discarded. If plates are replaced without relapping the seat, rapid wear and leakage may occur.

Assembly

1. Insert metal valve gasket into the suction and/or discharge opening of the head. The metal valve gasket should always be replaced when the valve is reinstalled.

2. Insert cleaned or new valve assembly. Make sure the suction and discharge valves are in the proper suction and discharge opening in the head. NOTE: The spec 3 suction valves for a model 91 and 291 compressor are pre-set so no adjustments to liquid relief pressure are necessary.

3. Replace the holddown screw and tighten to the value listed in Appendix B to ensure the valve gasket is properly seated. NOTE: Gaskets and O-rings are not normally reusable.

4. Replace the O-ring and valve cap and tighten to the value listed in Appendix B. O-rings sealing the valve caps should be replaced.

11. Valve bumper

12. Valve gasket

See valve holddown and valve assembly part details in the appendix for a complete list of part numbers and descriptions.

5. Check bolts and valve holddown screws after first week of operation. Re-torque if necessary. See Appendix B for torque values.

Valve Inspection and/or Replacement for Models 491, 691 and 891 Compressors

Before removing and inspecting the valves, begin by depressurizing and purging (if necessary) the unit.

Disassembly

1. Unscrew the valve cap/nut and remove the O-ring from the coverplate.

adjusting screw to set the liquid relief pressure. To set the liquid relief pressure, the screw bottom must be tightened to 1.8" from the top of the valve body.

2. Remove the valve cover plate, O-ring and holddown screw by removing each of the four bolts. NOTE: Since the holddown screw has been secured with an impact wrench at the factory, you will probably need to wait to remove the holddown screw until after the cover plate has been removed. At this point in time, the holddown screw can be easily removed from the cover plate. The holddown screw on model 691 and 891 is most easily removed with the special wrench supplied with your compressor at time of purchasing.

3. After the cover plate and O-ring have been removed, the valve spacer (model 491 only), valve cage, valve assembly and valve gasket can be lifted out.

4. Inspect valves for breakage, corrosion, debris, and scratches on the valve plate. In many cases, valves may simply be cleaned and reinstalled. If the valves show any damage, they should be repaired or replaced. Replacement is usually preferable although repair parts are available. If valve plates are replaced, seats should also be lapped until they are perfectly smooth. If more than .005 in. must be removed to achieve a smooth surface, the valve should be discarded. If plates are replaced without relapping the seat, rapid wear and leakage may occur.

Assembly

1. Insert metal valve gasket into the suction and/or discharge opening of the head. The metal valve gasket should always be replaced when the valve is reinstalled.

2. Insert cleaned or new valve assembly. Make sure the suction and discharge valves are in the proper suction and discharge opening in the head.

8. Check bolts and valve holddown screws after first week of operation. Re-torque if necessary. See Appendix B for torque values.

5.2 Heads

A compressor head very seldom requires replacement if the compressor is properly maintained. The primary cause of damage to a head is corrosion and the entry of solid debris or liquid into the compression chamber. Improper storage can also result in corrosion damage to the head (for proper storage instructions see chapter 6).

Many compressor repair operations require removal of the head. While the compressor is disassembled, special care should be taken to avoid damage or corrosion to the head. If the compressor is to be left open for more than a few hours, bare metal surfaces should be coated with rust preventative.

When reassembling the compressor, make sure the bolts are retightened as shown in Appendix B.

5.3 Piston Rings and Piston Ring

Expanders

Piston ring life will vary considerably from application to application. Ring life will improve dramatically at lower speeds and temperatures.

1. To replace the piston rings, depressurize the compressor and purge if necessary.

2. Remove the head to gain access to the compressor cylinder.

3. Insert the valve cage and valve spacer (NOTE: spacer applies to model 491 compressor only).

4. Replace the O-ring and valve cover plate. Torque bolts to the value listed in Appendix B. CAUTION: Be sure the holddown screw has been removed.

5. Insert the holddown screw and tighten to the value listed in Appendix B to ensure the valve gasket is properly seated. NOTE: Gaskets and O-rings are not normally reusable.

6. Replace the O-ring (or gasket) and valve cap/nut and tighten to the value listed in Appendix B. O-rings sealing the valve cap should be replaced if they show signs of wear or damage. Valve caps sealed by flat metals gaskets should be reinstalled with new gaskets.

7. NOTE: The Model 491 Spec 3 suction valve has an

3. Loosen the piston head bolts. Remove the piston as shown in figure 5.3A by pinching two loose bolts together.

Figure 5.3A: Piston removal

4. Piston rings and expanders may then be easily removed and replaced. Corken recommends replacing expanders whenever rings are replaced. To determine if rings should be replaced, measure the radial thickness and compare it to the chart in Appendix C.

5.4 Pistons

Models 91, 291, 491, and 691

1. To replace the pistons, depressurize the compressor and purge if necessary.

7. Reinstall the piston platform with the same thickness of shims as before, BUT DO NOT REINSTALL THE

ROLL PIN.

8. Install the cylinder and install the piston heads with new piston rings and expanders.

2. Remove the compressor cylinder and head (see section 5.2).

3. Remove the piston head by loosening and removing the socket head bolts holding the piston head to the piston platform (see figure 5.3A).

4. Next, remove the lock pin with a pair of needle nose pliers. The locknut may then be removed and the piston platform lifted off the end of the piston rod.

5. Check the thrust washer and shims for damage and replace if necessary.

6. Before installing the new piston, measure the thickness of the existing shims. For Models 91, 291, and 491, the shims are placed between the thrust washer and piston platform. For model 691, the shims are placed between the platform and piston head (see figures 5.4A and 5.4B).

“X” Piston Clearance

Piston Locknut

Lock Pin

Piston Ring Expander

Piston

Bolt

Piston Ring

9. Now measure dimension “X” shown in the illustration. If this measurement does not fall within the tolerances shown in Appendix B, remove the piston, adjust the shims as necessary and remeasure the “X” dimension.

10. When the piston is properly shimmed, tighten the lock nut to the torque value shown in Appendix B.

11. Now install a new lock pin and lock the piston nut in place.

12. Install the piston head and tighten the socket head bolts in an alternating sequence.

13. Reinstall the head (see section 5.2) and follow standard startup procedure. (Note: Some compressors may have self-locking nuts without roll pins.)

Model 891

1. To replace the pistons, depressurize the compressor and purge if necessary.

2. Remove the cylinder cap, head and cylinder.

3. Remove the piston cap by loosening and removing the socket head bolts holding the piston cap to the piston (see figure 5.3A).

Piston Head

Shims

Figure 5.4A: Piston cross section model sizes 91 through 491

Piston Head

Figure 5.4B: Piston cross section model 691

Thrust

Washer

“X” Piston Clearance

Shims

Platform

Piston Rod

Piston Locknut

Lock Pin

Platform

Piston Rod

Piston

Cylinder

Piston Ring Expander

Bolt

Cylinder

Piston Ring

4. Next, remove the lock nut and lift the piston off the end of the piston rod.

5. Check the thrust washer and shims for damage and replace if necessary.

6. Before installing the new piston, measure the thickness of the existing shims.

7. Replace the cylinder.

8. Install the piston with the same thickness of shims as before, and with new piston rings and expanders.

9. Now remove a lower valve and measure dimension “Y” at the bottom of the piston shown in Appendix E—Piston Assembly Details. If this measurement does not fall within the tolerances listed in the piston assembly details (Appendix E), remove the piston, adjust the shims as necessary and measure the “Y” dimension.

(Y) (Y)

Piston

Piston bottom dead center

(X) (X)

15. Replace the previously removed valves. Best results will be obtained if new valve gaskets are used.

16. Follow standard startup procedures.

5.5 Piston Rod Packing

Adjustment

Piston rod packing should be adjusted or replaced whenever leakage becomes noticeable. Typically, it is a good idea to replace piston rod packing and piston rings at the same time. For instructions on replacing the piston rod packing, see section 5.6.

NOTE: Packing that cannot be adjusted should be replaced.

Piston

Piston top dead center

10. When the piston is properly shimmed, tighten the lock nut as shown in Appendix B.

11. Replace the piston cap with the same thickness of shims as before.

12. Reinstall the piston cap and cylinder head.

13. Now remove an upper valve and measure dimension “X” at the top of the piston shown in Appendix E— Piston Assembly Details. If this measurement does not fall within the tolerances in Appendix E, remove the cylinder head and piston cap and adjust the shims as necessary. Repeat the steps and measure the “X” dimension again.

14. When the piston cap is properly shimmed, tighten the socket head bolts in an alternating sequence. Torque socket head bolt to the values listed in Appendix B.

Figure 5.5A: Packing adjusting nuts.

5.6 Cylinder and Packing Replacement

Cylinders very seldom require replacement if the compressor is properly maintained. The primary cause of damage to cylinders is corrosion and the entry of solid debris or liquid into the compression chamber. Improper storage can also result in corrosion damage to cylinder (for proper storage instructions see chapter 6).

If the cylinder does become damaged or corroded, use a hone to smooth the cylinder bore and then polish it to the value shown in Appendix B. If more than .005 in. must be removed to smooth the bore, replace the cylinder. Cylinder liners and oversized rings are not available. OVERBORING THE CYLINDER WILL RESULT IN GREATLY REDUCED RING LIFE.

Many compressor repair operations require removal of the cylinder. While the compressor is disassembled, special care should be taken to avoid damage or corrosion to the cylinder. If the compressor is to be left open for more than a few hours, bare metal surfaces should be coated with rust preventative.

When reassembling the compressor, make sure the bolts are retightened to the valves shown in Appendix B.

Packing Replacement Instructions

Caution: Bleed all pressure from the compressor and piping, and purge (if necessary), before starting to install new piston rod packing. After repair, the unit should be pressure tested and checked for leaks at all joints and gasket surfaces. When the compressor is being used with toxic, dangerous, flammable or explosive gases, this pressure and leak testing should be done with air or a dry, inert gas such as nitrogen.

For simplicity, heads, pistons, and inspection plates are not shown. For specific construction details and actual part numbers, consult the appendix in the back of this IOM manual. Use instructions below that apply to the MODEL and SERIAL NUMBER of your compressor. Be careful to arrange packing sets in the proper order.

Cleanliness:

Prior to installation, inspect all parts for cleanliness and visible defects. There should be absolutely no scratches, dings, porosity, or foreign materials on bearing surfaces, sealing surfaces, and packing cartridge inner and outer diameters.

Workmanship:

Your Corken compressor is a precision piece of equipment with very close tolerances. Treat it as such. Never beat on it to get parts in or out.

Model 91 Compressor

(Refer to Appendix E for packing assembly details)

Disassembly of Packing

1. Depressurize and open the compressor.

5. Install locking device (part number 1192) into adjusting screw and cut, leaving 1/8" exposed. Tighten adjusting screw until plastic locking device engages the first thread in the crosshead guide.

6. Oil piston rod and install the packing installation cone (part number 4005) over the threaded end of the piston rod.

7. Carefully slip the crosshead guide over the piston rod; otherwise, you may damage the lips of the packing rings.

8. Remove packing installation cone.

9. Install the crosshead guide O-ring, cylinder, piston and head.

Model 291 Compressor (serial number SS55685 and later)

Model 491 Compressor (serial number XC30633 and later)

(Refer to Appendix E for packing assembly details)

Disassembly of Packing

1. Depressurize and open the compressor.

2. Remove head, pistons and cylinder.

3. Remove cartridge holddown screw with special wrench supplied with the compressor and packing box cartridge.

4. Loosen adjusting screw and remove retainer ring, washers, packing spring and old packing from packing box cartridge.

2. Remove head, piston, cylinder, inspection plate and crosshead guide.

3. Loosen adjusting screw and remove retainer ring, washers, packing spring and old packing from crosshead guide.

Assembly of Packing

1. Clean, then lightly oil, packing area inside the crosshead guide.

2. Slightly thread in the adjusting screw into the crosshead guide.

3. Install packing rings including male and female packing rings one at a time as shown in Appendix E. Push in each one completely before adding the next ring. The quantity of packing rings required will vary due to tolerances; a good rule of thumb is to put in as many as are removed.

4. Insert thin packing box washer, packing spring and thicker washer into the top of the crosshead guide.

Assembly of Packing

1. Clean, and then lightly oil, packing area inside packing box cartridge.

2. Slightly thread in adjusting screw.

3. Install packing rings including male and female packing rings, one at a time, as shown in Appendix E. Push in each one completely before adding the next ring. The quantity of packing rings required will vary due to tolerances; a good rule of thumb is to put in as many as are removed.

4. Insert thin packing box washer, packing spring and thicker washer.

5. Push down on washer and insert retainer ring.

6. Tighten adjusting screw until plastic locking device (part number 1192) engages the first thread in the packing box cartridge.

7. Lubricate piston rod and replace cartridge O-ring.

8. Install packing installation cone part number 4005 over the threaded end of the piston rod.

Model 891 Compressor

(Refer to Appendix E for packing assembly details)

9. Carefully slip the packing cartridge over the piston rod; otherwise, you may damage the lips of the packing rings.

10. Remove packing installation cone.

11. Install and tighten cartridge holddown screw with special compressor wrench.

12. Install cylinder O-ring, cylinder, pistons, and head.

Model 691 Compressor

(Refer to Appendix E for packing assembly details)

Disassembly of Packing

1. Depressurize and open the compressor.

2. Remove head, pistons and cylinder.

3. Remove cartridge holddown screw with special wrench supplied with the compressor and packing box cartridge.

4. Loosen adjusting screw and remove retainer ring, washers, packing spring and old packing from packing box cartridge.

Disassembly of Packing (D-Style)

1. Depressurize and open the compressor.

2. Remove the cylinder cap, heads, pistons and cylinder.

3. Remove the packing barrels by prying upwardly under each one and lifting entire packing barrel/cartridge assembly up from piston rod.

4. Remove the four socket head screws that hold the packing box cartridge to the barrel.

5. Remove segmented packing and cups from barrel.

6. Remove lower retainer ring, washers, packing spring and old V-ring packing from packing box cartridge.

Assembly of Packing (D-Style)

1. Replace packing as required. The segmented packing and cups are located in the packing barrel while the V-ring packing is located in the packing box cartridge.

NOTE: Always use new O-rings when replacing the packing.

2. V-ring packing set:

Assembly of Packing

1. Clean then lightly oil packing area inside packing box cartridge.

2. Thread in adjusting screw until locking device (part number 1192) is engaged into first thread of the packing cartridge.

3. Install packing rings, including male and female packing rings, one at a time, as shown in Appendix E. Push in each one completely before adding the next ring.

4. Insert a packing washer, packing spring, and another packing washer.

5. Push down on washer and insert retainer ring.

6. Oil piston rod and replace cartridge O-ring.

7. Install packing installation cone (part number 3905) over the threaded end of the piston rod.

8. Carefully slip the packing cartridge over the piston rod; otherwise, you may damage the lips of the packing rings.

9. Install and tighten cartridge holddown screw with special compressor wrench.

10. Replace cylinder O-ring, cylinder, pistons and head.

NOTE: The instructions below are for packing

specification “J”. Depending on the packing specification used in your compressor, the order of assembly for the packing rings, V-ring packing, washers and packing spring will vary. Refer to Appendix E to view the V-ring packing arrangements and follow the order of assembly and V-ring direction. If you do not know the packing arrangement used in your compressor, refer to the model number identification codes listed in Appendix A.

a. Clean and lightly oil the packing area inside the

packing box cartridge.

b. Insert the oil deflector ring through the bottom

opening of the packing box cartridge.

c. Insert the first retainer ring followed by a washer.

d. Insert the packing spring followed by another washer.

e. Insert a male packing ring followed by four V-rings

and one female packing ring. NOTE: Insert packing rings and V-rings one at a time. Refer to Appendix E for the proper direction of the male and female packing rings and V-rings.

f. Lastly, insert the final washer. Push in on the

washer and install the second retainer ring.

3. Segmented packing:

NOTE: The instructions below are for packing

specification “J”. Depending on the packing specification used in your compressor, the order of assembly for the segmented packing arrangement (radial or tangent) will vary. Refer to Appendix E to view the segmented packing arrangements. If you do not know the packing arrangement used in your compressor, refer to the model number identification codes listed in Appendix A.

a. Clean the segmented packing cups and the area

inside the packing barrel.

b. Insert the segmented packing cups, segmented

packing pairs and backup rings one at a time in the order shown in Appendix E.

c. Reattach the packing box cartridge to the packing

barrel using the four socket head screws.

4. Install three O-rings on the packing barrel and packing box cartridge as shown in the D-Style Crosshead Guide Details in Appendix E.

5.7.1 Wrist Pin Bushing Replacement

1. To replace the wrist pin bushing, remove the retainer rings that position the wrist pin in the crosshead.

2. Press out the wrist pin so the crosshead and connecting rod may be separated. Inspect the wrist pin for wear and damage and replace if necessary.

3. Press out the old wrist pin bushing and press a new bushing into the connecting rod. DO NOT MACHINE THE O.D. OR I.D. OF THE BUSHING BEFORE PRESSING INTO CONNECTING ROD.

4. Make sure the lubrication hole in the bushing matches the oil passage in the connecting rod. If the holes do not align, press out and insert a new one. Bore the wrist pin bushing I.D. as indicated on the respective connecting rod assembly details. These pages are located in Appendix E. Over boring the bushing can lead to premature failure of the wrist pin bushing.

5. Inspect the oil passage for debris and clean thoroughly before proceeding.

5. Install packing installation cone (part number 3905) over the threaded end of the piston rod.

6. Carefully install barrel/cartridge assemblies over the piston rods, noting the alignment of the barrels as they sit on the crosshead guide. The valve scallops on the barrels must align properly with the valves in the cylinder.

7. Remove packing installation cone.

8. Replace pistons, cylinders, heads and cylinder cap. See details in Section 5.3 for proper assembly of pistons.

9. Rotate unit by hand to ensure proper assembly.

5.7 Bearing Replacement for

Crankcase and Connecting Rod

1. To replace the crankcase roller bearings, wrist pin bushing and connecting rod bearings, begin by removing the head, cylinder, piston, crosshead guide and crosshead assembly.

2. Drain the crankcase and remove the inspection plate(s).

3. Before disassembly, choose and mark one connecting rod and the corresponding connecting rod cap. DO NOT MIX CONNECTING RODS AND CAPS. Loosen and remove the connecting rod bolts in order to remove the crosshead and connecting rod assembly.

6. Press the wrist pin back into the crosshead and wrist pin and reinstall retainer rings. NOTE: The fit between the wrist pin and bushing is tighter than ordinary lubricated air compressors and combustion engines.

5.7.2 Replacing Connecting Rod Bearings

Connecting rod bearings are easily replaced by removing the semicircular bearings. Make sure the indentations in the connecting rod bearing and connecting rod line up when installing the new bearings. MAKE SURE THE ARROW AND/OR ALIGNMENT NOTCH ON CONNECTING ROD AND CAP ARE ALIGNED.

Before reinstalling the crosshead/connecting rod assembly, make sure the crankshaft throw and bearing surface are clean and lubricated. Tighten the connecting rod bolts to the torques listed in Appendix B.

5.7.3 Replacing Crankcase Roller Bearings

To inspect the roller bearings, remove the flywheel from the crankshaft and then remove the bearing carrier and crankshaft from the crankcase. If corrosion or pitting is present, the roller bearings should be replaced. When replacing roller bearings, always replace the entire bearing, not just the cup or the cone.

1. To replace the bearings, press the cups out of the crankcase and bearing carrier and press the cones off the crankshaft.

2. Press the new bearings into position and reassemble the crankshaft and bearing carrier to the crankcase. When reinstalling the bearing carrier, make sure the oil

Figure 5.7.3: Bearing carrier replacement.

pump shaft slot is aligned with the pin in the crankshaft. Make sure to install the bearing carrier gasket so the oil passage hole is not blocked (see figure 5.7.3).

3. In order to check the crankshaft endplay, the oil pump must first be removed (see section 5.8).

4. Press the end of crankshaft towards the crankcase; if a clicking noise or motion is detected, the crankshaft has too much endplay. See Appendix B.

5. To reduce endplay, remove the bearing cover and remove a thin shim. Recheck the endplay after replacing the bearing cover.

6. When there is no detectable endplay, the shaft must still be able to rotate freely. If the crankshaft sticks or becomes abnormally warm, then the crankshaft bearings are too tight. If the crankshaft is too tight, add more shims, but make sure not to over shim. (Appendix B lists the proper crankshaft endplay). When the crankshaft can be rotated freely by hand with proper endplay, the rest of the compressor can be reassembled. If the crankshaft roller bearings are too tight or too loose, premature bearing failure will result.

7. Reinstall the flywheel on the crankshaft and check the run out as shown in Appendix B.

2. Inspect the gears in the oil pump for corrosion or pitting and replace if necessary.

3. Inspect the oil pump shaft bushing in the bearing carrier. If the bushing is corroded, pitted or worn, the oil pump shaft bushing should be replaced.

4. Before reassembling the oil pump mechanism, replace the O-rings in the oil pump cover and on the oil pump adapter shaft (see figure 5.8).

5. Rotate the drive pin in the crankshaft to a vertical position for easiest reassembly.

6. Insert the shaft adapter so it engages the drive pin.

7. Next, insert the spring, spring guide, and oil pump assembly. The tang on the oil pump must align with the slot in the shaft adapter.

8. Install the pump cover so the pin on the case is in the opening on the oil pump assembly as shown in figure

5.8. When you are sure the pin is properly aligned, install the cover bolts finger tight.

9. Rotate the crankshaft by hand to ensure smooth operation. Then rotate it in opposite directions, listening for a click, which indicates proper alignment of the oil pump’s pins and slots.

5.8 Oil Pump Inspection

If the compressor operates for a prolonged period with dirty or contaminated crankcase oil, damage to the oil pump may result.

1. To check the oil pump, unbolt the pump cover and remove the oil pump, spring guide, spring, and oil pump shaft adapter as shown in figure 5.8.

10. Finally, tighten the bolts in an alternating sequence. See section 3.3 for directions on oil pressure adjustment.

Figure 5.8

Chapter 6—Extended Storage Procedures

3. Operate for a few minutes while fogging oil into the compressor suction.

4. Relieve V-belt tension.

Following a few simple procedures will greatly minimize the risk of corrosion and damage. Corken recommends the following precautions to protect the compressor during storage:

5. Plug all openings to prevent entry of insects and moisture. (The cylinders may also be protected by the use of a vapor phase inhibitor, silica gel, or dry nitrogen gas. If the silica gel is used, hang a tag on the unit

1. Drain the crankcase oil and refill with rust inhibiting oil.

2. When a compressor is returned from long-term

indicating that it must be removed before start-up.)

6. Store in a dry area, off the ground if possible.

storage, the compressor’s nameplate should be removed and the new oil poured over the crossheads

7. Rotate the flywheel every two weeks if possible.

to ensure good crosshead lubrication at startup.

8. If possible, store compressor in a climate controlled area.

6.1 Repair Kits

Compressor Repair Kits

Part Number 35 49 -X1 3550-X1 3551-X1 3552-X1 3552-X4 5578-X3A

Model Number 90J3, 91J3 290K3, 291M3 490K3, 491M3 690K3, 690P3 690M3, 691M3 891M3 Suction valve assembly 3 483 -1X 3483-1X (2) 253 2-1X 3948-X (2) 3948-2X (2) 3856-2X (4) Discharge valve assembly 3485-X 3485-X (2) 2439-X (2) 3857-X (2) 3857-2X (2) 3857-2X (4) Connecting rod bearing (pair) 1367 1367 (2) 1491 (2) 1719 (2) 3542 (2) 3542 (2)

Packing set 1452-1X1 1452-1X1 (2) 1452-1X1 (2) 17 25 -2X (2 ) 172 5-2X ( 2)

Piston rings 1772 (3) 1772 (6) 1773 (6) 1739 (6 ) 173 9 (6) 1739 (8) Ring expanders 1775 (3) 1775 (6) 1776 (6) 1740 ( 6) 1740 ( 6) 1740 (8) Gasket set O-ring O-ring O-ring Oil seal 3259 1278 1507 (490 only) — 3526 3526 Oil seal — — 4438 (491 only) — — — Adapter plate gasket — — 148 6 (2) — — — Oil deflector ring — — — — — 1732 (2)

Quantities greater than one are shown in parenthesis .

All repair kits are furnished with Buna-N O-rings which are suitable for LPG a nd NH3 applications.

172 5-2X,

3810 -X1

2526 -XA 1281-XA 1481-X6A 174 4 -X1A 174 4-X1A 3970 -X1A

— — — — 2-261A (2) — — — 2-242A (2) — — — — — 2-253A (2) — — —

6.2 Gasket Sets

Model 91 Gasket Set (2526-XA)

Part No. Description Qty

2-235A O-ring (Buna-N) 2

2526 Crankcase gasket 1

2717 Valve gasket (aluminum) 2

2729 Crankcase inspection plate gasket 1

2-031A O-ring (Buna-N) 2

2244 Inspection plate gasket 1

2716 Valve cap gasket (aluminum) 2

2725 Bearing carrier gasket 1

Model 291 Gasket Set (1281-XA)

Part No. Description Qty

1281 Filter screen screw gasket 1

1651 Inspection plate gasket 1

2-113A O-ring (Buna-N) 2

2-228A O-ring (Buna-N) 1

2702 Crankcase gasket 1

2716 Valve cap gasket (aluminum) 4

2732 Center headbolt gasket (steel) 2

119 0 Adapter plate gasket 2

1285 Bearing carrier gasket 1

2-031A O-ring (Buna-N) 4

2-13 5A O-ring (Buna-N) 2

2-235A O-ring (Buna-N) 4

2713 Crankcase inspection plate gasket 1

2717 Valve gasket (aluminum) 4

1276 Filter screen 1

2-011A O-ring 1

2-111A O-ring 1

2-112 A O-ring 2

2-116A O-ring 1

Model 491 Gasket Set (1481-X6A)

Part No. Description Qty

1418 Valve gasket (aluminum) 4

1480 Center headbolt gasket (steel) 2

1488 Inspection plate gasket 1

1511 Crankcase inspection plate gasket 1

2-13 9A O-ring (Buna-N) 2

2-228A O-ring (Buna-N) 1

1281 Filter screen screw gasket 1

1478 Valve cap gasket (steel) 4

1481 Head gasket 1

1489 Crankcase gasket 1

1513 Bearing carrier gasket 1

2-14 3A O-ring (Buna-N) 4

2-243A O-ring (Buna-N) 2

1276 Filter screen 1

2-011A O-ring 1

2-111A O-ring 1

2-112 A O-ring 2

2-116A O-ring 1

Model 691 Gasket Set (1744-X3A)

Part No. Description Qty

176 0 Inspection plate gasket 1

2-031A O-ring (Buna-N) 4

2-231A O-ring (Buna-N) 2

2-235A O-ring (Buna-N) 4

2-261A O-ring (Buna-N) 2

2123 Crankcase inspection plate gasket 2

2131 Bearing carrier gasket 1

2716 Valve cap gasket (aluminum) 4

4127 Lubricator gasket 1

1281 Filter screen screw gasket 1

1761 Crankcase gasket 1

2-228A O-ring (Buna-N) 1

2-233A O-ring (Buna-N) 2

2- 247A O-ring (Buna-N) 2

2114 Valve gasket (aluminum) 4

2129 Oil inlet gasket 1

217 7 Flange gasket 2

3874 Access cover gasket 2

1276 Filter screen 1

2-011A O-ring 1

2-112 A O-ring 2

2-116A O-ring 1

2-218A O-ring 2

Model 891 Gasket Set (3970-X1A)

Part No. Description Qty

1281 Filter screen screw gasket 1

1761 Crankcase gasket 1

2-036A O-ring (Buna-N) 8

2-231A O-ring (Buna-N) 4

2-238A O-ring (Buna-N) 2

2114 Valve gasket (aluminum) 8

2131 Bearing carrier gasket 1

4127 Lubricator gasket 1

176 0 Inspection plate gasket 1

2-031A O-ring (Buna-N) 8

2-228A O-ring (Buna-N) 1

2-235A O-ring (Buna-N) 8

2-246A O-ring (Buna-N) 4

2123 Crankcase inspection plate gasket 1

3874 Access cover gasket 2

3906 Gasket spiral wound 2

1276 Filter screen 1

2-011A O-ring 1

2-112 A O-ring 2

2-116A O-ring 1

2-118A O-ring 2

Appendix A—Model Number Identification Code and Available Options

Reciprocating Vertical Compressors (Plain Style) LPG and Anhydrous Ammonia Models

Plain Style (Single Packed)

Base Model #

Inlet 3/4" NPT 3/4" NPT 1-1/4" NPT 2" NPT Outlet 3/4" NPT 3/4" NP T 1-1/4" NPT 1-1/2 " N PT Weight lbs. (kg) 145 (65.8) 19 0 ( 86 .1) 3 00 (136.1) 670 (303.9)

Base Model #

Inlet 3/4" Class 300 RF 3/4" Class 300 RF 1-1/4" Class 300 RF 2" Class 300 RF Outlet 3/4" Class 300 RF 3/4" Class 300 RF 1-1/4" Class 300 RF 2" Class 300 RF Weight lbs. (kg) 145 (65.8) 19 0 ( 86 .1) 3 00 (136.1) 670 (303.9)

Specification Fields

Packing Arrangement

Crankcase Style

Valves

Piston Ring and Packing Material

Gasket Material

O-ring Material

Intercooler

Flywheel

Protective Coating

Piston Rod Coating

Registered trademark of the DuPont company.

Registered trademark of TTI Group Ltd.

Inlet pressure above atmospheric

Splash lubricated Standard NA NA NA J Extended crankshaft Optional Optional Optional NA E Pressure lubricated crankcase Standard crankcase with heater Standard crankcase drilled for heater

Liquid relief suction valves

Standard suction and discharge valve

PTFE piston ring with PTFE packing material PTFE piston ring with Alloy 50 packing material

Aluminum gasket material

Buna-N Standard A

®1

Neoprene

Not applicable—single stage

14" flywheel used in conjunction with extended crankshaft Heavy dut y flywheel Optional H No flywheel supplied No charge option N Standard flywheel Standard S

No coating Standard N

®2

Nitrotec

91 291 491 691

F91 F291 F491 F691

Standard A

NA Standard Standard Standard M

NA Optional Optional Optional MH

NA NA NA Optional MR

Standard NA 3

NA Standard 3P

Optional NA 4

NA Optional 4P

Standard Standard Standard NA

NA NA NA Standard

Standard B

Optional B

Standard N

NA Optional Optional NA E

Standard N

Model Number

Base X X X X X X X X X X

+ 70 hidden pages

Corken 91, 491, 291, F91, F291 Installation, Operation & Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual