Instruction Manual and Replacement Parts List Offshore Compressors High Pressure Breathing Air Compressor Units O10-D O10-E3
September 2002 BAUER Compressors, Inc. 1328 Azalea Garden Road Norfolk, Virginia 23502-1944
MNL-0311 Phone: (757) 855-6006 Fax: (757) 855-6224 www.bauercomp.com
OFFSHORE COMPRESSORS-O10 SECTION 1: INTRODUCTION 1.1 General 1.1.1 How To Use This Manual This manual contains the operating and maintenance instructions for the Bauer Compressors, Inc. product listed on the front cover. All instructions in this manual should be observed and carried out as written to prevent damage or premature wear to the product or the equipment served by it. If these operating instruction are not followed or changes are made to the product without prior written authorization, including the use of parts not supplied by Bauer Compressors, Inc., any claims under warranty shall be void. Please contact our customer service department at the number listed on the front of this manual for assistance. The instructions for installing this product are contained in Section H of this manual. They must be read, understood and complied with prior to operating the product. The safety instructions applicable to this product are contained in Section F. They must be read, understood and complied with prior to operating the product. The instructions for long term storage (over 90 days) of this product are contained in Section G. Section I is a set of forms which may be reproduced as needed to record operating hours, purification cartridge adjusted operating hours, scheduled maintenance actions or suggested corrections to this manual. If your unit is equipped with nonstandard accessories and/or options, supplemental information is normally included in other documentation; i.e. OEM Manuals or additional Bauer Manuals. Important instructions concerning the endangerment of personnel, technical safety or operator safety will be specially emphasized in this manual by placing the information in the following types of safety notices WARNING Data contained in this notice must be adhered to exactly in order to avoid endangering personnel
CAUTION Data contained in this notice must be complied with in order to avoid damage to or destruction of the machine or its associated equipment.
NOTE Data contained in this notice advises of technical requirements that require particular attention by the operator or the maintenance technician
While every effort is made to ensure the accuracy of the information contained in this manual, Bauer Compressors, Inc. will not, under any circumstances be held accountable for any inaccuracies or the consequences thereof. September 2002
-1-
How To Use This Manual
MNL-0311 1.1.2 •
How to Use the Replacement Parts List The use of repair parts other than those included in the Bauer Replacement Parts Lists may create unsafe conditions over which Bauer has no control. Such unsafe conditions can lead to accidents that may be life-threatening, cause substantial bodily injury, and/or result in damage to the equipment. Therefore, BAUER Compressors, Inc. can bear no responsibility for equipment in which non-approved repair parts are installed.
•
A lozenge ◊ in the Item Number column indicates the part number for a complete assembly.
•
a dagger (†) in the Qty column with or without an ellipis (…) in the Part Number column means the part is illustrated for assembly purposes only and is not available for sale as an individual component. This part can be obtained by ordering the complete assembly.
•
AR in the Qty column means that the item is cut or manufactured to the size which the customer specifies.
•
A dash (—) in the Item Number column indicates that there is more than one part number applicable to the preceding Item Number.
When placing an order for spare parts, please provide the following information to ensure delivery of the correct parts. Model Number Serial Number Part Number
Date of Manufacture Quantity required Part Description
Example: Junior-E3; manufactured 1998; Serial number 32165; requiring 2 reed valves, p/n N04860. The model number, date of manufacture and serial number can be found of the compressor unit identification plate on the compressor unit’s frame.
Figure 1.1-1
Compressor Unit Identification Plate
BAUER COMPRESSORS, INC. NORFOLK, VIRGINIA U.S.A
BAUER COMPRESSORS
MODEL NO.
BLOCK NO.
SERIAL NO.
PRESSURE
PSIG
CHG. RATE
CFM
CAPACITY MOTOR
CFM HP
PH VOLTS DATE OF MANUFACTURE
SPEED
RPM
HZ
AMPS LBL-004
While every effort is made to ensure the accuracy of the information contained in this manual, BAUER Compressors, Inc. will not, under any circumstances be held accountable for any inaccuracies or the consequences thereof. How to Use the Replacement Parts List
-2-
1st Edition
OFFSHORE COMPRESSORS-O10 1.1.3
Revisions and Changes
Ed.\Rev.\Change
Date
Base Edition
September 2002
Ed\Rev\Change
Effected Pages
September 2002
Notes
Approval JD
Ed\Rev\Change
-3-
Effected Pages
Revisions and Changes
OFFSHORE COMPRESSORS-O10 Para. Title 1.2 Table of Contents
Page
SECTION 1: INTRODUCTION 1.1 General....................................................................................................................................................................................... 1 1.1.1 How To Use This Manual................................................................................................................................................... 1 1.1.2 How to Use the Replacement Parts List ............................................................................................................................. 2 1.1.3 Revisions and Changes ....................................................................................................................................................... 3 1.2 Table of Contents....................................................................................................................................................................... 5 1.3 List of Figures............................................................................................................................................................................ 9 1.4 Description and Specifications ................................................................................................................................................ 11 1.4.1 Unit Description................................................................................................................................................................ 11 1.4.2 Unit Specifications............................................................................................................................................................ 12 1.4.2.1 O10-D ............................................................................................................................................................................... 12 1.4.2.1.1 Compressor Block, IK12.14 II.......................................................................................................................................... 12 1.4.2.1.2 Compressor Drive ............................................................................................................................................................. 12 1.4.2.2 O10-E3 .............................................................................................................................................................................. 13 1.4.2.2.1 Compressor Block, IK12.14 II.......................................................................................................................................... 13 1.4.2.2.2 Compressor Drive ............................................................................................................................................................. 13 1.4.2.3 Purification System Applicability..................................................................................................................................... 13 SECTION 2: OPERATION 2.1 Electric Motor or Diesel Engine Driven Units ........................................................................................................................ 15 2.1.1 Pre-start Checks ................................................................................................................................................................ 15 2.1.2 Start-up Procedure ............................................................................................................................................................ 15 2.1.2.1 Electric Motor ................................................................................................................................................................... 15 2.1.2.2 Diesel Engine .................................................................................................................................................................... 15 2.1.3 Post Start Procedures ........................................................................................................................................................ 16 2.1.4 Shutdown Procedures........................................................................................................................................................ 16 2.1.4.1 Electric Motor ................................................................................................................................................................... 17 2.1.4.2 Diesel Engine .................................................................................................................................................................... 17 SECTION 3: MAINTENANCE AND PARTS 3.1 Compressor Block - IK12.14 II ............................................................................................................................................... 19 3.1.1 Description ........................................................................................................................................................................ 19 3.1.2 Component Location......................................................................................................................................................... 19 3.1.3 Air Flow Diagram ............................................................................................................................................................. 20 3.1.4 Lubrication System ........................................................................................................................................................... 21 3.1.4.1 Type of Oil ........................................................................................................................................................................ 21 3.1.4.2 Oil Level Check ................................................................................................................................................................ 22 3.1.4.3 Oil Change ........................................................................................................................................................................ 23 3.1.5 Intake Filter ....................................................................................................................................................................... 23 3.1.5.1 Description ........................................................................................................................................................................ 23 3.1.5.2 Intake Filter Maintenance ................................................................................................................................................. 23 3.1.6 Intermediate Separator ...................................................................................................................................................... 24 3.1.6.1 Maintenance ...................................................................................................................................................................... 24 3.1.7 Cooling.............................................................................................................................................................................. 25 3.1.7.1 Maintenance ...................................................................................................................................................................... 25 3.1.8 Compressor Valves and Heads ......................................................................................................................................... 25 3.1.8.1 Functional Description...................................................................................................................................................... 25 3.1.8.2 General Instructions for Changing the Valves.................................................................................................................. 26 3.1.8.3 Changing the 1st Stage Valve ........................................................................................................................................... 27 3.1.8.4 Changing the 2nd Stage Valves ........................................................................................................................................ 28
September 2002
-5-
Table of Contents
MNL-0311 Para. 3.1.8.5 3.1.8.6 3.1.8.6.1 3.1.8.6.2 3.1.9 3.1.10 3.1.10.1 3.1.10.2
Title
Page
Changing the 3rd Stage Valves .........................................................................................................................................29 Changing the 4th Stage Valves .........................................................................................................................................32 Removal ............................................................................................................................................................................32 Reassembly .......................................................................................................................................................................33 Replacement Parts List......................................................................................................................................................34 Troubleshooting ................................................................................................................................................................52 Troubleshooting Table ......................................................................................................................................................52 Repair Instructions ............................................................................................................................................................53
3.2 4 Stage Automatic Condensate Drain System .........................................................................................................................55 3.2.1 Description ........................................................................................................................................................................55 3.2.1.1 Compressor Operating ......................................................................................................................................................56 3.2.1.2 Condensate Draining .........................................................................................................................................................56 3.2.1.3 Start Unloading .................................................................................................................................................................57 3.2.1.4 Standstill Drainage ............................................................................................................................................................57 3.2.1.5 Condensate Drain Piping...................................................................................................................................................57 3.2.1.6 Electrical Connections ......................................................................................................................................................57 3.2.1.7 ACD Timer.......................................................................................................................................................................57 3.2.1.8 Condensate Drain Separator..............................................................................................................................................58 3.2.1.9 ACD Maintenance.............................................................................................................................................................58 3.2.2 Replacement Parts List......................................................................................................................................................59 3.2.3 Trouble shooting ...............................................................................................................................................................66 SECTION 4: MAINTENANCE SCHEDULE 4.1 IK12.14 II Compressor Block..................................................................................................................................................67 4.1.1 Preventive Maintenance Tasks..........................................................................................................................................67 4.1.2 Maintenance Records .......................................................................................................................................................67 4.1.3 Maintenance Intervals .......................................................................................................................................................67 SECTION 5: PURIFICATION SYSTEMS 5.1 General .....................................................................................................................................................................................69 5.1.1 System Configurations ......................................................................................................................................................69 5.1.2 General Purification System Procedures...........................................................................................................................69 5.1.3 Chamber Safety Bore ........................................................................................................................................................70 5.1.4 Manual Condensate Drainage ...........................................................................................................................................70 5.1.5 Model, Serial Number and Part Number Identification ....................................................................................................70 5.1.5.1 Compressor Dataplate .......................................................................................................................................................70 5.1.5.2 Purification System Dataplate...........................................................................................................................................71 5.1.5.3 Cartridge Installation Dataplate ........................................................................................................................................71 5.1.6 Cartridge Operating Life ...................................................................................................................................................72 5.1.6.1 Calculating the Maximum Cartridge Operating Hours .....................................................................................................72 5.1.6.2 Calculating the Adjusted Cartridge Operating Hours .......................................................................................................72 5.1.7 Air Purification Cartridge Operating Hours......................................................................................................................74 5.2 P2 Purification System.............................................................................................................................................................75 5.2.1 Component Description ....................................................................................................................................................75 5.2.1.1 Chamber ............................................................................................................................................................................75 5.2.1.2 Cartridge............................................................................................................................................................................76 5.2.1.2.1 Cartridge Construction .....................................................................................................................................................76 5.2.1.2.2 Cartridge Handling............................................................................................................................................................76 5.2.1.3 Coalescing Oil/Water Separator........................................................................................................................................76 5.2.1.4 Condensate Drain Valve ...................................................................................................................................................76 5.2.1.5 Check Valves ....................................................................................................................................................................76 5.2.1.6 Bleed Valve .......................................................................................................................................................................76 5.2.1.7 Pressure Maintaining Valve ..............................................................................................................................................76
Table of Contents
-6-
1st Edition
OFFSHORE COMPRESSORS-O10 Para. 5.2.1.8 5.2.1.9 5.2.1.9.1 5.2.1.9.2 5.2.2 5.2.2.1 5.2.2.2 5.2.2.3 5.2.3
Title
Page
Safety Valve...................................................................................................................................................................... 77 Securus® Air Purification Monitoring System ................................................................................................................. 77 Securus® Cartridge ............................................................................................................................................................ 77 Securus® Indicator............................................................................................................................................................ 77 Maintenance ...................................................................................................................................................................... 78 Coalescing Oil/Water Separator ....................................................................................................................................... 78 Cartridge Replacement...................................................................................................................................................... 79 Leaking at the Safety Bore................................................................................................................................................ 79 Replacement Parts List ..................................................................................................................................................... 80
SECTION 6: COMPRESSOR DRIVE SYSTEM 6.1 Horizontal ................................................................................................................................................................................ 85 6.1.1 Maintenance of the V-belt and Sheave ............................................................................................................................. 85 6.1.1.1 Checking the Sheave......................................................................................................................................................... 85 6.1.1.2 Checking the V-belt .......................................................................................................................................................... 85 6.1.1.3 V-belt tension.................................................................................................................................................................... 85 6.1.1.4 Maintenance of the Drive Motor....................................................................................................................................... 86 6.1.1.4.1 Lubricating the Drive Motor ............................................................................................................................................. 86 6.2 Vertical Self Tensioning .......................................................................................................................................................... 87 6.2.1 Maintenance of the V-belt and Sheaves............................................................................................................................ 87 6.2.1.1 Check The Sheaves. .......................................................................................................................................................... 87 6.2.1.2 Check the V-belt ............................................................................................................................................................... 87 SECTION 7: MISCELLANEOUS 7.1 Pneumatic Valves and Controls............................................................................................................................................... 89 7.1.1 Nonadjustable Valves ....................................................................................................................................................... 89 7.1.2 Pressure Maintaining Valve .............................................................................................................................................. 89 7.1.3 Safety Valves .................................................................................................................................................................... 90 7.2 Electrical Controls ................................................................................................................................................................... 91 7.2.1 Final Pressure Switch........................................................................................................................................................ 91 7.2.1.1 Operating Set Point Adjustment ....................................................................................................................................... 91 7.2.1.1.1 Switch characteristics........................................................................................................................................................ 91 7.3 Fill Hoses ................................................................................................................................................................................. 93 7.3.1 Replacement Parts List. .................................................................................................................................................... 93 APPENDIX A: REFERENCE DATA A.1 Tightening Torque Values ................................................................................................................................................... 97 A.1.1 Torque Sequence Diagrams .............................................................................................................................................. 97 A.2 Approved Lubricants Chart ................................................................................................................................................. 98 A.3 Conversion Formulas ........................................................................................................................................................... 98 A.4 Glossary of Abbreviations and Acronyms........................................................................................................................... 99 APPENDIX B: SAFETY B.1 General Safety Precautions ................................................................................................................................................ 101 B.2 Safety Warning Labels....................................................................................................................................................... 103 APPENDIX C: LONG TERM STORAGE C.1 General............................................................................................................................................................................... 105 C.2 Preparations ....................................................................................................................................................................... 105 C.2.1 Units Equipped with a Filter System .............................................................................................................................. 105 C.3 Preserving the Compressor ................................................................................................................................................ 105 C.3.1 Preventive Maintenance During Storage ........................................................................................................................ 105
September 2002
-7-
Table of Contents
MNL-0311 Para. C.4 C.5
Title
Page
Lubrication Oils for Preservation.......................................................................................................................................106 Reactivating the Compressor Unit .....................................................................................................................................106
APPENDIX D: UNPACKING, HANDLING AND INSTALLATION D.1 Unpacking and Handling ...................................................................................................................................................107 D.2 Installation of the Compressor Unit ...................................................................................................................................107 D.2.1 General ............................................................................................................................................................................107 D.2.2 Ventilation.......................................................................................................................................................................108 D.2.2.1 Outdoor Installation ........................................................................................................................................................108 D.2.2.2 Indoor Installation ...........................................................................................................................................................108 D.2.2.3 Natural Ventilation..........................................................................................................................................................109 D.2.2.4 Forced Ventilation...........................................................................................................................................................109 D.2.3 Electrical Installation ......................................................................................................................................................110 D.2.3.1 Electric Drive ..................................................................................................................................................................110 D.2.3.2 Electrical Supply .............................................................................................................................................................110 APPENDIX E: REPRODUCIBLE FORMS E.1 Maintenance Record Forms ...............................................................................................................................................113 E.1.1 Scheduled Maintenance Form ........................................................................................................................................113 E.1.2 Record of Operating Hours ............................................................................................................................................116 E.1.3 Purifier Cartridge Adjusted Operating Hours. ................................................................................................................117 APPENDIX F: ADDITIONAL DOCUMENTS F.1 Diagrams and Drawings.....................................................................................................................................................119 F.2 Other Documents ...............................................................................................................................................................119
Table of Contents
-8-
1st Edition
OFFSHORE COMPRESSORS-O10 Para. Title 1.3 List of Figures Figure 1.1-1 Figure 2.1-1 Figure 2.1-2 Figure 2.1-3 Figure 2.1-4 Figure 3.1-1 Figure 3.1-2 Figure 3.1-3 Figure 3.1-4 Figure 3.1-5 Figure 3.1-6 Figure 3.1-7 Figure 3.1-8 Figure 3.1-9 Figure 3.1-10 Figure 3.1-11 Figure 3.1-12 Figure 3.1-13 Figure 3.1-14 Figure 3.1-15 Figure 3.1-16 Figure 3.1-17 Figure 3.1-18 Figure 3.1-19 Figure 3.1-20 Figure 3.1-21 Figure 3.1-22 Figure 3.1-23 Figure 3.1-24 Figure 3.1-25 Figure 3.1-26 Figure 3.1-27 Figure 3.1-28 Figure 3.1-29 Figure 3.1-30 Figure 3.1-31 Figure 3.1-32 Figure 3.2-1 Figure 3.2-2 Figure 3.2-3 Figure 3.2-4 Figure 3.2-5 Figure 3.2-6 Figure 3.2-7 Figure 5.1-1 Figure 5.1-2 Figure 5.1-3 Figure 5.1-4 Figure 5.1-5 Figure 5.1-6 Figure 5.2-1 Figure 5.2-2 Figure 5.2-3
Page
Compressor Unit Identification Plate .................................................................................................................... 2 Electric Drive ON/OFF Switch ........................................................................................................................... 16 Diesel Fuel Valve ................................................................................................................................................ 16 Diesel Decompression Lever............................................................................................................................... 16 Diesel Electric Starter .......................................................................................................................................... 16 IK12.14 II Compressor Block, Front View ......................................................................................................... 19 Air Flow Diagram................................................................................................................................................ 20 Lube Oil Circuit................................................................................................................................................... 21 Oil Sight Glass..................................................................................................................................................... 22 Oil Filler .............................................................................................................................................................. 22 Removing the Oil Filter Cover ............................................................................................................................ 22 Replacing the Oil Filter ....................................................................................................................................... 22 Intake Filter.......................................................................................................................................................... 23 3rd Stage Intermediate Separator......................................................................................................................... 24 Valve Operation................................................................................................................................................... 25 1st Stage Valve Operation ................................................................................................................................... 26 1st Stage Valve Head and Valves........................................................................................................................ 27 2nd Stage Valves ................................................................................................................................................. 28 3rd Stage Valve Head and Valves ....................................................................................................................... 29 Using the Special Tool PN 004555 ..................................................................................................................... 30 Securing the Intake Valve.................................................................................................................................... 31 4th Stage Valve Head and Valves ....................................................................................................................... 32 Removing the 4th Stage Pressure Valve.............................................................................................................. 33 Crankcase Assembly............................................................................................................................................ 34 1st/2nd Stage Piston and Cylinder....................................................................................................................... 36 3rd Stage Piston and Cylinder ............................................................................................................................. 37 4th Stage Piston and Cylinder ............................................................................................................................. 38 4th Stage Piston and Sleeve................................................................................................................................. 39 1st Stage Valve Head and Valve ......................................................................................................................... 40 2nd Stage Valves and Valve Head....................................................................................................................... 41 3rd Stage Valves and Valve Head ....................................................................................................................... 42 4th Stage Valves and Valve Head ....................................................................................................................... 44 2nd Stage Intermediate Separator........................................................................................................................ 45 3rd Stage Intermediate Separator......................................................................................................................... 46 Intake Filter.......................................................................................................................................................... 47 Cooling System.................................................................................................................................................... 48 Lubrication System.............................................................................................................................................. 50 4 Stage Automatic Condensate Drain System ..................................................................................................... 55 ACD Operation Diagrams ................................................................................................................................... 56 ACD Timer .......................................................................................................................................................... 57 4 Stage ACD System ........................................................................................................................................... 59 ACD Manifold and Valves .................................................................................................................................. 60 3rd Stage Condensate Drain Valve...................................................................................................................... 62 Oil and Water Separator Condensate Drain Valve .............................................................................................. 64 Cartridge Safety Venting ..................................................................................................................................... 70 Compressor Unit Identification Plate .................................................................................................................. 70 Purification System Dataplate (typical)............................................................................................................... 71 Cartridge Installation Dataplate (typical) ............................................................................................................ 71 Correction Factor for Cartridge Operating Hours ............................................................................................... 73 Example Record of Adjusted Operating Hours ................................................................................................... 73 P2 Purification System ........................................................................................................................................ 75 Oil and Water Separator ...................................................................................................................................... 78 Cartridge Replacement ....................................................................................................................................... 79
September 2002
-9-
List of Figures
MNL-0311 Para.
Title
Figure 5.2-4 Figure 5.2-5 Figure 5.2-6 Figure 6.1-1 Figure 6.1-2 Figure 6.2-1 Figure 7.1-1 Figure 7.1-2 Figure 7.2-1 Figure 7.3-1 Figure 7.3-2 Figure 7.3-3 Figure 7.3-4 Figure A.1-1 Figure D.1-1
List of Figures
Page
P2 Oil and Water Separator .................................................................................................................................80 27” Chamber Assembly .......................................................................................................................................81 Securus® Air Purification Monitoring System ....................................................................................................82 Horizontal Motor Mount (typical) .......................................................................................................................85 V-belt Deflection .................................................................................................................................................86 Vertical Motor Mount (typical) ...........................................................................................................................87 Pressure Maintaining Valve.................................................................................................................................89 Safety Valves .......................................................................................................................................................90 Pressure Switch....................................................................................................................................................91 Dual Fill Hose Assembly .....................................................................................................................................93 SCUBA Fill Hose Assembly ...............................................................................................................................94 Low Pressure Hose Adapter Assembly ...............................................................................................................95 Special Fill Adapter Assembly ............................................................................................................................96 6 Bolt and 4 Bolt Torque Sequence .....................................................................................................................97 Lifting Devices ..................................................................................................................................................107
-10-
1st Edition
OFFSHORE COMPRESSORS-O10 1.4 Description and Specifications 1.4.1 Unit Description The BAUER O10 -E3 model is a three phase electric motor driven unit in a vertical configuration. The O10-D model is a diesel engine driven unit in a horizontal configuration for both units the capacity is 10.2 SCFM charging rate with discharge pressures of up to 5,000 PSIG. Standard features •
BAUER Breathing Air Purification System
•
Air-cooled Interstage Coolers and Aftercooler
•
Interstage and Final Separator with Manual Drains
•
Interstage and Final Relief Valves
•
Belt Guard designed to meet OSHA guidelines
•
Inlet Filter
•
High Temperature Switch
•
Hourmeter
•
Low Oil Pressure Switch
•
Oil Pressure Gauge
•
Final Pressure Switch
•
Final Pressure Gauge
•
Automatic Condensate Drain
Factory Installed Optional Features The following optional items may have been added if ordered at time of manufacture. •
Securus® Electronic Purification Monitoring System
•
Electronic Carbon Monoxide Monitor with Alarm and Calibration Kit
•
Hydrogen Sulfide Monitor with Audible Alarm
September 2002
-11-
Unit Description
MNL-0311 1.4.2 Unit Specifications All specifications are subject to change without prior notice. 1.4.2.1
O10-D Medium Charging Rate Free Air Delivery Inlet pressure Operating pressure, max. Ambient temperature range
air 10.2 scfm1 8.5 scfm2 atmospheric 5,000 psig 32° to 105° F
1.4.2.1.1 Compressor Block, IK12.14 II No. of stages No. of cylinders Cylinder bore, 1st stage Cylinder bore, 2nd stage Cylinder bore, 3rd stage Cylinder bore, 4th stage Piston Stroke Intermediate pressure, 1st stage Safety valve setting, 1st stage Intermediate pressure, 2nd stage Safety valve setting, 2nd stage Intermediate pressure, 3rd stage Safety valve setting, 3rd stage Direction of rotation when facing flywheel Compressor speed Oil capacity Oil Pressure Recommended oil (Synthetic) Maximum Inclination
4 3 4.2 in. (105 mm) 4.15/3.46 in. (105/88 mm) 1.10 in. (28 mm) 0.47 in. (12 mm) 1.57 in. (40 mm) 44 psig (2.5-3 bar) 80 psig (5.5 bar) 261 psig (14 - 18 bar) 348 psig (24 bar) 1233 psig (55 - 85 bar) 1378 psig (95 bar) CCW 1180 RPM 3.0 qts. 73 psig BAUER OIL-0024 15° in all directions
1.4.2.1.2 Compressor Drive
-D
Fuel
Cylinders
Power
RPM
BAUER PN
Diesel
1
10 Hp
1800
ENG-0052
1.
Based on recharging an 80 cubic foot tank from 500 to 3000 PSIG
2.
Referenced to standard inlet conditions of 68°F and 36% humidity at 14.70 psia.
Unit Specifications
-12-
1st Edition
OFFSHORE COMPRESSORS-O10 1.4.2.2
O10-E3 Medium Charging Rate Free Air Delivery Inlet pressure Operating pressure, max. Ambient temperature range
air 10.2 scfm1 8.5 scfm2 atmospheric 5,000 psig 32° to 105° F
1.4.2.2.1 Compressor Block, IK12.14 II No. of stages No. of cylinders Cylinder bore, 1st stage Cylinder bore, 2nd stage Cylinder bore, 3rd stage Cylinder bore, 4th stage Piston Stroke Intermediate pressure, 1st stage Safety valve setting, 1st stage Intermediate pressure, 2nd stage Safety valve setting, 2nd stage Intermediate pressure, 3rd stage Safety valve setting, 3rd stage Direction of rotation when facing flywheel Compressor speed Oil capacity Oil Pressure Recommended oil (Synthetic) Maximum Inclination
4 3 4.2 in. (105 mm) 4.15/3.46 in. (105/88 mm) 1.10 in. (28 mm) 0.47 in. (12 mm) 1.57 in. (40 mm) 44 psig (2.5-3 bar) 80 psig (5.5 bar) 261 psig (14 - 18 bar) 348 psig (24 bar) 1233 psig (55 - 85 bar) 1378 psig (95 bar) CCW 1180 RPM 3.0 qts. 73 psig BAUER OIL-0024 15° in all directions
1.4.2.2.2 Compressor Drive
-E3
Voltage
Frequency
Phase
Power
RPM
Type
208 - 460 VAC
60Hz
3Φ
7.5 Hp
3600
ODP
1.4.2.3 Purification System Applicability The O10 Offshore Compressors may have the P2 or the P2S Purification Systems. The P2S is a factory installed option.
1.
Based on recharging an 80 cubic foot tank from 500 to 3000 PSIG
2.
Referenced to standard inlet conditions of 68°F and 36% humidity at 14.70 psia.
September 2002
-13-
Unit Specifications
OFFSHORE COMPRESSORS-O10 SECTION 2: OPERATION 2.1 Electric Motor or Diesel Engine Driven Units The safety instructions applicable to this product are contained in Appendix B. They must be read, understood and complied with prior to operating the product. 2.1.1 Pre-start Checks 1. Ensure that all scheduled maintenance is completed. 2. Check compressor oil level. Refer to Paragaph 3.1.4.2. 3. Check compressor diesel drive engine oil level. Refer to Original Equipment Manufacturers (OEM) manual. 2.1.2 Start-up Procedure 1. Complete all Pre-start checks. 2. Verify that all connections downstream of the compressor are secure. 3. Open the condensate drain valves to relieve any remaining pressure. 4. Close the condensate drain valves. 5. Apply electric power to the unit. 6. Refer to the following instructions for the specific type of compressor drive. 2.1.2.1 Electric Motor 7. Turn the ON/OFF switch to the ON position. (See Figure 2.1-1). 8. Immediately check the direction of motor rotation (CCW when viewed from the flywheel side}. 9. Return the ON/OFF Switch to the OFF position if rotation is incorrect. See Paragraph 3.1.10.1 for corrective action. 2.1.2.2 Diesel Engine 1. Read and understand the OEM manual operating instructions. 2. Check the fuel level and refill the fuel tank if required 3. Open the fuel valve. (See Figure 2.1-2). 4. Move the Decompression Lever to START (See Figure 2.1-3). 5. Turn the ignition key to the start position. (See Figure 2.1-4). Release the key after the engine is started.
September 2002
-15-
Pre-start Checks
MNL-0311
Figure 2.1-1
Electric Drive ON/OFF Switch
Figure 2.1-2
Diesel Fuel Valve
Figure 2.1-3
Diesel Decompression Lever
Figure 2.1-4
Diesel Electric Starter
2.1.3 Post Start Procedures 1. Allow the compressor to build up pressure. Monitor the pressure gauge. 2. Listen to the unit as it operates. If excessive knocking or vibrations are observed shut down the unit. 3. Refer to the Troubleshooting section for additional instructions. 4. Allow the compressor to reach full pressure. 5. Fill storage bottles. 2.1.4 Shutdown Procedures 6. Verify all bottle valves and fill valves are closed. 7. Refer to Paragaph 2.1.4.1 or Paragaph 2.1.4.2 for the shut down procedures for each type of compressor drive. Post Start Procedures
-16-
1st Edition
OFFSHORE COMPRESSORS-O10 8. After shutting down the compressor drive, open the condensate drain valves to relieve any remaining pressure and drain any moisture from the intermediate separators and the oil and water filter. 9. Close the condensate valves. 10. If the compressor is to remain idle for six months or longer, refer to Section C, Long Term Storage for preservation instructions. 2.1.4.1 Electric Motor 1. Turn the ON/OFF switch to the OFF position. (See Figure 2.1-1). 2.1.4.2 Diesel Engine 1. Move the decompression lever to the STOP position. (See Figure 2.1-3). 2. Close the fuel valve. (See Figure 2.1-2).
September 2002
-17-
Shutdown Procedures
OFFSHORE COMPRESSORS-O10 SECTION 3: MAINTENANCE AND PARTS 3.1 Compressor Block - IK12.14 II 3.1.1 Description The IK12.14 II compressor block is used to compress air up to 6000 psi. This compressor is a four stage, three cylinder air cooled, oil lubricated reciprocating compressor. The cylinders are arranged in a “W” configuration, the 1st/2nd stage vertical stepped cylinder is in the center, 3rd stage on the right and 4th stage on the left looking from the filter side. These compressor blocks are particularly suitable for continuous operation because of their rugged design and corrosion resistant intermediate filter and cooler assemblies. 3.1.2
Component Location Figure 3.1-1
IK12.14 II Compressor Block, Front View
1. 1st Stage Valve Head 2. 1st Stage Safety Valve 3. 2nd Stage Intake Manifold 4. Oil Filler Neck 5. 4th Stage Cylinder 6. 3rd Stage Safety Valve 7. 3rd Stage Intermediate Separator 8. 3rd Stage Intercooler 9. Manual Condensate Drain Valvea 10. Condensate Drain Connector a.
11. Intake Filter 12. 2nd Stage Pressure Manifold 13. 3rd Stage Cylinder 14. 2nd Stage Safety Valve 15. Oil Filter Housing 16. 2nd Stage Intermediate Separator 17. 2nd Stage Intercooler 18. Oil Drain Plug 19. 4th Stage Aftercooler
Used only if ACD is not installed
September 2002
-19-
Description
MNL-0311 3.1.3 Air Flow Diagram Refer to Figure 3.1-2. The air is drawn in through intake filter (1), compressed to the final pressure in cylinders (2, 3, 4, and 5) and cooled by intercoolers (6, 7 and 8) and aftercooler (9). The safety valves (13, 14, 15 and 16) protect from overpressure in the individual stages. The compressed air is filtered by intermediate separator (10 and 11) and oil and water separator assembly (12). The intermediate separator (10 and 11) and oil and water separator (12) are drained by condensate valves (18). An Automatic Condensate Drain system is available as an option. The pressure maintaining valve (17) keeps the pressure constant within the separators (10, 11 and 12). Figure 3.1-2
Air Flow Diagram
13 8
6
7
15
1
9
14 16
2 11
10
17
3 5
12 4
18
1. 2. 3. 4. 5. 6. 7. 8. 9.
Air Filter 1st Stage Cylinder 2nd Stage Cylinder 3rd Stage Cylinder 4th Stage Cylinder 1st Stage Intercooler 2nd Stage Intercooler 3rd Stage Intercooler 4th Stage Aftercooler
Air Flow Diagram
18
18
10. Intermediate Separator after 2nd Stage 11. Intermediate Separator after 3rd Stage 12. Oil and Water Separator 13. 1st Stage Safety Valve 14. 2nd Stage Safety Valve 15. 3rd Stage Safety Valve 16. 4th Stage Safety Valve (Final Pressure) 17. Pressure Maintaining Valve 18. Manual Condensate Drain Valves
-20-
1st Edition
OFFSHORE COMPRESSORS-O10 3.1.4 Lubrication System Refer to Figure 3.1-3. The compressor is provided with forced-feed lubrication. The oil pressure is produced by a low speed gear pump. The oil pressure is approximately 73 psi. The oil pump (1) is coupled to and driven by the crankshaft. It pumps oil through the oil filter (2) and a minimum pressure valve (3) to the 4th stage cylinder. The oil is then distributed by the guide piston (4) of the 4th stage and lubricates all the moving parts of the compressor block. The minimum pressure valve allows for oil pressure indication at a pressure gauge and/or electronic oil pressure monitoring. Figure 3.1-3
Lube Oil Circuit
3 2 4 1
5
5
1. Oil Pump 2. Oil Filter 3. Minimum Pressure Valve
4. Guide Piston 5. Oil Sight Glass
3.1.4.1 Type of Oil For proper care and maintenance of the compressor, using the correct oil is of vital importance. Due to the thermal load on the compressor only high quality oil should be used. You are recommended to restrict oils to those which have been approved by BAUER Compressors, Inc. and are listed in Unit Specifications found in Section 1.4.
September 2002
-21-
Lubrication System
MNL-0311
Figure 3.1-4
Oil Sight Glass
Figure 3.1-5
Oil Filler
Figure 3.1-6
Removing the Oil Filter Cover
Figure 3.1-7
Replacing the Oil Filter
3.1.4.2 Oil Level Check Check the oil level at the sight gauge on either side of the compressor block (See Figure 3.1-4) every day before putting the compressor into operation. Oil level must be between the minimum and maximum marks. Oil level must never be below the minimum mark as this will cause severe damage due to lack of lubrication. Oil level must also not exceed the maximum mark as this will cause excessive lubrication of the compressor and may result in a carbon buildup on the valves.
Lubrication System
-22-
1st Edition
OFFSHORE COMPRESSORS-O10 3.1.4.3 Oil Change See the Maintenance Schedule, Section 4 for the recommended interval. 1. Run the compressor until it is warm then shut it down. 2. (See Figure 3.1-5). Remove the cap from the oil filler neck. 3. Drain oil while it is still warm by means of the oil drain plug. CAUTION Replace the oil filter every oil change. Failure to do so will cause the filter to clog and the bypass valve to open resulting in unfiltered oil being circulated and possible damage to the compressor. 4. (See Figure 3.1-6). Remove the two bolts (1) with a 13 mm wrench. Remove the oil filter cover (2) 5. (See Figure 3.1-7). Remove the oil filter (1) from the rubber gasket at the cover. 6. Mount a new filter element (P/N N25326) and replace and fasten oil filter cover. 7. Slowly pour new oil through the oil filler neck until the level reaches the maximum mark on the sight gauge. 8. Wait a few minutes and adjust the oil level if necessary before putting the unit into operation. 3.1.5 Intake Filter 3.1.5.1 Description A dry, micronic filter is used to filter the intake air, see Figure 3.1-8.
Figure 3.1-8
Intake Filter
O-Ring Body
Spring
Filter Cartridge
Cap
3.1.5.2 Intake Filter Maintenance The filter cartridge must be cleaned and changed at regular intervals. See the Maintenance Schedule, Section 4 for the recommended interval. 1. Clean the filter cartridge with a brush or by blowing air from the inside of the cartridge to the outside. 2. Turn the cartridge 90° when replacing it. Change the cartridge filter after it has been turned three times and thus is dirty on all sides. 3. Clean the inside of the filter body with a damp cloth. take care to prevent dust from entering the intake pipe. 4. Replace the O-ring if necessary.
September 2002
-23-
Intake Filter
MNL-0311 3.1.6 Intermediate Separator Two intermediate separators are mounted on the compressor, one after the 2nd stage and another after 3rd stage. These separators are designed to remove oil and water which accumulates due to the cooling of the air after the compression process. Separation is achieved by means of centrifugal action. In the 2nd stage separator the design of the filter head provides this action. In the 3rd stage separator the centrifugal action is provided by a vortex plate additionally a sintered metal filter is provided to remove dirt contamination.. Figure 3.1-9
3rd Stage Intermediate Separator
Filter Head Knurled Nut Distribution Plate
Baffle Funnel
Filter Insert
Center Screw
WARNING Dynamic Loading The rapid depressurizing and repressurizing of the intermediate separator during condensate draining subjects it to metallurgical stresses. To prevent catastrophic failure with the possibility of damage, injury or death the intermediate separator must be replaced after 85,000 load cycles. A load cycle equals one depressurization- repressurization. The BAUER recommended frequency of condensate draining is every fifteen minutes and is a balance between maximizing the life of the oil and water separator chamber and maintaining the quality of the delivered air. 3.1.6.1 Maintenance Proper operation of the compressor requires that the intermediate separator be properly serviced. See the Maintenance Schedule Section 4 for the correct interval. See Figure 3.1-9 and proceed as follows: 1. Remove piping connected to the filter head. 2. Screw off the knurled nut. Intermediate Separator
-24-
1st Edition
OFFSHORE COMPRESSORS-O10 3. Remove filter head along with the sintered metal filter. 4. Remove the center screw and separate the sintered metal filter, baffle cone, and vortex plate from the filter head. 5. Use hot soapy water to clean the filter insert and blow it dry with compressed air. 3.1.7 Cooling The cylinders of the compressor, the intermediate coolers and the after cooler are air cooled. For this purpose the compressor is equipped with a fanwheel which draws the cooling air through the unit. The fanwheel is driven by the drive motor V-belt and is also used as the compressor flywheel. 3.1.7.1 Maintenance When dirty, clean the finned tubes, valve heads and cylinders by blowing off the dirt and dust with low pressure compressed air (80 -125 psi) 3.1.8 Compressor Valves and Heads 3.1.8.1 Functional Description The valve heads of the individual stages form the top part of the cylinders. (See Figure 3.1-10). Figure 3.1-10 Valve Operation
The intake and pressure valves are fitted inside the valve heads. Note that the valves are operated by the flow of the medium. On the intake stroke, the intake valves open and the medium flows into the cylinders. At the start of the pressure stroke the intake valve closes and the medium opens the pressure valve. The intake and pressure valve of the 1st stage are in a combined plate valve under the valve head. (See Figure 3.1-11.)
September 2002
-25-
Cooling
MNL-0311
Figure 3.1-11 1st Stage Valve Operation
Pressure Side
Intake Side
Top View
3.1.8.2 General Instructions for Changing the Valves • Always replace valves as a complete set. •
Carefully clean dirty valves. Never use a sharp tool for this purpose. Soak the valves in Varsol and clean with a soft brush.
•
Check the individual components for excessive wear. If the valve seat or valve discs are dented, replace the valves.
•
Check the valve space in the valve heads for dirt, and clean if necessary.
•
Use only satisfactory gaskets and O-rings during reassembly.
•
Observe the correct sequence when reassembling.
•
After finishing all maintenance work on the valves, turn the compressor manually using the flywheel and check whether all items have been correctly installed.
•
30 minutes after restarting the compressor, stop the unit, let it cool down to ambient temperature, and retighten valve studs and cap nuts. Otherwise the gasket set may cause a leak.
•
Remove and check the valves every 1000 operating hours, unless otherwise specified in the Maintenance Schedule.
•
Replace the valves every 2000 operating hours to avoid fatigue failure, unless otherwise specified in the Maintenance Schedule.
Compressor Valves and Heads
-26-
1st Edition
OFFSHORE COMPRESSORS-O10
Figure 3.1-12 1st Stage Valve Head and Valves 6
1
5 2
3
4
1. Valve Head 2. Gasket 3. Plate Valve
4. O-ring 5. O-ring 6. Allen Screw
3.1.8.3 Changing the 1st Stage Valve See Figure 3.1-12 and proceed as follows: 1. Remove valve head (1). 2. Remove valve gasket (2) 3. Note orientation of plate valve (3) before removing it. 4. Check condition of valve gasket (2) and O-ring (4). Replace if required. 5. Reassembly is the reverse of the above steps. Ensure that the plate valve mark “TOP” is facing up.
September 2002
-27-
Compressor Valves and Heads
MNL-0311
Figure 3.1-13 2nd Stage Valves
1 2 3 2 2 4 2 1
5
1. Manifold 2. Gasket 3. Intake Valve
4. Pressure Valve 5. Allen Screw
3.1.8.4 Changing the 2nd Stage Valves See Figure 3.1-13 and proceed as follows: 1.
Remove the lines from the intake and pressure manifolds (1).
2. Remove the Allen Screws (5). 3. Remove gaskets (2) and replace with new ones. 4. Clean intake valve (3) and pressure valve(4) and check for deterioration. 5. Reassemble in reverse order of above.
Compressor Valves and Heads
-28-
1st Edition
OFFSHORE COMPRESSORS-O10
Figure 3.1-14 3rd Stage Valve Head and Valves 1
8
2
3 7 4
6 5
1. 2. 3. 4.
Cap Nut Stud Pressure Plug O-ring
5. 6. 7. 8.
Pressure Valve Intake Valve Valve Head Allen Screw
3.1.8.5 Changing the 3rd Stage Valves 3.1.8.5.1 Removal See Figure 3.1-14 and proceed as follows: 1. Remove the intake and pressure lines from the valve head (7). 2. Remove the allen screws (8) holding the valve head onto the cylinder. 3. Replace two of the screws with two 8mm diameter metal pins of any length. 4.
Use these pins as a holding fixture by securing them in a vise with the valve head on top.
5. Using the special tool provided with the unit, remove the intake valve (6) (See Figure 3.1-15). 6. Turn the valve head over and replace it on the metal pins. 7. Remove the cap nut (1) 8. Unscrew the stud (2) approximately five turns. 9. Remove the pressure plug (3) and take out the valve parts. 10. Clean the intake and pressure valves and check for wear 11. Clean and check the valve springs. Compare their dimensions with the values in Table Table 3-1:. 12. Clean the valve head. check that the intake and pressure valve bores are in perfect condition. September 2002
-29-
Compressor Valves and Heads
MNL-0311 13. Using a precision straightedge, check that the underside of the valve head is flat. If necessary use an emery cloth to smooth out the surface.
Figure 3.1-15 Using the Special Tool PN 004555
NOTE Valve seats and plate valves must not show any signs of wear or damage. Replace damaged or worn parts.
Valve Stroke
Minimum
Maximum
Intake Valve
0.032 in (0.80 mm)
0.04 in (1.05 mm)
Pressure Valve
0.026 in (0.65 mm)
0.037 in (0.95 mm)
Valve Spring
Normal Length
Intake Valve
0.35 - 0.41 in (9 - 10.5 mm)
Pressure Valve
0.83- 0.95 in (21 - 24 mm)
Table 3-1: Valve Dimension Limits
Compressor Valves and Heads
-30-
1st Edition
OFFSHORE COMPRESSORS-O10
Figure 3.1-16 Securing the Intake Valve
3.1.8.5.2 Reassembly. 1. Replace the intake valve (6) using the special tool to tighten it. CAUTION The intake valve plate and valve spring must not be jammed. 2. Check the intake valve functions correctly by blowing compressed air through the valve in the direction of flow. 3. Secure the intake valve by peening the valve head aluminum over the screw-in thread of the intake valve in two places opposite one another. Use a small drift pin, approximately 5mm in diameter. (See Figure 3.1-16). 4. Insert the O-ring (4) and the pressure valve parts(5). 5. Check the pressure valve function and stroke by lifting the valve parts. 6. Ensure the stud (2) is unscrewed, then screw in the pressure plug (3)and tighten. 7. Screw the stud (2) in firmly, fit a new gasket and secure it with the cap nut (1). 8. Replace the valve head (7) on the cylinder and secure it with the screws (8). 9. Reconnect the intake and pressure lines.
September 2002
-31-
Compressor Valves and Heads
MNL-0311
Figure 3.1-17 4th Stage Valve Head and Valves 1 9
2 3
8 4 5 7
6
1. 2. 3. 4. 5.
Cap Nut Gasket Stud O-ring Pressure Valve
6. 7. 8. 9.
Intake Valve Valve Head Valve Head Cover Allen Screw
3.1.8.6 Changing the 4th Stage Valves 3.1.8.6.1 Removal See Figure 3.1-17 and proceed as follows: 1. Remove the intake and pressure lines from the valve head (7). 2. Remove the cap nut (1) and loosen stud (3) three or four turns. 3. Remove the screws (9) holding the valve head onto the cylinder and take off valve head cover (8). 4. Remove the pressure valve by putting two screwdrivers into the removal groove of the pressure valve body. See Figure 3.1-18. It may be necessary to loosen the valve body first by turning it with a 13 mm wrench used on the flat surfaces. 5. Insert two 8mm diameter metal pins, any length, in the holes in the valve head and secure them in a vise with the valve head on top of the vise. The intake valve should be facing up. 6. Using the special tool provided with the unit (See Figure 3.1-15), remove the intake valve (6).
Compressor Valves and Heads
-32-
1st Edition
OFFSHORE COMPRESSORS-O10
Figure 3.1-18 Removing the 4th Stage Pressure Valve
3.1.8.6.2 Reassembly 1. Replace the intake valve (6) using the special tool to tighten it. 2. Check the intake valve functions correctly by blowing compressed air through the valve in the direction of flow. 3. Secure the intake valve as follows: (See Figure 3.1-16) Peen the valve head aluminum over the screwin thread of the intake valve in two places opposite one another. Use a small drift pin, approximately 5mm in diameter. 4. Reinstall the pressure valve (5) by putting O-ring (4) into valve head (7). Check it for abrasions. 5. Insert pressure valve through O-ring and into valve bore. 6. Put on valve head cover (8). 7. Reassemble valve head cover and valve head to cylinder. Torque screws (9) to the proper value. 8. Screw in stud (3). Put on gasket (2). Screw on cap nut. (1)
September 2002
-33-
Compressor Valves and Heads
MNL-0311 3.1.9
Replacement Parts List
Figure 3.1-19 Crankcase Assembly 6 11 12 13
2
15
3 28
4
16
1 14
17 8
18
9 10 26 27
19
25
16 5
4
18
17 22
7
19
Item Qty ◊ 1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 1 1 1 2 1 1 1 1 1 1 1 1 1 1
22
23 24
20 21
Part No.
Description
Notes
076743 076740 078104 N2638 N2635 66209 N15406 N15265 66684 N170 N3745 61054 N15412 73830 N4776
Crankcase assembly Crankcase Crankshaft, complete Roller Bearing Circlip Bearing Cap Roller Bearing O-ring Cover Shaft Seal O-ring Plug O-ring Oil Filling Pipe O-ring
with accessories, driving gear
Replacement Parts List
IK12.14 II
-34-
1st Edition
OFFSHORE COMPRESSORS-O10 Figure 3.1-19 (cont.) Item Qty 15 16 17 18 19 20 21 22 23 24 25 26 27 28
2 8 2 2 2 1 1 2 4 4 4 4 6 3
Crankcase Assembly
Part No.
Description
SCR-0020 WAS-0021 N4163 PLU-0040 N25475 N1316 N4570 78038 WAS-0030 NUT-0076 WAS-0031 N350 SCR-0113 N16126
Allen Screw Washer Gasket Plug Oil Sight Gauge Gasket Plug Support Spring Washer Hex Nut Washer Hex Head Screw Hex Head Screw Countersunk Screw
September 2002
Notes
-35-
Replacement Parts List
MNL-0311
Figure 3.1-20 1st/2nd Stage Piston and Cylinder TOP 5
7
3
TOP 8 5
4
6
1
11 10
9 2
Item Qty ◊ 1 2 3 4 5 6 7 8 9 10 11
1 1 1 1 1 2 † 1 1 4 4 4
Part No.
Description
Notes
78110 77998 N4654 78095 78097 N484 N802 N25842 N25396 N215 WAS-0021 NUT-0119
Piston and Cylinder Assembly Stepped Cylinder O-ring Piston Assembly, IK12.14 II Stepped Piston Circlip Piston Pin Piston Ring Set Piston Ring Set Stud Washer Self Locking Hex Nut
IK12.14 II 88/105 mm
Replacement Parts List
-36-
88/105 mm
1st Stage,105 mm 2nd Stage, 88 mm
1st Edition
OFFSHORE COMPRESSORS-O10
Figure 3.1-21 3rd Stage Piston and Cylinder 5 6
1 2 3
7
9
4 11 10 8
Item Qty ◊ 1 2 3 4 5 6 7 ◊ 8 9 10 11
1 1 1 1 1 4 4 4 1 1 2 † 1
9
Part No.
Description
78335 67940 N7063 66222 N2640 N370 WAS-0021 N2790 78334 67942 N484 N1429 N19833
Cylinder, 3rd Stage Cylinder O-ring Guide Cylinder O-ring Self Locking Hex Nut Washer Stud Piston Assembly Piston Circlip Piston Pin Piston Ring Set
September 2002
Notes
-37-
28 mm
Items 8-11
Replacement Parts List
MNL-0311
Figure 3.1-22 4th Stage Piston and Cylinder 1
2
3 4
6
5 7
9 8
12 10
Item Qty ◊ 1 2 3 4 5 6 7 8 9 10 11 12
1 1 1 1 1 1 4 4 4 1 1 † 2
Part No.
Description
78044 078045 76754 N7063 62476 N2640 NUT-0119 WAS-0021 N2790 072165 N858 N1429 N484
Cylinder, 4th Stage Piston and Sleeve Assembly Cylinder O-ring Guide Cylinder O-ring Self Locking Hex Nut Washer Stud Guide Piston Assembly Guide Piston Piston Pin Circlip
Replacement Parts List
11
Notes
-38-
(See Figure 3.1-23)
Items 10 - 12
1st Edition
OFFSHORE COMPRESSORS-O10
Figure 3.1-23 4th Stage Piston and Sleeve 1 2
3 5 4
Item Qty ◊ 1 2 3 4 5
1 1 1 1 1 1
Part No.
Description
078045 † N23755 † N2320 †
Piston and Sleeve Assembly Piston O-ring Piston Liner O-ring Piston Ring Set
September 2002
Notes
-39-
Available only with 078045 Available only with 078045 Available only with 078045
Replacement Parts List
MNL-0311
Figure 3.1-24 1st Stage Valve Head and Valve 6
1
5 2
3
4
Item Qty ◊ 1 2 3 4 5 6
1 1 1 1 1 1 4
Part No.
Description
073429 67936 67979 N17950 N17959 N1539 N354
1st Stage Valve Head Valve Head Gasket Plate Valve O-ring O-ring Allen Screw
Replacement Parts List
Notes
-40-
1st Edition
OFFSHORE COMPRESSORS-O10
Figure 3.1-25 2nd Stage Valves and Valve Head
1 2 3 2 2 4 2 1
5
Item Qty ◊ 1 2 3 4 5
1 2 4 1 1 8
Part No.
Description
73435 78562 56668 N4067 N4068 SCR-0133
Valve Head, 2nd Stage Manifold Gasket Intake Valve Pressure Valve Allen Screw
September 2002
Notes
-41-
Replacement Parts List
MNL-0311
Figure 3.1-26 3rd Stage Valves and Valve Head
19 18 20 17
16
15 1 7
8
14
13
6 2
5
12
4
11
9
10 3
Item Qty ◊ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1
7
Part No.
Description
69792 14123 012836 † † † † 240 014582 012835 † † 1026 † N3521 14332
Valve Head, 3rd Stage Valve Head Intake Valve Assembly Intake Valve Body Spring Valve Plate Valve Seat Gasket Pressure Valve Assembly Pressure Valve Insert Valve Seat Valve Plate Spring Valve Insert O-ring Spring Washer
Replacement Parts List
Notes
-42-
Items 3 - 6 Available only with 012836 Available only with 012836 Available only with 012836 Available only with 012836 Items 9, 14 - 19 Items 10 - 13 Available only with 012835 Available only with 012835 Available only with 012835
1st Edition
OFFSHORE COMPRESSORS-O10 Figure 3.1-26 (cont.) Item Qty 16 17 18 19 20
1 1 1 1 6
3rd Stage Valves and Valve Head
Part No.
Description
14124 71064 N380 N84 SCR-0180
Coupling Stud Gasket Cap Nut Allen Screw
September 2002
Notes
-43-
Replacement Parts List
MNL-0311
Figure 3.1-27 4th Stage Valves and Valve Head 1 9
2 3
8 4 5 7
6
Item Qty ◊ 1 2 3 4 5 6 7 8 9
1 1 1 1 1 1 1 1 1 6
Part No.
Description
68607 N3623 N3625 71065 N2789 014121 07790 65191 14118 N1282
Valve Head, 4th Stage Cap Nut Gasket Stud O-ring Pressure Valve Intake Valve Valve Head Valve Head Cover Allen Screw
Replacement Parts List
Notes
Includes Item 4
-44-
1st Edition
OFFSHORE COMPRESSORS-O10
Figure 3.1-28 2nd Stage Intermediate Separator
3 1
2 4
5
6 7
Item Qty ◊ 1 2 3 4 5 6 7
1 † 1 1 1 † 1 1
Part No.
Description
78269 … N3556 76613 13937 … N1316 N20215
Intermediate Separator Filter Head O-ring Screw In Part Assembly Knurled Ring Filter Housing Gasket Connector
September 2002
Notes
-45-
Available only with 78269
Available only with 78269
Replacement Parts List
MNL-0311
Figure 3.1-29 3rd Stage Intermediate Separator
2
8
3 1
4 5 9
6
7
10
11 12
Item Qty ◊ 1 2 3 4 5 6 7 8 9 10 11 12
1 1 † 1 1 1 1 1 1 1 † 1 1
Part No.
Description
78189 78188 … 12784 12785 N2726 12786 N3556 76613 13937 … N1316 N20215
Intermediate Separator Filter Head Assembly Filter Head Distribution Plate Baffle Funnel Filter Insert Center Screw O-ring Threaded Assembly Knurled Ring Filter Housing Gasket Connector
Replacement Parts List
Notes
-46-
Available only with 78189 Available only with 78189
1st Edition
OFFSHORE COMPRESSORS-O10
Figure 3.1-30 Intake Filter
4 3
7
2 6
1 5
Item Qty ◊ 1 2 3 4 5 6 7
1 † 1 1 1 1 † 1
Part No.
Description
13758 12771 10528 N4451 N70 13757 12770 N3374
Intake Filter Assembly Intake Filter Cover Pressure Spring O-ring Filter Insert O-ring Intake Filter Housing Clamp
September 2002
Notes
-47-
Available only with 13758
Available only with 13758
Replacement Parts List
MNL-0311
Figure 3.1-31 Cooling System 7 11
65 4
89
10
1 4 5 6 7 18
4140
27 17
3
31
32 16 27 26
19
23 20
◊ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1 1 1 1 4 4 4 4 1 4 3 3 1 3 3 1 1 1 1
27
27 49 37 36 38 48
27
33
26 27
39
32 33
6 54 27
32
30
31 33
35 34
31
35 34
25
Part No.
Description
78293 078295 N20202 N00001 N25451 N25452 N25449 N25450 N20231 N00293 WAS-0021 NUT-0119 078200 011887 078199 078301 N20208 056983 071148
Cooling System Assembly 1st - 2nd Stage Intercooler Fitting Dome Nut Gasket O-ring Banjo Fitting Banjo Bolt Male Connector Gasket Washer Hexagon Nut Self Locking Fan Guard Double Strap Bracket Stud Aftercooler Connector Gasket Connector, Male
Replacement Parts List
7 28
27
15 26
22
4
7 6 5
46
31 32
42 9
28 27
22
Item Qty
27 28
30
21
24
27
27
2
12 13 14
42
9
26 27
30
Notes
-48-
1st Edition
OFFSHORE COMPRESSORS-O10 Figure 3.1-31 (cont.) Item Qty 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49
4 12 4 8 2 5 1 5 14 3 1 4 4 4 4 4 4 2 1 1 1 1 2 2 1 1 1 1 1 1 1
Cooling System, IK12.14 II
Part No.
Description
N19501 NUT-0118 N03313 WAS-0024 062773 N03494 078195 N20059 N01316 N00052 078197 N04530 NUT-0119 CON-0041 077894 SCR-0020 N02460 004479 N20197 N20014 078303 N20188 N00842 PLU-0036 N00204 N20201 078300 078297 10255 78706 010253
Hexagon Screw Hexagon Nut Self Locking Washer Washer Tube Clamp Stud 3rd - 4th Stage Intercooler Fitting Gasket Plug Connecting Tube Plug Nut Male Connector Clamp Hexagon Screw Washer Gasket, Copper Stud Male Connector Connecting Tube Male Connector Gasket Plug Plug Connector Connecting Tube 2nd - 3rd Stage Intercooler Safety Valve Safety Valve Safety Valve
September 2002
Notes
-49-
Replacement Parts List
MNL-0311
Figure 3.1-32 Lubrication System
1
13 14
2 3 4
5
12
17 11 18
16
19
6
10
16
16
17
15 16 9
17
Item Qty ◊ 1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 1 1 1 1 1 1 2 2 4 1 1 2 2 2
Part No.
Description
077884 77885 N4058 N25327 77774 N25326 77878 N25328 N2889 SCR-0180 78421 N24585 RNG-0070 N19506 WAS-0021
Lubrication System Assembly Oil Filter Cover O-ring O-ring Rubber Gasket Filter Element Oil Pump Cover Allen Screw Gasket Allen Screw Gasket Gear Pump O-ring Hex Head Screw Washer
Replacement Parts List
8
7
Notes
-50-
1st Edition
OFFSHORE COMPRESSORS-O10 Figure 3.1-32 (cont.) Item Qty 15 16 17 18 19
1 4 3 1 1
Lubrication System
Part No.
Description
077970 N1316 N52 076757 N2037
Regulating Valve Gasket Plug Connecting Tube Assembly Male Connector
September 2002
Notes
-51-
Replacement Parts List
MNL-0311 3.1.10 Troubleshooting Preventive maintenance usually involves replacing the valves, gaskets, and sealing rings as well as carrying out the maintenance work. 3.1.10.1 Troubleshooting Table Trouble
Cause
Remedy
No oil pressure
1. Low oil level
1. Check oil level.
Oil foam in crankcase
1. Last stage piston worn 2. Last stage pressure valve defective
1. Operate compressor with final stage valve head removed. If oil flows continuously out of cylinder, replace piston and sleeve. 2. Replace last stage valves.
Compressor output insufficient
1. Condensate drain valve(s) or fittings leaking. 2. Premature opening of final safety valve. 3. Piston rings worn 4. Excessive piston clearance 5. Pipes leaking
1. 2. 3. 4. 5.
Safety valves between stages releasing pressure
1. Intermediate pressure too high 2. Valves not closing properly
1. Service and clean valves. 2. Service and clean valves.
Compressor running too hot.
1. Insufficient supply of cooling air 2. Intake or outlet valve not closing properly 3. Wrong direction of rotation.
1. Check location for adequate ventilation 2. Check and clean valves, replace as necessary 3. Check arrow on compressor and correct accordingly.
Oil residue in delivered air
1. Improper maintenance of filters, purifier cartridge saturated. 2. Wrong oil type
1. Service filters, change purifier cartridge. 2. Change to proper oil and clean valves.
Compressor rotates in wrong direction
1. Electrical phases not connected properly
1. Reverse two of the three phase leads at the switch box. Do NOT change the leads at the motor terminal.
Troubleshooting
-52-
Tighten and reseal. Replace. Replace. Replace. Tighten.
1st Edition
OFFSHORE COMPRESSORS-O10 3.1.10.2 Repair Instructions Repair work can be carried out on the compressor block to a certain extent but a certain level of experience and skill is necessary. It should be noted however that no repair should be carried out on the crankshaft nor on the bearings. Also safety valves are not repaired but always replaced.
September 2002
-53-
Troubleshooting
OFFSHORE COMPRESSORS-O10 3.2 4 Stage Automatic Condensate Drain System 3.2.1 Description The automatic condensate drain system operates electropneumatically and is comprised of the following: An electrically controlled solenoid valve. Two pneumatically operated condensate drain valves A condensate separator/silencer
An electrical timer A condensate manifold A condensate collector bottle
The automatic condensate drain system drains the intermediate separators and the oil and water separator every 15 minutes during operation. Additionally the automatic condensate drain system unloads the compressor during the starting phase and drains these separators at shutdown of the compressor unit.
Figure 3.2-1
4 Stage Automatic Condensate Drain System 1 4
2 8
3
5
9
7
6
1. 2. 3. 4. 5.
Solenoid valve Condensate drain valve Condensate drain manifold Control air connection 2nd Stage intermediate separator condensate
September 2002
6. 7. 8. 9.
-55-
3rd Stage intermediate separator condensate Oil and water separator condensate connection Condensate collector bottle connection Manual condensate drain valve
Description
MNL-0311
Figure 3.2-2
2
ACD Operation Diagrams
6
3
2
5
4 1
Normal Operation
1
4
5
Control Pressure Condensate
Control Pressure Condensate
1. Solenoid Valve 2. 2nd Stage Intermediate Separator 3. 3rd Stage Intermediate Separator
6
3
Condensate Draining 4. 3rd Stage Condensate Drain Valve 5. Oil and Water Separator Condensate Drain Valve 6. Oil and Water Separator
3.2.1.1 Compressor Operating The normally open solenoid valve (1) controls the condensate draining of the 2nd stage intermediate separator (2). The normally open 3rd stage condensate drain valve (4) controls the condensate draining of the 3rd stage intermediate separator (3). The normally open oil and water separator condensate drain valve (5) controls the condensate draining of the oil and water separator (6). The control air for the 3rd stage condensate drain valve (4) is taken from the 2nd stage intermediate separator (2). The control air for the oil and water separator condensate drain valve (5) comes from the 3rd stage intermediate separator (3). As the compressor is started, the solenoid valve (1) is electrically energized and closes. This allows the pressure to buildup in the intermediate separators (2 and 3). This pressure buildup results in control air closing both condensate drain valves (4 & 5). 3.2.1.2 Condensate Draining Every 15 minutes the timer deenergizes the solenoid valve (1) for approximately 6 seconds. The solenoid valve (1) opens and drains the condensation from the 2nd stage intermediate separator (2). Due to the pressure loss in the 2nd stage intermediate separator the control air for the 3rd stage condensate drain valve (4) is also removed. As the pressure of the control air is dropping, the piston of the 3rd stage condensate drain valve (4) becomes unloaded and the remaining control air is vented through a relief port. Then the piston of the drain valve is fully raised by pressure from the 3rd stage separator, and the condensate is drained. This in turn causes a pressure loss in the 3rd stage intermediate separator (3) and the control air for the oil condensate drain valve (5) is removed and the oil and water separator condensate drain valve opens and drains the oil and water separator (6).
Description
-56-
1st Edition
OFFSHORE COMPRESSORS-O10 3.2.1.3 Start Unloading The unloading of the compressor during the starting phase is possible because of the lack of control air immediately after starting the unit. As the unit is switched on the solenoid valve (1) is energized and closes. After the compressor has attained nominal speed, pressure builds in the intermediate separators (2 and 3) and the control air closes the condensate drain valves (4 and 5). Once these valves close, the compressor delivers to the consuming device. 3.2.1.4 Standstill Drainage At compressor shutdown, the solenoid valve (1) is deenergized and opens. This drains the condensate and relieves the pressure in the 2nd stage intermediate separator (2). This action in turn removes the control air form the condensate drain valves (4 & 5) which open and drain and relieves the pressure in the 3rd stage intermediate separator (3) and oil and water separator (6). 3.2.1.5 Condensate Drain Piping The outlet opening of the condensate drain manifold is equipped with a tube connector. From here the condensation is directed into a collecting bottle by means of a tube to the pre-separator elbow and a condensate drain separator. 3.2.1.6 Electrical Connections For electrical connection of the automatic condensate drain, refer to any included wiring diagrams. CAUTION The condensate drain interval is adjusted at the factory. If the regular operating time of the compressor unit is less than the drain cycle, adjust the timing relay accordingly to ensure regular draining of the oil and water separator. If the compressor is shut off before the first drain cycle is completed, the timing relay would be reset each time causing the drain cycle to be started again. The condensate drain cycle would never be completed, which could result in flooding of the separator and damage to the connected systems. 3.2.1.7 ACD Timer Automatic condensate drain timer controls the frequency of the drain intervals and the duration of the drain period of the solenoid valve. This timer is a 120V, solid state, encapsulated, recycling timer. Both the on and the off times are adjustable. Its range is 1-100 minutes on, 0.1-10 seconds off. Figure 3.2-3
ACD Timer
"ON" Time "OFF" Time
September 2002
-57-
Description
MNL-0311 3.2.1.8 Condensate Drain Separator The condensate drainage is a mixture of oil, water and air. The Condensate Drain Separator is utilized to separate the oil and water from the air. The oil and water is then piped to the Condensate Collector Bottle where the oil and water mixture is stored until it can be disposed of properly. 3.2.1.9 ACD Maintenance The condensate drain valves are provided with manual drain valves to verify correct operation of the automatic system. The automatic condensate drain system must be serviced once a week as follows: 1. Open all manual drain valves one after the other. 2. Observe the drainage of condensation. 3. If the system drains more than 2 ounces of liquid per stage, either the system or the corresponding condensate drain valve is not working properly. 4. Find the fault and remedy accordingly. 5. If little or no condensation emerges, the automatic system is operating properly. 6. The condensate collection bottle should be emptied regularly. Due care must be taken to ensure that any oil which is drained with the condensate is disposed of properly. Check local, state and federal regulations.
Description
-58-
1st Edition
OFFSHORE COMPRESSORS-O10 3.2.2
Replacement Parts List
Figure 3.2-4
4 Stage ACD System
1
4 3
2
5 6 Item Qty ◊ 1 2 3 4 5 6
1 1 1 1 1 1 1
Part No.
Description
063761 064007 N16382 064009 064008 N293 N9155
Automatic Condensate Drain System Manifold Solenoid Valve Condensate Drain Valve Condensate Drain Valve Gasket Reducer
September 2002
Notes
-59-
Replacement Parts List
MNL-0311
Figure 3.2-5
ACD Manifold and Valves
13
7 6 3 8
9
11 2 10
Item Qty 1 2 3 4 5 6 7 8 9 10 11 12 13
1 1 1 1 1 1 1 1 2 1 1 4 1
4
Part No.
Description
064009 064008 064007 064004 N2320 N3625 N829 N2507 N638 071224 N20305 SCR-0133 N16266
Condensate Drain Valve Condensate Drain Valve Manifold Valve Connection O-ring Gasket Allen Screw O-ring O-ring Connecting Tube Male Elbow Allen Screw Plug
Replacement Parts List
5
1
12
Notes
-60-
1st Edition
This page is inserted to provide proper page sequencing
6
8
9
5
1
2
7
10 4
3
- 61 -
MNL-0311
Figure 3.2-6
3rd Stage Condensate Drain Valve
1 15
2 3
4 5
6 16 7 8 9
10
15
11 12
14
Item Qty ◊ 1 2 3 4 5 6 7
1 1 1 1 1 1 1 1
13
Part No.
Description
064009 064000 N16269 064003 N638 N4881 064001 N2507
Condensate Drain Valve Top Flange Sealing Ring Piston O-ring O-ring Valve Body O-ring
Replacement Parts List
Notes
-62-
1st Edition
OFFSHORE COMPRESSORS-O10 Figure 3.2-6 (cont.) Item Qty 8 9 10 11 12 13 14 15 16
1 1 1 1 1 1 1 8 1
3rd Stage Condensate Drain Valve
Part No.
Description
064005 N4496 064002 064498 065500 N16334 N15088 SCR-0150 067458
Valve Seat O-ring Base Flange Drain Tap Seat Drain Tap Assembly Male Tee Hose Allen Screw Tool Set for Item 12
September 2002
Notes
-63-
Replacement Parts List
MNL-0311
Figure 3.2-7
Oil and Water Separator Condensate Drain Valve
1 16 2 3 4 5 6
7
17 8 9 10
11
16
12 13
15
Item Qty ◊ 1 2 3 4 5 6 7
1 1 1 1 1 1 1 1
14
Part No.
Description
064008 64000 064011 N16269 064003 N638 N4881 064001
Condensate Drain Valve Top Flange Spring Sealing Ring Piston O-ring O-ring Valve Body
Replacement Parts List
Notes
-64-
1st Edition
OFFSHORE COMPRESSORS-O10 Figure 3.2-7 (cont.) Item Qty 8 9 10 11 12 13 14 15 16 17
1 1 1 1 1 1 1 1 8 1
Oil and Water Separator Condensate Drain Valve Parts List
Part No.
Description
Notes
N2507 064005 N4496 064002 064498 065500 N16334 N15088 SCR-0150 067458
O-ring Valve Seat O-ring Base Flange Drain Tap Seat Drain Tap Assembly Male Tee Hose Allen Screw Tool Set
for 065500
September 2002
-65-
Replacement Parts List
MNL-0311 3.2.3
Trouble shooting
Trouble
Cause
Remedy
Solenoid Valve does not drain.
1. Solenoid valve receives no electrical signal 2. Plunger of drain valve sticking
1. Check connections, timer. Replace if necessary. 2. Clean or replace valve.
Condensate Drain Valve does not drain.
1. Solenoid valve does not depressurize drain valve. 2. No control medium available. 3. Solenoid valve sticking. 4. Drain valve sticking in open position
1. Check solenoid valve, replace if necessary 2. Check supply lines 3. Clean or replace 4. Clean or replace
Trouble shooting
-66-
1st Edition
OFFSHORE COMPRESSORS-O10 SECTION 4: MAINTENANCE SCHEDULE 4.1 IK12.14 II Compressor Block 4.1.1 Preventive Maintenance Tasks Task
Reference
Check Oil Level
Paragaph 3.1.4.2
Operate Unit To Final Pressure And Check Final Pressure Switch
Paragraph 2.1
Check Automatic Condensate Drain
Paragraph 3.2
Check V-belt
Paragraph 6.1
Service Air Intake Filter
Paragaph 3.1.5.2
Check All Connections For Leakage
…
Change Oil Filter
Paragaph 3.1.4.3
Test Valves
Paragaph 3.1.8.2
Clean Separator Sintered Metal Filter
Paragaph 3.1.6.1
Change Oil
Paragaph 3.1.4.3
Change Oil Filter
Paragaph 3.1.4.3
Replace Valves
Paragaph 3.1.8.2
Check Opening Pressure Of Final Safety Valve
Paragraph 2.1
Change Synthetic Oil, If Operated For Less Than 2,000 Hours
Paragaph 3.1.4.3
Check Fasteners For Tightness
…
4.1.2 Maintenance Records We recommend that all maintenance work be recorded, showing the date and details of the work carried out. This will help to avoid expensive repairs caused by missed maintenance work. If it is necessary to make a claim against the warranty, it will help to have proof that regular maintenance has been carried out and that the damage has not been caused by insufficient maintenance. For this purpose Maintenance Record Sheets are included in Appendix E and may be copied as required. Additionally a form for recording operating hours is included in Appendix E and may be copied as required. 4.1.3
Maintenance Intervals NOTE
All maintenance intervals refer to normal operating conditions. Operating the compressor under extreme conditions like high temperatures, humidity or continuous operation may shorten the intervals significantly. If in doubt, please contact the BAUER service department. September 2002
-67-
Preventive Maintenance Tasks
MNL-0311
3000
1/2a
2000
Special
1000
Biennially
Annually
Weekly
Daily
Operating Hours 500
Calendar Periods
Check Oil Level Operate unit to final pressure and check final pressure switch Check automatic condensate drain Check V-belt Service air intake filter Check all connections for leakage Change Oil Filter Test Valves Clean separator sintered metal filter Change Synthetic Oil Change Oil Filter Replace Valves Check opening pressure of final safety valve Replace oil and water separator, if required Change Synthetic Oil, if operated for less than 2,000 hours Check fasteners for tightness a.
1/2 Hour after maintenance
Maintenance Intervals
-68-
1st Edition
OFFSHORE COMPRESSORS-O10 SECTION 5: PURIFICATION SYSTEMS 5.1 General The purpose of all BAUER breathing air purification systems is to remove oil, water, taste and odor from the compressed air stream before final delivery. For this reason BAUER purification systems are installed immediately before the compressed air delivery point. 5.1.1 System Configurations BAUER compressor units are available with various purifications systems either as standard features or factory installed options. The purification systems that apply to the models listed in this manual are found in the Purification System Applicability Chart in Paragraph 1.4.
Number and Type of Cartridges Title
Dryer
Purification
Securus
Processing Capacity Othera
in cubic ft (ft)3
P0 Purification System
…
…
…
TX
3,200
P1 Purification System
…
1
…
…
15,000
P2 Purification System
…
1
…
…
40,000
P2 with Securus®
…
…
1
…
67,000
P4 Purification System
1
1
…
…
60,000
P5 Purification System
1
1
…
…
90,000
P5 with Securus®
1
…
1
…
150, 000
P10 Purification System
2
1
…
140,000
P10 with Securus®
2
…
…
230,000
P12 Purification Systemb
1
1
CO
420, 000
P14 Purification Systemb
2
1
CO
650,000
1
a.
TX = Triplex® combined dryer and purifier, 5,000 pst maximum service pressure: CO = Carbon Monoxide conversion
b.
P12 and P14 are only available with the Securus® Moisture Monitoring System.
5.1.2 General Purification System Procedures 1. Keep an accurate record of operating hours to ensure exact attention to maintenance intervals 2. Change all cartridges before reactivating a compressor unit that has been out of service more than three months. Leave cartridges in the unit as long as it is out of service. 3. While out of service keep all condensate drain valves closed. Maintain a pressure of 700 to 1,100 psi (50 to 80 bar) within the system to prevent moisture from entering the compressor and purification system. September 2002
-69-
System Configurations
MNL-0311 5.1.3 Chamber Safety Bore The chambers in all BAUER purification systems are designed to prevent pressurization if the cartridge is missing, not seated properly or damaged (See Figure 5.1-1). Without a cartridge properly in place the safety bore is not sealed, the air escapes into the atmosphere, no pressure can be built up and thus it is ensured that unfiltered air is not supplied to the consuming device. If air is escaping from the safety bore remove and check cartridge. If necessary replace the cartridge or O-rings. Figure 5.1-1
Cartridge Safety Venting
Venting Bore
No Cartridge Installed
Cartridge Installed
5.1.4 Manual Condensate Drainage The condensate must be drained from the oil and water separator before changing any cartridge, before beginning each filling procedure and in the absence of an Automatic Condensate Drain System, every fifteen minutes during the filling procedure. This is done by slowly opening the condensate drain valves. They are opened approximately 1/3 of a turn to the left and held open until the condensate is completely drained. The condensate drain valves close by spring pressure but if necessary may be tightened by hand to ensure they are completely air tight. 5.1.5 Model, Serial Number and Part Number Identification 5.1.5.1 Compressor Dataplate The model number, date of manufacture and serial number can be found of the compressor unit identification plate on the compressor unit’s frame.
Figure 5.1-2
Compressor Unit Identification Plate
BAUER COMPRESSORS, INC. NORFOLK, VIRGINIA U.S.A
SERIAL NO. MOTOR
CFM
PRESSURE
PSIG
CHG. RATE
CFM
SPEED
RPM
HZ
AMPS
HP
PH VOLTS DATE OF MANUFACTURE
Chamber Safety Bore
COMPRESSORS
BLOCK NO.
MODEL NO. CAPACITY
BAUER
-70-
LBL-004
1st Edition
OFFSHORE COMPRESSORS-O10 5.1.5.2 Purification System Dataplate Refer to the compressor unit purification system dataplate (See Figure 5.1-3) on the compressor front to determine your purification system model and specifications.
Figure 5.1-3
Purification System Dataplate (typical)
PURIFICATION SYSTEM
BAUER COMPRESSORS
MODEL NO. MAX. PRESSURE
psig
AIR PROCESSED
cu. ft.
O-RING BACK-UP RING LBL-
5.1.5.3 Cartridge Installation Dataplate The function performed by each chamber in the purification system is determined by the type of cartridge installed in that chamber. Refer to the cartridge installation dataplate on the chamber to determine the purpose and part number of the cartridge installed in that chamber. (See Figure 5.1-4).
Figure 5.1-4
Cartridge Installation Dataplate (typical)
CARTRIDGE TO BE INSTALLED
BAUER COMPRESSORS
CARTRIDGE FOR CARTRIDGE NO. 1328 Azalea Garden Road - Norfolk Virginia 23502-1944 Phone: (757) 855-6006 Fax: (757) 855-8224
LBL-
September 2002
-71-Model, Serial Number and Part Number Identification
MNL-0311 5.1.6 Cartridge Operating Life Every BAUER Purification System is designed to process a certain volume of air before the cartridges require replacement. By using special test equipment that measures the quality of air at the outlet any quality reduction may be detected. However as most compressor owners do not have this test equipment the recommended method of determining cartridge operating life is to maintain a written record of the volume of air processed by the purification system. Each BAUER compressor block is rated to produce a standard volume of air per minute and by using this number and the air processing capability of the purification system it is possible to calculate the maximum operating hours before the cartridges need to be replaced. See Paragraph 5.1.6.1 for the method of determining this figure. The ambient air temperature and its ability to cool the compressor will effect the operating life of the cartridge. See Paragraph 5.1.6.2 for the method of calculating this adjustment factor. The optimum place to measure the temperature is at the inlet to the final separator as this best reflects the temperature of the air as it enters the chambers. Experience has shown that this temperature is approximately 10° F above the ambient temperature. Therefore for the purpose of calculating cartridge operating life use the Ambient Air Temperature plus 10° F. Form-0018, titled Air Purification Cartridge Operating Hours for recording the ambient temperature, operating time and adjustment factor is found in Paragaph 5.1.7. It is suggested that it be copied, placed in a protective folder and kept with the unit to record the adjusted operating hours. An example of how this form is used is shown in Figure 5.1-6. 5.1.6.1 Calculating the Maximum Cartridge Operating Hours 1. From the purification system dataplate (See Figure 5.1-3) on the unit determine the Air Processed (cu.ft.) 2. From the compressor unit dataplate (See Figure 5.1-2) determine the Capacity (CFM). 3. Divide the Air Processed by the Capacity to obtain the Maximum Operating Time in minutes 4. Divide the Maximum Operating Time in minutes by 60 to obtain the Maximum Operating Hours. 5. Record the answer on the Air Purification Cartridge Operating Hours form. 5.1.6.2 Calculating the Adjusted Cartridge Operating Hours 1. Using the Air Purification Cartridge Operating Hours form (FORM-0018) record the Date, Operating Hours and Ambient Air Temperature plus 10° F. 2. Using either the graph or the chart in Figure 5.1-5 determine the Correction Factor. 3. Divide the Operating Hours by the Correction Factor and record it under the column labeled Today. 4. Add the hours recorded in Today to the previous Total and record it as the current Total. 5. When the Total approaches the Maximum Operating Hours replace the Cartridges.
Cartridge Operating Life
-72-
1st Edition
OFFSHORE COMPRESSORS-O10
Figure 5.1-5
Correction Factor for Cartridge Operating Hours
Temperature
Correction Factor
°F
°C
32 41 50
0 5 10
3.80 2.62 1.85
59 68 77
15 20 25
1.34 1.00 0.75
86 104 122
30 35 40
0.57 0.43 0.34
Figure 5.1-6 Date
3.0 C o r 2.5 r e c t 2.0 i o n 1.5 F a 1.0 c t o 0.5 r 0.0 41 5
50 10
59 15
68 20
77 25
86 30
Example Record of Adjusted Operating Hours Operating hours
Ambient temp. during compression
Correction factor
Adjusted cartridge hours Today
Total
7/19/99
8
92oF
0.48
16.66
16.66
11/21/99
4
45o
2.25
1.78
18.44
September 2002
104 °F 40 °C
-73-
Cartridge Operating Life
MNL-0311 5.1.7
Date
Air Purification Cartridge Operating Hours
Operating hours
Ambient temp. during compression
Air Purification Cartridge Operating Hours
-74-
Correction factor
Adjusted cartridge hours Today
Total
1st Edition
OFFSHORE COMPRESSORS-O10 5.2 P2 Purification System 5.2.1 Component Description The P2 Purification System major components are a Coalescing Oil and Water Separator, a Dryer Chamber and a Purification Chamber. Figure 5.2-1 shows the functional interconnection of all the components. TheP2 purification system is available with the Securus Moisture Monitoring System as a factory installed option. As part of this option the Purification Chamber is replaced with a Securus® Purification Chamber.
Figure 5.2-1
P2 Purification System
6
7 IN OUT
5 3
1
2 3
4
1. 2. 3. 4.
Inlet Coalescing Oil/Water Separator Condensate Drain Valve Check Valves
5. Bleed Valve 6. Pressure Maintaining Valve 7. Purification Chamber 8. Safety Valve
5.2.1.1 Chamber Each chamber is made up of an anodized aluminum alloy filter housing and a filtering cartridge. There are two general types of filtering cartridges, drying or purifying. The cartridge type is determined by the ingredients packed in the cartridge. The chamber is named after the type of cartridge it contains, i.e. dryer chamber or purification chamber.
September 2002
-75-
Component Description
MNL-0311 5.2.1.2 Cartridge 5.2.1.2.1 Cartridge Construction The casing, top and bottom of all cartridges are aluminum and are packed with one or more of the following ingredients. 1. A catalyst to convert carbon monoxide to carbon dioxide. 2. Activated carbon which absorbs oil vapors effecting taste and odor. 3. Molecular sieve to absorb oil and water. 5.2.1.2.2 Cartridge Handling 1. Never open the protective packaging a cartridge comes in prior to its actual use. The highly sensitive filter materials will absorb moisture from the atmosphere becoming saturated and useless. 2. Used cartridges must be disposed of in accordance with local regulations. 5.2.1.3 Coalescing Oil/Water Separator The air leaving the final stage is cooled in the aftercooler to approximately 18 - 27°F (10 -15°C) above ambient temperature and then enters the oil and water separator. The oil and water separator works by means of a sintered metal filter which separates liquid oil and water particles from the compressed air.
WARNING Dynamic Loading The rapid depressurizing and repressurizing of the oil and water separator during condensate draining subjects it to metallurgical stresses. To prevent catastrophic failure with the possibility of damage, injury or death the oil and water separator (P/N 079416) must be replaced after 44,000 load cycles. A load cycle equals one depressurization- repressurization. The BAUER recommended frequency of condensate draining is every fifteen minutes and is a balance between maximizing the life of the oil and water separator chamber and maintaining the quality of the delivered breathing air. 5.2.1.4 Condensate Drain Valve A manually operated valve used for maintenance and before start-up to drain the condensed liquids from the coalescing oil and water separator. 5.2.1.5 Check Valves Valves allowing compressed air to flow in only one direction. One is used to maintain pressure in the chamber when the compressor is not operating. The other check valve prevents back-flow from filled storage cylinders or tanks. 5.2.1.6 Bleed Valve A manually operated valve used to release the pressure in the chamber before maintenance. 5.2.1.7 Pressure Maintaining Valve The pressure maintaining valve ensures that pressure is built up in the system from the start of delivery, thus achieving constant optimum purification. It also assures proper working conditions for the final stage of compression.
Component Description
-76-
1st Edition
OFFSHORE COMPRESSORS-O10 5.2.1.8 Safety Valve The safety valve is located on the coalescing oil and water separator and acts as the safety valve for the final stage of the compressor. 5.2.1.9 Securus® Air Purification Monitoring System The Securus® Electronic Air Purification Monitoring System is a factory installed option which warns the operator in advance of expiration of the life of the cartridges. The Securus® Indicator receives signals concerning the condition of the drying agent inside the Securus® cartridge from the attached sensors and supplies the appropriate control signals whenever the preset threshold values have been reached. 5.2.1.9.1 Securus® Cartridge The Securus® Cartridge is packed with a catalyst which converts carbon monoxide to carbon dioxide, activated carbon which absorbs oil vapors, molecular sieve which absorbs oil and water and the sensor components of the Securus® Electronic Air Purification Monitoring System. 5.2.1.9.2 Securus® Indicator The operating condition of the Securus® Air Purification System is indicated by the color and state of four LED’s on the front of the Securus® Indicator and is shown in the following table.
Color
State
Green
Continuos
Satisfactory
The unit is in operation
Yellow
Flashing
Cartridge Change Pre-warning
The unit is in operation. The green LED will also illuminate.
Red
Flashing
Cartridge Change Required
The unit is shutdown and can not be started until the cartridges are changed.
Red
Continuos
Cable Failure or Missing Cartridge
The unit is shutdown.
No operating voltage or electronic failure
The unit is shutdown.
No LEDs Illuminate
Indication
Compressor Unit Status
NOTE After applying power it will take about ½ second for the appropriate LED to illuminate. During this time the status of the Securus® Air Purification System is tested.
September 2002
-77-
Component Description
MNL-0311 5.2.2 Maintenance 5.2.2.1 Coalescing Oil/Water Separator To remove the sintered metal filter proceed as follows: 1. Disconnect the power and shut off the inlet supply line if applicable. 2. Depressurize the system by means of the bleed valve. 3. Remove the tubes connected to the side of the filter head (1). 4. Unscrew and remove the filter head. 5. Unscrew the sintered metal filter (2) from the filter head. 6. Remove the center screw (3) to remove the sintered metal filter. 7. Clean the sintered metal filter using hot soapy water. Blow dry with compressed air. 8. After cleaning the element, record the number of operating hours to ensure exact attention to the maintenance intervals. 9. Lubricate the threads and O-rings as well as the threaded part of the sintered metal filter with petroleum jelly. Apply sparingly. 10. Dry the inside of the filter housing with a clean cloth and check for corrosion before reinstalling the sintered metal filter. 11. In the event you discover corrosion, replace the corroded parts with new BAUER parts. Figure 5.2-2
Oil and Water Separator
1. Filter Head 2. Sintered Metal Filter 3. Center Screw
1
4 2 3
Maintenance
-78-
1st Edition
OFFSHORE COMPRESSORS-O10 5.2.2.2 Cartridge Replacement To change the cartridge, proceed as follows. See Figure 5.2-3 Figure 5.2-3
Cartridge Replacement
1. Disconnect the power and shut off the inlet supply line, if applicable. 2. Depressurize the system by means of the bleed valve. 3. Unscrew the chamber head using the special wrench supplied. 4. Pull out the cartridge using the lifting ring on top of the cartridge. 5. Dry the inside of the chamber with a clean cloth and check for corrosion. 6. Replace all corroded parts with new BAUER parts. 7. Remove the shipping covering and the protective cap from the bottom of the cartridge. 8. Lubricate the O-rings with white petroleum jelly. Apply sparingly. 9. Install the new cartridge. Be sure the cartridge snaps into place. 10. Reinstall the chamber head. 11. Close the bleed valve, restore the power and reconnect the inlet supply line, if applicable. NOTE If air is detected bleeding out from the bottom of the chamber, the cartridge has not been installed properly or is missing. Follow the instructions in Paragaph 5.2.2.2. 5.2.2.3 Leaking at the Safety Bore 1. Remove the cartridge following steps 1. to 4. in Paragaph 5.2.2.2. 2. Install cartridge if missing. 3. Remove cartridge and inspect O-rings. 4. Replace O-rings if necessary. 5. Ensure protective caps and devices have all been removed. 6. Replace cartridge following steps 8. to 11. in Paragaph 5.2.2.2
September 2002
-79-
Maintenance
MNL-0311 5.2.3
Replacement Parts List
Figure 5.2-4
P2 Oil and Water Separator 1
2
3
4
2
5
Item Qty ◊ 1 2 3 4 5
1 † 2 1 † †
Part No.
Description
079416 … N04736 061860 … …
Oil/Water Separator Assembly Separator Head Backup Ring Sintered Metal Filter Separator Housing Bottom Plug
Replacement Parts List
Notes
-80-
Available only with 079416
Available only with 079416 Available only with 079416
1st Edition
OFFSHORE COMPRESSORS-O10
Figure 5.2-5
27” Chamber Assembly
1 2 3
4 5
6
8
5 4
7
◊ 1 2 3 4 5 6 7 8
1 2 1 † 2 2 † † 1
80144 012293 061237 80147 N04736 N04735 80158 80148 058827A
September 2002
Chamber Assembly Tool Post Screw Cover Plate Filter Head Back-up Ring O-ring Filter Housing Filter Bottom Purification Cartridge
-81-
27”
Available only with 80144
Available only with 80144 Available only with80144 MS/AC/MS/HP
Replacement Parts List
MNL-0311
Figure 5.2-6
Securus® Air Purification Monitoring Systema
6 2
7
3
8 9
5
10 17 16
4
15 14 13 12 11
3 2
18
1 a.
The Securus Air Purification Monitoring System is a Factory Installed Option which may not apply to your equipment
Item Qty
Part No.
Description
Notes
◊ 1 2 3 4 5 6 7 8 9
80145 80148 N04736 N04735 060037A 80158 ADP-0204 059850 012293 06135
Securus® Chamber Assembly Bottom Plug Backup Ring O-ring Securus® Cartridge Filter Body Adapter, Right Angle Socket, RF type Tool Post Screw Cover Plate
27” Available only with 80145
1 † 2 2 1 † 1 1 2 1
Replacement Parts List
-82-
Available only with 80145
1st Edition
OFFSHORE COMPRESSORS-O10 Figure 5.2-6 (cont.) Item Qty 10 11 12 13 14 15 16 17 18
† 1 1 1 1 1 1 1 1
Securus® Air Purification Monitoring System
Part No.
Description
Notes
80159 059855 059852 059854 060062 059853 059851 002181 N15095
Filter Head Nut Drawback Screw Loose Pin Compression Spring Fixed Pin Bolt Compression Spring Securus® Indicator
Available only with 80145
September 2002
-83-
110 - 120VAC, 50 - 60 Hz
Replacement Parts List
OFFSHORE COMPRESSORS-O10 SECTION 6: COMPRESSOR DRIVE SYSTEM 6.1 Horizontal The compressor is driven by the drive motor through a V-belt. The direction of rotation, as seen facing the flywheel, is counterclockwise. Observe the arrow on the compressor block. Figure 6.1-1
Horizontal Motor Mount (typical)
4 5
1
6
2
3
1. Compressor Block 2. Compressor Flywheel 3. Compressor Mount
4. V-belt 5. V-belt sheave 6. Electric Motor
6.1.1 Maintenance of the V-belt and Sheave 6.1.1.1 Checking the Sheave. Before a new drive belt is installed, the condition of the sheave should be checked. A dirty or rusty sheave impairs the drive’s efficiency and abrades the cover of the belt, which results in premature failure. A worn sheave shortens belt life as much as 50%. If the groove is worn to the point where the belt bottoms, slippage may result and the belt may burn. If the side wall is “dished out,” the bottom shoulder ruins the belt prematurely by wearing off the bottom corners. 6.1.1.2 Checking the V-belt Inspect the V-belt regularly for damage and wear. Replace if necessary. 6.1.1.3 V-belt tension V-belt tension is adjusted by sliding the motor until pressing down on the V-belt between the sheaves results in an approximate deflection of 3/8” (10 mm). (See Figure 6.1-2).
September 2002
-85-
Maintenance of the V-belt and Sheave
MNL-0311
Figure 6.1-2
V-belt Deflection Approximate Deflection 3/8 " (10mm)
6.1.1.4 Maintenance of the Drive Motor For maintenance of the electric motor refer to the OEM manual, if included, or see an instruction plate attached to the motor. If maintenance instructions are shown for the motor, they supersede these general instructions. WARNING Always disconnect the electrical power before working on the motor 6.1.1.4.1 Lubricating the Drive Motor 1. Stop the motor. 2. Disconnect the power and lock the system out of service. 3. Wipe all grease fittings (fill and drain) clean. 4. Remove the fill and drain plugs from the bearing hub. 5. Free the drain hole of any hard grease. Use a piece of wire if necessary. 6. Add grease using a low pressure grease gun. The amount and type of grease added is very important. Only enough grease should be added to replace the grease used by the bearing. Too much grease can be as harmful as insufficient grease. The grease cavity should be filled 1/3 to 1/2 full. 7. Start the motor and let it run for approximately 30 minutes. 8. Stop the motor, wipe off any drained grease and replace the filler and drain plugs. 9. The motor is ready for operation.
Maintenance of the V-belt and Sheave
-86-
1st Edition
OFFSHORE COMPRESSORS-O10 6.2 Vertical Self Tensioning The compressor is driven by the drive motor through a V-belt. The direction of rotation, as seen facing the flywheel, is counterclockwise. Observe the arrow on the compressor block. Check the V-belt regularly for damage and wear. See Paragraph 6.2.1.2. Replace if necessary.
Figure 6.2-1
Vertical Motor Mount (typical)
1 2
3
4
5 6
7
1. 2. 3. 4.
Compressor block Compressor flywheel V-belt Compressor mount
5. V-belt sheave 6. Electric motor 7. Swinging motor mount
6.2.1 Maintenance of the V-belt and Sheaves 6.2.1.1 Check The Sheaves. Before a new set of drive belts are installed, the condition of the sheaves should be checked. Dirty or rusty sheaves impair the drive’s efficiency and abrade the cover of the belts, which results in premature failure. Worn sheaves shorten belt life as much as 50%. If the grooves are worn to the point where the belt bottoms, slippage may result and the belts may burn. If the side walls are “dished out,” the bottom shoulder ruins the belt prematurely by wearing off the bottom corners. 6.2.1.2 Check the V-belt Check the V-belt regularly for damage and wear. Replace if necessary. V-belt tension is adjusted automatically by the weight of the motor, which is mounted on a hinged motor plate.
September 2002
-87-
Maintenance of the V-belt and Sheaves
OFFSHORE COMPRESSORS-O10 SECTION 7: MISCELLANEOUS 7.1 Pneumatic Valves and Controls 7.1.1 Nonadjustable Valves The condensate drain valve, bleed valve and check valves are not adjustable. The condensate drain valve and bleed valve have seats and seals which should be replaced if the valve leaks. Check valves are not adjustable or repairable and must be replaced if they malfunction.
Figure 7.1-1
Pressure Maintaining Valve 2 1
7.1.2 Pressure Maintaining Valve The pressure maintaining valve is adjusted at the factory to the required pressure and does not normally require maintenance or readjustment. The factory settings are: Final Pressure Setting 2,000-5,000 psi (138-350 bar) 6,000 psi (414 bar) If readjustment does become necessary proceed as follows.
Minimum PMV Setting 2,175 psi (150 bar) 3,000 psi (207 bar)
1. Loosen the locking nut (1). 2. Set the adjusting screw (2) to the required pressure using an appropriate hex type wrench. 3. Turn clockwise to increase pressure, counterclockwise to decrease pressure. 4. Determine if the PMV is properly adjusted: a. b. c. d.
Depressurize the final separator and purifier chamber by slowly opening the bleed valve. Close the bleed valve and start the compressor. Observe the final pressure gauge and note the pressure at which the valve opens (delivers). If the pressure is not at the specified pressure ± 200 psi, readjust the PMV.
September 2002
-89-
Nonadjustable Valves
MNL-0311 7.1.3
Safety Valves Figure 7.1-2
Safety Valves
The safety valve must be checked periodically for proper functioning. 1. Operate the compressor with the shut-off valve closed until the safety valve vents. 2. Note the pressure registered on the pressure gauge. The safety valve is adjusted at the factory to the required pressure and does not normally require maintenance or readjustment. In case readjustment does become necessary, have the safety valve adjusted by a BAUER qualified technician (contact the BAUER service department for details) or return the valve to the factory.
Safety Valves
-90-
1st Edition
OFFSHORE COMPRESSORS-O10 7.2 Electrical Controls 7.2.1 Final Pressure Switch The automatic switching of the compressor unit off and on is governed by the final pressure switch. The value of this switch is adjustable. The approximate actuation value (differential) of the final pressure switch is fixed at whatever pressure setting is required for proper operation of the unit. This switch must never be set above the original order pressure. If the pressure switch is exposed to system or surge pressures greater than the maximum pressure rating printed on the device nameplate, leakage from the switch and/or a change of operating set points may result. Figure 7.2-1
Pressure Switch
2
1
7.2.1.1 Operating Set Point Adjustment Secure the hex body (1) with an open end wrench. Hand turn the adjustment sleeve (2) clockwise to increase the set point, counterclockwise to decrease the set point (note the orientation of the switch in Figure 7.2-1). The differential is fixed though the range varies according to the pressure setting. 7.2.1.1.1 Switch characteristics Adjustable range, final pressure Adjustable range, final pressure (low1) Actuation differential range, final pressure Actuation differential range, final pressure (low1) Contact rating Temperature range
4000 to 7500 psig 1650 to 4400 psig 350 to 800 psig 200 to 500 psig 5 Amps @ 125/250VAC -40° to 165° F
Wire Code
1.
Lead
Color
Normally Closed
Blue
Common
Purple
Normally Open
Red
Low final pressure setting is optional.
September 2002
-91-
Final Pressure Switch
OFFSHORE COMPRESSORS-O10 7.3 Fill Hoses 7.3.1 Replacement Parts List. Figure 7.3-1
Dual Fill Hose Assembly
9
8
11
Hose Storage Assembly
10 12
4
13 14
7 6
5
3 2
1
Item Qty 1 2 3 4 5 6 7 8 9 10 11
2 2 2 2 2 2 2 2 2 2 1
Part No.
Description
Notes
HOS-0080 CON-0039SS VAL-0006 CON-0042SS GAG-0010W CVR-0002 065126 ADP-0113 CON-0017SS VAL-0169 N04483
High pressure hose assembly Male connector Needle valve Male run tee Pressure gauge Protection cover Bleed valve 5000psi Fill adapter Hex nipple connector Safety valve O-Ring
Rubber
September 2002
-93-
CGA, 4500 psi SCBA 300 to 6000psi
Replacement Parts List.
MNL-0311
Figure 7.3-2
SCUBA Fill Hose Assembly 1 2 7, 8 3 4
5 6
Item Qty 1 2 3 4 5 6 7 8
1 1 1 1 1 1 1 1
Part No.
Description
Notes
HOS-0080 CON-0039SS VAL-0006 TEE-0013SS CON-0017SS YOK-0001 GAG-0010W CVR-0002
High pressure hose assembly Male connector Needle valve Male run tee Hex nipple connector SCUBA Fill Yoke Pressure gauge Protection cover
0-5000psi Rubber
Replacement Parts List.
-94-
1st Edition
OFFSHORE COMPRESSORS-O10
Figure 7.3-3
Low Pressure Hose Adapter Assembly 1
2 3
4
Item Qty 1 2 3 4
1 1 1 1
Part No.
Description
Notes
ADP-0112 TEE-0012SS ADP-0058 VAL-0302
Fill Adapter Tee Fill Adapter Safety Valve
for 2216 psi cylinder 1/4” NPT SS CGA 347 x 1/4”NPT SS 2250-3000 psi
September 2002
-95-
Replacement Parts List.
MNL-0311
Figure 7.3-4
Special Fill Adapter Assembly
3
4
2 1 5
Item Qty 1 2 3 4 5
1 1 1 1 1
Part No.
Description
ADP-0176SS RED-0002SS TEE-0012SS ADP-0058 VAL-0302
Adapter Reducing Bushing Tee Fill Adapter Safety Valve
Replacement Parts List.
Notes
CGA
-96-
1st Edition
OFFSHORE COMPRESSORS-O10 APPENDIX A:
REFERENCE DATA
A.1 Tightening Torque Values 1. Unless otherwise specified in text, the torque values in Table 1 apply. 2. The indicated torque values are valid for bolts in greased condition. 3. Self locking nuts must be replaced on reassembly 4. Pipe connections (swivel nuts) should be tightened just enough so that leakage is stopped. Not more than finger tight plus up to an additional 1/2 turn. Bolt or Screw
Size
Max. Torque
Hex and socket head
1/4” (M 6)
7 ft. lbs. (10 Nm)
Hex and socket head
5/16” (M 8)
18 ft. lbs. (25 Nm)
Hex and socket head
3/8” (M 10)
32 ft. lbs. (45 Nm)
Hex and socket head
1/2” (M 12)
53 ft. lbs. (75 Nm)
Hex and socket head
9/16” (M 14)
85 ft. lbs. (120 Nm)
Hex and socket head
5/8” (M 16)
141 ft-lbs (200 Nm)
Table A-1: Torque Values
A.1.1
Torque Sequence Diagrams Figure A.1-1 6 Bolt and 4 Bolt Torque Sequence
1 6
3
4
5 2
September 2002
-97-
3
1
2
4
MNL-0311 A.2 Approved Lubricants Chart Unless otherwise specified in text, use the lubricants in Table 2. Usage
Lubricants
O-rings, rubber and plastic parts; filter housing threads, sealing rings
Parker Super “O” Lube
Bolts, nuts, studs, valve parts, copper gaskets and tube connection parts (threads, cap nut and compression rings)
Never-Seez NSWT, Pipe Dope or teflon tape
Paper gaskets
DOW Corning 732 or equivalent silicon compound applied on both sides before assembly,
High temperature connections
DOW Corning 732 or equivalent temperature resistant compound,
Tube connection ferrules,
Never-Seez NSWT
Table A-2: Lubricant Chart A.3 Conversion Formulas °F = 9/5°C + 32 °C = 5/9 x (°F-32) PSI = BAR x 14.5 BAR =PSI x 0.06895
-98-
1st Edition
OFFSHORE COMPRESSORS-O10 A.4 Glossary of Abbreviations and Acronyms † AC ACD ASME CW CCW CGA DIN DOT E1 E3 HP MS NEC NEMA NFPA OSHA ODP OEM PCB PMV SC
Available Only as Part of a Complete Assembly Activated Charcoal, removes odor and taste automatic condensate drain American Society of Mechanical Engineers clockwise counterclockwise Compressed Gas Association Deutsches Institut für Normung Department of Transportation single phase electrical supply three phase electrical supply Chemical Catalyst, converts Carbon Monoxide to Carbon Dioxide Molecular Sieve, removes moisture National Electrical Code National Electrical Manufacturers Association National Fire Protection Association Occupational Safety & Health Administration open drip-proof (motor) Original Equipment Manufacturer printed circuit board pressure maintaining valve Securus® Moisture Sensing Device
September 2002
-99-
OFFSHORE COMPRESSORS-O10 APPENDIX B:
SAFETY
B.1 General Safety Precautions • Read the operating manual before installing or operating this compressor unit. Follow appropriate handling, operation and maintenance procedures from the very beginning. The maintenance schedule contains measures required to keep this compressor unit in good condition. Maintenance is simple, but must be executed regularly to achieve safe operation, maximum efficiency and long service life. •
We recommend that all maintenance work be recorded in a service book, showing the date and details of the work carried out. This will help to avoid expensive repairs caused by missed maintenance work. If it is necessary to make a claim against the warranty, it will help to have proof that regular maintenance has been carried out and that the damage has not been caused by insufficient maintenance.
•
This compressor unit must be installed, operated, maintained and repaired only by authorized, trained and qualified personnel.
•
Consult and follow all OSHA, NEMA, ASME and local regulations, laws and codes covering the installation and operation of this compressor and accessories before operating the unit.
•
Do not operate this unit in excess of it’s rated capacity, speed, pressure, temperature, or otherwise than in accordance with the instructions contained in this manual. Operation of this unit in excess of the conditions set forth in this manual will subject the unit to limits which it may not be designed to withstand.
•
Keep safety guards in place.
•
Do not modify the compressor or its systems.
•
Do not wear loose clothing around machinery. Loose clothing, neckties, rings, wrists watches, bracelets, hand rags, etc. are potential hazards.
•
Provide adequate fire protection. Make sure fire extinguishers are accessible. Select alternate routes of escape and post such routes.
•
Make sure you are equipped with all required safety equipment; hearing protection, safety glasses, hard hats, safety shoes and fire extinguisher.
•
Visually inspect the unit before starting. Remove and /or replace any loose or broken components, tools, valves, missing equipment, etc.
•
Do not tamper with, modify, or bypass safety and shutdown equipment.
•
Do not tighten or adjust fitting or connections under pressure.
•
The use of plastic pipe or rubber hose in place of steel tube or iron pipe, soldered joints or failure to insure system compatibility of flex joints and flexible hose can result in mechanical failure, property damage, and serious injury or death.
•
The use of plastic or nonmetallic bowls on line filters without metal guards can be dangerous.
•
Replace damaged fan blades promptly. Fan assemblies must remain in proper balance. An unbalanced fan can fly apart and create an extremely dangerous condition.
September 2002
-101-
MNL-0311 •
Allow the compressor to cool before servicing. Whenever the compressor is shut down and overheating is suspected, a minimum period of 15 minutes must elapse before opening the crankcase. Premature opening of the crankcase of an overheated unit can result in an explosion.
•
Incorrect placement of the inlet and pressure valves in a compressor cylinder head can cause an extremely dangerous condition. Refer to the appropriate section of this manual before installing or replacing valves.
•
Before doing any work involving maintenance or adjustment, be sure the electrical supply has been disconnected, and the complete compressor system has been vented of all internal pressure. Failure to follow these warnings may result in an accident causing personal injury and/or property damage.
•
Before working on the electrical system, be sure to disconnect the electrical supply from the system at the circuit breaker or other manual disconnect. Do not rely on the ON/OFF switch to disconnect the electrical supply.
•
Installer must provide an earth ground and maintain proper clearance for all electrical components.
•
All electrical installation must be in accordance with recognized national, state, and local electrical codes.
•
A compressor which has been used for gas service is unsuitable for air applications. Should the purchaser and/or user proceed to use the compressor for air service after it has been used for gas, the purchaser/user assumes all liability resulting therefrom without any responsibility being assumed by Bauer Compressors, Inc. The purchaser is urged to include the above provision in any agreement for resale of this compressor.
•
The use of repair parts other than those listed in this manual or purchased from BAUER Compressors, Inc. may create unsafe conditions over which BAUER has no control. Such unsafe conditions can lead to accidents that may be life-threatening, cause substantial bodily injury, and/or result in damage to the equipment. Therefore, BAUER Compressors, Inc. can bear no responsibility for equipment in which non-approved repair parts are installed
-102-
1st Edition
OFFSHORE COMPRESSORS-O10 B.2 Safety Warning Labels Notes, labels and warning signs are displayed on the compressor unit according to model, application or equipment and may include any of the following.
HOT SURFACES DO NOT TOUCH! Danger of burning if cylinders, cylinder heads, or pressure lines of individual compressor stages are touched. HIGH VOLTAGE! Life threatening danger of electrical shock. Maintenance work on electric units or operating equipment should be carried out by a qualified electrician or by a person supervised by a qualified electrician according to electrical regulations. AUTOMATIC COMPRESSOR CONTROL UNIT MAY START WITHOUT WARNING! Before carrying out maintenance and repair work, switch off at the main switch and ensure the unit will not restart. THE INSTRUCTIONS MUST BE READ BEFORE OPERATING UNIT! The instruction manual and all other applicable instructions, regulations, etc. must be read and understood by the operating personnel before using the machine. HEARING PROTECTION MUST BE WORN! Hearing protectors must be worn when working on a machine which is running. DIRECTION OF ROTATION! When switching on the machine, check the arrow to ensure correct direction of rotation by the drive motor.
September 2002
-103-
OFFSHORE COMPRESSORS-O10 APPENDIX C:
LONG TERM STORAGE
C.1 General If the compressor unit will be out of service for more than six months, it should be preserved in accordance with the following instructions: 1. Make sure that the compressor is kept indoors in a dry, dust-free room. 2. Cover the compressor with plastic sheets only if no condensation will form under the sheet. 3. Remove the sheet from time to time and clean the outside of the unit. 4. If this procedure cannot be followed, or if the compressor will be out of service for more than 24 months, please contact the BAUER Service Department for special instructions. C.2 Preparations Prior to preserving the compressor unit, it must be run until warm, i.e., up to the specified service pressure. Operate the unit for approximately 10 minutes, then carry out the following checks. 1. Check all pipes, filters and valves (including safety valves) for leakage. 2. Tighten all couplings, as required. 3. After 10 minutes, open the outlet valve and operate the compressor at adjusted minimum pressure using the pressure maintaining valve for approximately 5 minutes. 4. After the 5 minutes, shut the compressor unit down and completely drain all separators and filters. Close all valves. 5. Remove filter heads and lubricate the threads with petroleum jelly. C.2.1 Units Equipped with a Filter System 1. Ensure that cartridges remain in the purification system chambers. This will prevent oil from entering the outlet lines as a result of preservation procedures. 2. Remove the intake filter/intake pipe completely. C.3 Preserving the Compressor 1. Operate the compressor again and slowly spray approximately 0.35 oz. (10 cc) of oil into the inlet port while the compressor is running. Keep the shut-off valve open and the condensate drain valves closed. 2. After spraying the oil into the inlet port, run the compressor unit for an additional 5 minutes before shutting the compressor unit down. 3. Close the shut-off valve. 4. Close the inlet port with a dust cap and/or tape. C.3.1 Preventive Maintenance During Storage Operate the compressor once every six months as follows: 1. Remove the dust cap from the inlet port and install the inlet filter. 2. Open the outlet valve and allow the system to run approximately 5 minutes until there is outflow from the valve and oil is visible in the sight glass of the oil regulating valve. 3. Shut down the compressor. September 2002
-105-
MNL-0311 4. Open the condensate drain valves, depressurize the unit, then close the drain valves again. 5. Remove the intake filter and replace the dust cap on the inlet port. C.4 Lubrication Oils for Preservation 1. After prolonged storage periods, the oil will age in the compressor crankcase. The oil must be drained at least every 24 months and replaced with fresh oil. 2. The stated period can only be attained when the crankcase is sealed during the preservation period in accordance with the preservation requirements. 3. After changing the oil, the compressor must be operated according to the instructions above. 4. Check the lubrication of the compressor during the every-six-month brief operation. 5. The oil pump is functioning properly when oil can be seen flowing through the sight glass of the oil pressure regulator or if the oil pressure gauge indicates the prescribed pressure. C.5 Reactivating the Compressor Unit 1. Remove the dust cap from the inlet port and install the intake filter. 2. Check the oil level of the compressor. If necessary, change the oil. 3. The motor must be thoroughly dry before applying power. 4. For units with a purification system, change all cartridges. 5. Run the compressor with open outlet valve for approximately 10 minutes. Check for proper operation of the lubricating system. 6. After 10 minutes, close the shut-off valve and run the system up to final pressure until the final pressure safety valve vents. On compressor units with a compressor control system, raise the pressure switch setting the switch above normal limits to override the pressure switch. Be sure to reset the switch after checking. 7. Check the interstage safety valves for leakage. 8. Establish the cause of any faults and remedy. 9. Stop the unit when it is running properly. The compressor is then ready for operation.
-106-
1st Edition
OFFSHORE COMPRESSORS-O10 APPENDIX D:
UNPACKING, HANDLING AND INSTALLATION
D.1 Unpacking and Handling This compressor unit is packaged according to the requirements for shipping via the requested type of carrier service. It is possible that the compressor unit could have been damaged during shipping. For this reason, we urge you to thoroughly examine the unit for possible damage and report any such damage to the shipping company immediately. Care must be taken in unpacking the compressor unit. Serious damage could result by not checking for clearance between the item being unpacked and the packaging to be removed. Handling of the unpacked unit should be performed using only the following devices, see Figure D.1-1. Figure D.1-1 Lifting Devices
Fork Lift
Chain Hoist
Hand Truck
WARNING Be sure the lifting devices are capable of handling the weight of the unit (see Paragraph 1.4 for the weight of the unit). Before lifting the unit, secure all loose or swinging parts to keep them from moving. Stay clear of lifted load. The compressor unit may be furnished with one or more shipping braces for shipping and handling only. After installation and before operation, these braces must be removed entirely. Under no circumstances should the braces remain installed during operation or the manufacturer’s warranty for the compressor unit will be voided. The braces are all tagged and labeled. D.2 Installation of the Compressor Unit D.2.1 General The floor/site must be capable of supporting the weight of the unit. Secure the compressor unit to the floor using ½” lag bolts. Position the unit so that it is level. Permissible inclination of the compressor unit is listed in Paragraph 1.4. CAUTION The inclination values listed in Paragraph 1.4 are valid only if the oil level of the compressor is level with but does not exceed the upper mark of the oil dipstick or oil level sight glass September 2002
-107-
MNL-0311 Ensure that the compressor air intake is supplied with fresh air. The intake air must not contain any exhaust fumes or flammable vapors such as paint solvents, which may cause an internal fire. Make sure that the intake air is unobstructed and moisture in the intake air is kept to a minimum. It is important that units draw in clean air. The quality of the incoming air determines the quality of the compressed air. This is important even for industrial air, as any incoming fumes will also be compressed and will increase the toxicity to anyone working with the compressed air. If a remote control is provided, the unit must be equipped with a clearly visible plate warning the possibility of the unit starting. As an additional measure, anyone starting the unit by remote control must make sure that no one is checking or operating the unit. For this purpose, a second warning plate should be provided at the remote control unit. AUTOMATIC COMPRESSOR CONTROL UNIT MAY START WITHOUT WARNING! Before carrying out maintenance and repair work, switch off at the main switch and ensure the unit will not restart. Observe and maintain an ambient temperature range of 43° to 113° F. The area in which the compressor unit is installed should be well lit and easily accessible to facilitate servicing and routine maintenance. D.2.2 Ventilation During normal compression, heat is generated by the compressor and by the drive motor/engine. For aircooled compressor units, this heat needs to be vented away by sufficient ventilation. D.2.2.1 Outdoor Installation It is recommended that all gasoline and diesel engine driven compressor units be installed outdoors. Additionally, electrically driven compressor units may be installed outdoors only if enclosed with weatherproof enclosure panels. D.2.2.2 Indoor Installation The best location to install the compressor unit indoors is against an outside wall with a suitably large air vent in front of the cooling fan. Additionally, it is necessary to position an exhaust opening in the opposite wall, close to the ceiling or in the ceiling. As a basic rule of thumb, the room should be ventilated sufficiently so as to prevent the ambient room temperature from exceeding 105° F. Additional heat generating equipment or piping should be avoided or must be well insulated.
-108-
1st Edition
OFFSHORE COMPRESSORS-O10 D.2.2.3 Natural Ventilation Natural ventilation should only be used up to a maximum drive power of 20 hp. To determine the size of the required intake and exhaust openings, refer to the following table: Intake and Exhaust Openings Dependent on Room Volume (V) and Height (h) V = 1750 ft³ h = 6.5 ft
V = 3500 ft³ h = 10 ft
V = 7000 ft³ h = 13 ft
Intake (ft²)
Exhaust (ft²)
Intake (ft²)
Exhaust (ft²)
Intake (ft²)
Exhaust (ft²)
3
1.3
1.1
---
---
---
---
5
3.2
2.7
1.3
1.1
---
---
7.5
4.5
3.8
2.6
2.2
1.3
1.1
10
9.7
8.1
6.5
5.4
2.6
2.2
15
14.5
12.4
9.7
8.1
5.8
4.8
20
20.6
17.2
15.6
12.9
9.7
8.1
Drive hp
D.2.2.4 Forced Ventilation If the natural ventilation is insufficient, the circulation of cooling air must be increased by the installation of an exhaust fan. To determine the required intake opening and exhaust flow refer to the following table: Dependence on Room Size (V) and Height of Exhaust Opening (h)a Drive hp
a.
V = 1750 ft³ h = 8 ft
V = 3500 ft³ h = 10 ft
V = 7000 ft³ h = 13 ft
Intake (ft²)
Intake (ft²)
Intake (ft²)
Exhaust cfm
Exhaust cfm
Exhaust cfm
25
3.3
3300
3.2
3200
3.0
3000
30
4.0
3960
3.8
3840
3.6
3600
40
5.3
5280
5.1
5120
4.8
4800
50
6.6
6600
6.4
6400
6.0
6000
60
7.9
7920
7.7
7680
7.2
7200
75
9.9
9900
9.6
9600
9.0
9000
100
13.2
13200
12.8
12800
12.0
12000
125
16.5
16500
16.0
16000
15.0
15000
150
19.8
19800
19.2
19200
18.0
18000
The intake sizes given in the above table are for a cooling air velocity of 1000 ft./min. BAUER recommends that the cooling air velocity be in the range of 600 ft./min. to 2000 ft./min.
September 2002
-109-
MNL-0311 D.2.3 Electrical Installation D.2.3.1 Electric Drive When making the electrical connections to the system, the following instructions are mandatory: •
Comply with all local, state and federal regulations concerning electrical installation.
•
Arrange for the electrical connections to be made by a certified electrician only.
•
Ensure that the motor voltage, control unit voltage, and frequency conform with the main voltage and frequency. Do not connect the compressor unit to a voltage other than the one specified on the nameplate.
•
Provide all necessary cables and main fuses and a master disconnect switch. The fusing of the compressor must be carried out in compliance with local, state and national electrical regulations.
D.2.3.2 Electrical Supply The machine is factory wired according to order. If the voltage is to be changed, consult the factory for instructions and necessary parts. For standard models the only customer wiring necessary is from the customer supplied disconnect switch to the compressor unit’s electrical enclosures All wiring should be done by a licensed electrician familiar with national, state and local electrical codes. The use of improperly sized wire can result in sluggish operation, unnecessary tripping of overload relays and/or blowing of fuses. The following tables are provided as a guide for proper wire size.
1 PHASE Full Load Amps Motor hp
Fuse Ampsa
Minimum Wire Sizeb
120V
208V
230V
120V
208V
230V
120V
208V
230V
2
24
13.2
12
30
20
17.5
10
---
14
3
34
18.7
17
50
30
25
8
10
10
5
56
30.8
28
80
50
40
4
8
8
7.5
80
44
40
100
70
60
3
8
8
10
---
55
50
---
90
60
---
6
6
a.
Dual element time delay fuse amps.
b.
Normal copper wire with THW, THWN, or XHHW insulation.
-110-
1st Edition
OFFSHORE COMPRESSORS-O10
3 PHASE Motor hp
Full Load Amps
Fuse Ampsa
Minimum Wire Sizeb
208V
230V
460V
208V
230V
460V
208V
230V
460V
2
7.5
6.8
3.4
12
10
5.6
14
14
14
3
10.6
9.6
4.8
17.5
15
8
14
14
14
5
16.7
15.2
7.6
25
25
12
10
12
14
7.5
24.2
22
11
40
30
17.5
8
10
14
10
30.8
28
14
50
40
20
8
8
12
15
46.2
42
21
60
60
30
6
6
10
20
59.4
54
27
90
80
40
4
4
8
25
74.8
68
34
100
100
50
3
4
8
30
88
80
40
125
100
60
2
3
8
40
114
104
52
175
150
80
0
1
6
50
143
130
65
200
200
100
3/0
2/0
4
60
169
154
77
250
200
100
4/0
3/0
3
75
211.2
192
96
300
300
150
300
250
1
100
273
248
124
400
350
175
500
350
2/0
125
343.2
312
156
500
400
200
2-4/0
2-3/0
3/0
150
396
360
180
600
500
250
2-300
2-4/0
4/0
a.
Dual element time delay fuse amps.
b.
Normal copper wire with THW, THWN or XHHW insulation.
In the above tables, all values are based on 1996 NEC articles 430 and 310 (NFPA 70). These values are provided as a general guide; however, the information given on the motor nameplate supersedes the above information.
September 2002
-111-
OFFSHORE COMPRESSORS-O10 APPENDIX E:
REPRODUCIBLE FORMS
E.1 Maintenance Record Forms E.1.1 Scheduled Maintenance Form Daily
September 2002
Para.
-113-
Date
Signature
MNL-0311
Weekly or as required.
Para.
Date
Signature
500 Operating Hours.
Para.
Date
Signature
1,000 Operating Hours.
Para.
Date
Signature
2,000 Operating Hours.
Para.
Date
Signature
-114-
1st Edition
OFFSHORE COMPRESSORS-O10
3,000 Operating Hours.
Para.
Date
Signature
Annually.
Para.
Date
Signature
Biennially. (Every two years)
Para.
Date
Signature
September 2002
-115-
MNL-0311 E.1.2 Date Subtotal:
Record of Operating Hours Minutes
Total
Date
Minutes
Total
Subtotal:
-116-
1st Edition
OFFSHORE COMPRESSORS-O10 E.1.3
Purifier Cartridge Adjusted Operating Hours.
Date
September 2002
Operating hours
Ambient temp. during compression
-117-
Correction factor
Adjusted cartridge hours Today
Total
OFFSHORE COMPRESSORS-O10 APPENDIX F:
ADDITIONAL DOCUMENTS
F.1 Diagrams and Drawings Any included drawings, wiring diagrams, pneumatic flow diagrams, etc., will be bound in this manual next to the back cover. F.2 Other Documents OEM Manuals and other BAUER manuals may be included in the documentation shipping package.
September 2002
-119-
