Important Instructions: Liquid Transfer-Vapor Recovery Compressors
Important Instructions: Liquid Transfer-Vapor Recovery Compressors
Important Instructions: Liquid Transfer-Vapor Recovery Compressors
IMPORTANT
INSTRUCTIONS
LIQUID TRANSFER-VAPOR
RECOVERY COMPRESSORS
Warning: (1) Periodic inspection and maintenance of Corken products is essential. (2) Inspection, maintenance and installation of Corken products must be made only
by experienced, trained and qualified personnel. (3) Maintenance, use and installation of Corken products must comply with Corken instructions, applicable laws and
safety standards (such as NFPA Pamphlet 58 for LP-Gas and ANSI K61.1-1972 for Anhydrous Ammonia). (4) Transfer of toxic, dangerous, flammable or explosive
substances using Corken products is at user’s risk and equipment should be operated only by qualified personnel according to applicable laws and safety standards.
WARNING
Install, use and maintain this equipment according to Corken, Inc. instructions and all applicable
federal, state, local laws and codes, and NFPA Pamphlet 58 for LP-Gas or ANSI K61.1-1989 for
Anhydrous Ammonia. Periodic inspection and maintenance is essential.
Model No.
Serial No.
Date Purchased
Date Installed
Purchased From
Installed By
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 4
Liquid Transfer by Vapor Differential Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Residual Vapor Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Compressor Construction Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2. INSTALLING YOUR CORKEN COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 9
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Liquid Traps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Driver Installation / Flywheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Crankcase Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Truck Mounted Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Shutdown/Alarm Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3. STARTING UP YOUR CORKEN COMPRESSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 17
Inspection After Extended Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Flywheel and V-belt Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Crankcase Oil Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Startup Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4. ROUTINE MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5. ROUTINE SERVICE AND REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Cylinder and Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Piston Rings and Piston Ring Expanders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Piston Rod Packing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Wrist Pin Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Connecting Rod Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Roller Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Oil Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Servicing the Four-Way Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6. EXTENDED STORAGE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 29
APPENDIX
A. Model Number and Mounting Identification Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
B. Material Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
C. Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
D. Bolt Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
E. Clearance and Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
F. LPG Liquid Transfer Compressor Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Propane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
N-Butane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Ammonia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
G. Compressor Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
H. Compressor Log Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
CHAPTER ONE
INTRODUCTION
1.2 RESIDUAL VAPOR RECOVERY thumb is not to operate beyond the point at which
the inlet pressure is one-fourth the discharge
The Principle of Residual Vapor Recovery is just the pressure. Some liquids are so expensive that further
opposite of Liquid Transfer. After the liquid has been recovery may be profitable, but care should be taken
transferred, the Four-Way Control Valve (or alternate that the ratio of absolute discharge pressure to
valve manifolding) is reversed so that the vapors are absolute inlet pressure never exceeds 7 to 1. Further
drawn from the tank just unloaded and discharged excavation of very high value products would require
into the receiving tank. Always discharge the a Corken Two-Stage Gas Compressor.
recovered vapors into the liquid section of the
receiving tank. This will allow the hot, compressed Invariably, there is some liquid remaining in the tank
vapors to condense, preventing an undesirable after the liquid transfer operation. This liquid “heel”
increase in tank pressure. See Figure 1.2A. must be vaporized before it can be recovered, so do
not expect the pressure to drop immediately.
Residual Vapor Recovery is an essential part of the Actually, more vapor will be recovered during the
value of a Compressor. There is an economical limit first few minutes while this liquid is being vaporized
to the amount of vapors that should be recovered, than that during the same period of time later in the
however. When the cost of operation equals the operation. Remember that more than half of the
price of the product being recovered, the operation economically recoverable product is usually
should be stopped. For most cases in LP Gas and recovered during the first hour of operation on
Anhydrous Ammonia services, this point is reached properly sized equipment.
in the summer when the compressor inlet pressure
is 40 to 50 psig (3.8 to 4.5 Bars). A good rule of
Piston rod packing is used to seal the gas in the The typical Corken compressor valve consists of a
compression chamber and prevent crankcase oil seat, bumper, spring and valve disk as shown in
from entering the compressor cylinder. The packing Figure 1.3D. Special heat-treated alloys are utilized
consists of several PTFE V-rings sandwiched to prolong life of the valve in punishing non-
between a male and female packing ring and held in lubricated services. The valve opens whenever the
place by a spring (see Figure 1.3C). pressure on the seat side exceeds the pressure on
the spring side. The discharge valve is an inverted
version of the suction valve.
2.1 LOCATION
HEX NUT
Corken compressors are designed and manufactured 2” MIN. COMPRESSOR
for outdoor duty. For applications where the WASHER BASEPLATE
ALL SIDES
compressor will be subjected to extreme conditions GROUT BENEATH
for extended periods such as corrosive environments, BASE
arctic conditions, etc., consult Corken. Check local
CONCRETE FOUNDATION
safety regulations and building codes to assure WITH REINFORCEMENTS
installation will meet local safety standards. SHOULD BE USED ON
ALL MODELS
8” MIN.
Corken compressors handling toxic or flammable 1/2” “J” BOLTS
gases such as LPG/NH3 should be located outdoors. 12” LONG
A minimum of 18 inches (45 cm) clearance between
the compressor and the nearest wall is advised to NOTE:
LOCATE “J” BOLTS PER
make it accessible from all sides and to provide COMPRESSOR OUTLINE
unrestricted air flow for adequate cooling. DIMENSION DRAWINGS.
4-WAY A B C D E
1. Unload Tank Car into Position Open Open Close Close Close
Storage Tank One
2. Recover Vapors from Tank Position Close Open Open Close Close
Car into Storage Tank Two
4. Recover Vapors from Transport Position Close Close Open Close Open
or Truck into Storage Tank Two
5. Load Truck or Field Tank Position Open Close Close Close Open
from Storage Tank Two
6. Load Truck or Field Tank Position Close Open Close Open Close
from Tank Car One
7. Equalize Between Tank Car --- Open Open Close Open Open
and Storage Tank Without
using Vapor Pump
All piping must be in accordance with the laws and For Ammonia – The American National Standards
codes governing the service. In the United States, Institute, Inc., K61.1-1989, Storage and Handling of
the following codes apply: Anhydrous Ammonia.
For LP Gas – The National Fire Protection Association Copies of these are available from NFPA, 60
Pamphlet No. 58, Standard for the Storage and Baterymarch Street, Boston, Mass, 02110 and ANSI,
Handling of Liquefied Petroleum Gases. 1430 Broadway, New York, N.Y., 10018. Install, use
and maintain this equipment according to Corken
instructions and all applicable federal, state, and
local laws and previously mentioned codes.
MECHANICAL TRAP
FIGURE 2.4A
When the compressor will not be under more-or-less Corken’s most sophisticated trap provides the most
constant observation an automatic trap is thorough liquid separation (see Figure 2.4C). This
recommended (see Figure 2.4B). The automatic trap trap is larger and is ASME code stamped. It contains
replaces the float with electrical float switches. If the two level switches, one for alarm and one for
liquid level should rise too high, the level switch will shutdown. In some cases the alarm switch is used to
open and disconnect the power to the motor starter, activate a dump valve (not included with trap) or
stopping the compressor. This design ensures the sound an alarm for the trap to be manually drained
machine will be protected even when it is not under by the operator. This trap also contains a mist pad. A
close observation and is standard in the 109A and mist pad is a mesh of interwoven wire to disentrain
107A mounting configurations. fine liquid mists. The ASME code trap is standard in
the -109B and -107B mounting configurations.
NOTE: The level switch MUST be removed from 2.6. CRANKCASE LUBRICATION
the trap before grounding any welding devices
Non-detergent oil is recommended for Corken vertical
to the trap or associated piping! Failure to do so
compressors. Detergent oils tend to keep wear
will damage the switch contacts.
particles and debris suspended in the oil, whereas
non-detergent oils let them settle in the bottom of the
If your compressor is equipped with a liquid trap
crankcase. When non-detergent oils are not available,
of other than Corken manufacture, make sure it
detergent oils may usually be successfully substituted,
is of adequate size to thoroughly remove any
although compressors handling ammonia, amine, or
liquid entrained in the suction stream.
imine gases are notable exceptions. These gases
react with the detergent and cause the crankcase oil to
become corrosive and contaminated. Figures 2.6A
2.5 DRIVER
INSTALLATION / FLYWHEELS and 2.6B show recommended oil viscosities and
crankcase capacities.
Corken vertical compressors may be driven by either
electric motors or combustion engines (gasoline, Synthetic lubricants are generally not necessary.
diesel, natural gas, etc.). Corken compressors are Please consult the Factory if you are considering the
usually V-belt driven but they are also suitable for use of synthetic oil.
direct drive applications as well. Direct drive
applications require an extended crankshaft to allow
the attachment of a rigid metal coupling.
NOTE: Before initial startup of the compressor when installation is complete. Always check the
be sure the principal of using a compressor for flywheel runout before startup and readjust if it
liquid transfer by vapor differential pressure is exceeds the value listed in Appendix E.
understood (see Section 1.1). Read this entire
chapter, then proceed with the startup checklist. Bushing Diameter Bolt Torque
Size In. (cm) Ft.-lb. (kg-meter)
SF 4.625 (11.7) 30 (4.1)
3.1 INSPECTION AFTER E 6.0 (15.2) 60 (8.3)
EXTENDED STORAGE
J 7.25 (18.4) 135 (18.7)
If your compressor has been out of service for a long
period of time, you should verify that the cylinder
bore and valve areas are free of rust and other Tighten the belts so that they are taut, but not
debris (see the maintenance section of this manual extremely tight. Consult your V-belt supplier for
for valve and/or cylinder head removal instructions). specific tension recommendations. Belts that are too
tight may cause premature bearing failure.
Drain the oil from the crankcase and remove the
nameplate and crankcase inspection plate. Inspect
the running gear for signs of rust and clean or
replace parts as necessary. Replace the crankcase
inspection plate and fill crankcase with the
appropriate lubricant. Squirt oil on the X-heads and
rotate the crank by hand to ensure that all bearing
surfaces are coated with oil.
1. Become familiar with the function of all piping 1. Verify and note proper oil pressure. Shut down
associated with the compressor. Know each and correct any problem immediately.
line’s use!
2. Observe noise and vibration levels. Correct
2. Verify that actual operating conditions will match immediately if excessive.
the anticipated conditions.
3. Verify proper compressor speed.
3. Ensure that line pressures are within cylinder
pressure ratings. 4. Examine entire system for gas, oil or water levels.
5. Check all mounting shims, cylinder and piping 6. Check start-up voltage drop, running amperage
supports to ensure that no undue twisting forces and voltage at motor junction box (not at the
exist on the compressor. starter).
6. Verify that strainer elements are in place and clean. 7. Test each shutdown device and record set points.
7. Verify that cylinder bore and valve areas are clean. 8. Test all relief valves.
8. Check V-belt tension and alignment. Check drive 9. Check and record all temperatures, pressures
alignment on direct drive units. and volumes after 30 minutes and 1 hour.
9. Rotate unit by hand. Check flywheel for wobble 10. After 1 hour running time, tighten all head bolts,
or play. valve holddown bolts, and baseplate bolts.
* Piston ring life varies greatly, depending on application, gas, and operating pressures. Consult factory
for additional recommendations for your specific applications.
** Change oil every 2200 hours of operation or every 6 months, whichever occurs first. If the oil is unusually
dirty, change it as often as needed to maintain a clean oil condition. Change replacement filter 4225 with
every oil change.
5.1 VALVES
Test the Compressor valves by closing the inlet
piping valves while the unit is running; do not allow
the machine to operate in this way very long,
however. If the inlet pressure gauge does not drop to
zero almost immediately, one or more of the valves
is probably either damaged or dirty. It is possible of
course, that the pressure gauge itself is faulty.
The metal valve gasket should always be replaced *Some Spec 3 suction valves have an adjusting
when the valve is reinstalled. Make sure suction and screw to set the liquid relief pressure. To adjust,
discharge valves are in the right slots as shown in tighten the adjusting screw until it bottoms, then back
the illustrations. Reinstall cages and spacers, then one turn on the size 491. (91/291/691’s are pre-set).
tighten the valve hoiddown screw to the value listed
in Appendix D to ensure the valve gasket is properly
seated. O-rings sealing the valve cover and valve
cap should be replaced if they show any signs of
wear or damage. Valve caps sealed by flat metal
gaskets should be reinstalled with new gaskets.
Refer to Appendix D for torque values.
To replace the piston rings: Depressurize the Reinstall the piston platform with the same thickness
compressor and purge if necessary. Remove the of shims as before, BUT DO NOT REINSTALL THE
head to gain access to the compressor cylinder. ROLL PIN. Replace the cylinder and install the piston
Loosen the piston head bolts. Remove the piston as heads with new piston rings and expanders. Now
shown in Figure 5.3A by pinching two loose bolts measure dimension “X” shown in the illustration. If
together. Piston rings and expanders may then be this measurement does not fall within the tolerances
easily removed and replaced. Corken recommends shown in Appendix E, remove the piston, adjust the
replacing expanders whenever rings are replaced. shims as necessary and remeasure the “X”
dimension. When the piston is properly shimmed,
To determine if rings should be replaced, measure tighten the castellated nut as shown in Appendix D.
the radial thickness and compare it to the chart in Now install a new roll pin to lock the castellated
Appendix E. piston nut in place. Install the piston head and tighten
the socket head bolts in an alternating sequence.
Reinstall the head (see Section 5.5) and follow
standard startup procedure. (Note: New compressors
may have self-locking nuts without roll pins.)
5.7 OIL PUMP INSPECTION guide and oil pump assembly. The tang on the oil
pump must align with the slot in the shaft adapter.
If the compressor operates for a prolonged period Install the pump cover so the pin on the case is in the
with dirty or contaminated crankcase oil, damage to opening on the oil pump assembly as shown in
the oil pump may result. To check the oil pump, Figure 5.7A. When you are sure the pin is properly
unbolt the pump cover and remove the oil pump, aligned, install the cover bolts finger tight. Rotate
spring guide, spring and oil pump shaft adapter as the crankshaft by hand to ensure smooth operation.
shown in Figure 5.7A. Inspect the gears in the oil Then rotate it in opposite directions, listening for a
pump for corrosion or pitting and replace if click, which indicates proper alignment of the oil
necessary. Check the oil pump shaft bushing in the pump’s pins and slots. Finally, tighten the bolts in an
bearing carrier. If the bushing is corroded, pitted or alternating sequence. See Section 3.3 for directions
worn, the oil pump shaft bushing should be replaced. on oil pressure adjustment.
Before reassembling the oil pump mechanism,
replace the 0-rings in the oil pump cover and on the
oil pump adapter shaft (see Figure 5.7A). Rotate the
drive pin in the crankshaft to a vertical position for
easiest reassembly. Insert the shaft adapter so it
engages the drive pin. Next, insert the spring, spring
BEFORE DISASSEMBLY:
CHAPTER 6
EXTENDED STORAGE PROCEDURES
Following a few simple procedures will greatly 4. Plug all openings to prevent entry of insects and
minimize the risk of the unit becoming corroded and moisture. (The cylinders may also be protected
damaged. Corken recommends the following by the use of a vapor phase inhibitor, silica gel,
precautions to protect the compressor during storage: or dry nitrogen gas. If the silica gel is used, hang
a tag on the unit indicating that it must be
1. Drain the crankcase oil and refill with rust removed before a start-up.)
inhibiting oil.
5. Store in a dry area, off the ground if possible.
2. Operate for a few minutes while fogging oil into
the compressor suction. 6. Rotate the flywheel every two weeks if possible.
491
NOTE: MODELS ARE AVAILABLE WITH DIN IRON HEAD/CYLINDER 491/492 BASIC
MODEL NO. WILL BE DESIGNATED BY A "2" THE LAST DIGIT OF 491-3 MODEL
THE MODEL NO. 691/692
ALL INLET PRESSURE ABOVE ATMOSPHERIC A PACKING
A
ADJUSTMENT
91 ONLY SPLASH LUBRICATED CRANKCASE J
91-491 EXTENDED CRANKSHAFT E
ALL EXCEPT 91 STANDARD PRESSURE LUBRICATED CRANKCASE M
ALL EXCEPT 91 STANDARD CRANKCASE WITH CRANKCASE HEATER MH CRANKCASE
M
ALL EXCEPT 91 STANDARD CRANKCASE WITH EXTERNAL COMPRESSOR L STYLE
LUBRICATOR
ALL EXCEPT 91 STANDARD CRANKCASE WITH EXTERNAL COMPRESSOR LH
MODEL NUMBER
LUBRICATOR AND CRANKCASE HEATER
ALL LIQUID RELIEF SUCTION VALVES 3
ALL STANDARD SUCTION AND DISCHARGE VALVES 4
3
ALL SUCTION VALVE UNLOADERS 9 VALVES
ALL EXCEPT 391-491 SPEC 4 VALVES AS NOTED ABOVE WITH PEEK VALVE PLATES 4P
ALL EXCEPT 391-491 SPEC 9 VALVES AS NOTED ABOVE WITH PEEK VALVE PLATES 9P
91-491 SERIES PTFE PISTON RING AND PACKING MATERIAL F PISTON RING
F
691 PTFE PISTON RING AND ALLOY 50 PACKING MATERIAL AND PACKING
ALL SAME AS F WITH THE ADDITION OF K-RING SPACERS FK MATERIAL
ALL ALUMINUM GASKET MATERIAL B GASKET
B
ALL COPPER GASKET MATERIAL C MATERIAL
ALL IRON-LEAD GASKET MATERIAL D
ALL BUNA-N A O-RING
A
ALL NEOPRENE* B MATERIAL
ALL VITON* D
N
ALL SINGLE STAGE NOT APPLICABLE - SINGLE STAGE COMPRESSOR N INTERCOOLER
COMPRESSORS (NO INTERCOOLER)
191-491 SERIES ONLY 14" FLYWHEEL USED IN CONJUNCTION WITH EXTENDED E
CRANKSHAFT
S
91-491 SERIES ONLY HEAVY DUTY FLYWHEEL H FLYWHEEL
ALL NO FLYWHEEL SUPPLIED N
ALL STANDARD FLYWHEEL S
ALL NO COATING N PROTECTIVE
N N
COATING
ALL NITROTEC PISTON ROD COATING (STANDARD) N PISTON ROD
COATING
APPENDIX A
STANDARD OPTIONAL
PART SIZE MATERIAL SIZE MATERIAL
HEAD, CYLINDER 91, 291, 491, 691 DUCTILE IRON ASTM A536 NONE
CROSSHEAD GUIDE
CRANKCASE, FLYWHEEL ALL GRAY IRON ASTM A48, CLASS 30 NONE
BEARING CARRIER
FLANGE 691 DUCTILE IRON ASTM A536 690,691 STEEL WELDING
VALVE SEAT AND BUMPER 91,291 17-4 PH STAINLESS STEEL NONE
491 DUCTILE IRON ASTM A536
691 GRAY IRON ASTM A48, CLASS 30
VALVE PLATE 91,291 410 STAINLESS STEEL NONE
491 17-7 PH STAINLESS STEEL
691 STEEL, ROCKWELL 50C
VALVE SPRING 91,291,691 17-7 PH STAINLESS STEEL NONE
491 INCONEL
VALVE GASKETS ALL SOFT ALUMINUM ALL IRON-LEAD
PISTON ALL GRAY IRON ASTM A48, CLASS 30 NONE
C1050 STEEL,
PISTON ROD ALL HARD CHROMIUM PLATED NONE
ROCKWELL 60C
CROSSHEAD ALL GRAY IRON ASTM A48, CLASS 30 NONE
PISTON RINGS ALL PTFE, GLASS- AND MOLY-FILLED NONE
PISTON RING EXPANDERS ALL 302 STAINLESS STEEL NONE
HEAD GASKET 91, 291, 491, 691 O-RING (BUNA-N) 91,290,291, 491, 691 PTFE, VITON, NEOPRENE*
ADAPTER PLATE,
PACKING CARTRIDGE, ALL DUCTILE IRON ASTM A536 NONE
CONNECTING ROD
PACKING RINGS ALL PTFE, GLASS- AND MOLY-FILLED NONE
CRANKSHAFT ALL DUCTILE IRON ASTM A536 NONE
CONNECTING ROD ALL BIMETAL D-2 BABBIT NONE
BEARING
WRIST PIN ALL C1018 STEEL, ROCKWELL 62C NONE
WRIST-PIN BUSHING ALL BRONZE SAE 660 NONE
MAIN BEARING ALL TAPERED ROLLER NONE
INSPECTION PLATE ALL ALUMINUM NONE
O-RINGS ALL BUNA-N ALL PTFE, VITON, NEOPRENE*
RETAINER RINGS ALL STEEL NONE
MISCELLANEOUS GASKETS ALL COROPRENE NONE
APPENDIX B
SINGLE STAGE
Specifications 91 290 291 490 491 690 691
Cylinder Bore, Inches (cm) 3 3 3 4 4 4.5 4.5
First Stage (7.62) (7.62) (7.62) (10.16) (10.16) (11.43) (11.43)
Stroke, 2.5 2.5 2.5 3 3 4 4
Inches (cm) (6.35) (6.35) (6.35) (7.62) (7.62) (10.16) (10.16)
Piston Displacement
CFM (Lit/Min)
Min. at 300 RPM 3 (85) 6 (170) 6 (170) 13 (368) 13 (368) 22 (623) 22 (623)
Max. at 825 RPM 8 (226) 16 (453) 16 (453) 36 (1019) 36 (1019) 60 (1699) 60 (1699)
*Max. Pressure 350 280 350 280 350 280 350
psia (bars) (24.14) (19.31) (24.14) (19.31) (24.14) (19.31) (24.14)
Max. Motor Size HP 7.5 15 15 15 15 35 35
Max. Outlet 350 350 350 350 350 350 350
Temperature °F (°C) (177) (177) (177) (177) (177) (177) (177)
* These numbers specify pressure-containing abilities of the compressor cylinder and head. For many applications,
factors other than the pressure rating will limit the maximum allowable discharge pressure to lower values. These
factors include horsepower, temperature and rod load.
APPENDIX C
SIZE CONN. BEARING BEARING CRANK- X-HEAD CYL. VALVE VALVE PISTON PISTON VALVE VALVE
ROD CARRIER COVER CASE GUIDE TO COVER HOLD- LOCK SCREW CAP CAP
BOLT FT-LB FT-LB INSPEC FT-LB HEAD PLATE DOWN NUT TORQUE TORQUE TORQUE
FT-LB PLATE (1,2) BOLT SCREW TORQUE IN-LB (W/ GASKETS) (W/ O-RINGS)
FT-LB FT-LB FT-LB 2 FT-LB FT-LB FT-LB
FT-LB
91 28 38 38 15 30 20 -- 40 45 50 40 25
291 28 30 30 13 25 20 -- 40 45 50 40 25
491 30 26 35 8 33 33 35 40 45 100 40 25
691 40 40 40 9 40 30 37 40 60 100 40 25
(1) Preliminary tightening – snug all headbolts in the sequence shown. Final torqueing – torque all headbolts in the sequence shown to the listed value.
(2) Retorque to the listed value after 2 – 5 hours running time.
APPENDIX D
* Dimensions for honing are included with new bushings (which must be installed, then honed).
** Clearance should be set with machine cold.
APPENDIX E
DRIVER HORSEPOWER
LIQUID LIQUID
TRANSFER TRANSFER
AND WITHOUT
RESIDUAL RESIDUAL
DRIVER SEAVE VAPOR VAPOR PIPING SIZE
CAPACITY DISPLACEMENT COMPRESSOR SIZE P.D.* (2) RECOVERY RECOVERY (3)
SERVICE GPM (1) CFM MODEL RPM 1750 RPM 1460 RPM 100˚F 80˚F 100˚F 80˚F VAPOR LIQUID
APPENDIX F
DRIVER HORSEPOWER
LIQUID LIQUID
TRANSFER TRANSFER
AND WITHOUT
RESIDUAL RESIDUAL
DRIVER SEAVE VAPOR VAPOR PIPING SIZE
CAPACITY DISPLACEMENT COMPRESSOR SIZE P.D.* (2) RECOVERY RECOVERY (3)
SERVICE GPM (1) CFM MODEL RPM 1750 RPM 1460 RPM 100˚F 80˚F 100˚F 80˚F VAPOR LIQUID
APPENDIX F2
DRIVER HORSEPOWER
LIQUID LIQUID
TRANSFER TRANSFER
AND WITHOUT
RESIDUAL RESIDUAL
DRIVER SEAVE VAPOR VAPOR PIPING SIZE
CAPACITY DISPLACEMENT COMPRESSOR SIZE P.D.* (2) RECOVERY RECOVERY (3)
SERVICE GPM (1) CFM MODEL RPM 1750 RPM 1460 RPM 100˚F 80˚F 100˚F 80˚F VAPOR LIQUID
APPENDIX F3
APPENDIX G
Additional Notes:
Checked By:
APPENDIX H
Printed in U.S.A.
September 1999