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IMPORT ANT
INSTRUCTIONS
FD151 GAS COMPRESSOR
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.
IE103
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Table of Contents
Summary of Contents for Idex Corken FD151
- Page 1 IE103 IMPORT ANT INSTRUCTIONS FD151 GAS COMPRESSOR 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.
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Page 3: Table Of Contents
TABLE OF CONTENTS CHAPTER ONE:HOW YOUR CORKEN COMPRESSOR WORKS ......4 1.1 Why Corken Compressors are Special..........4 1.2 Running Gear . -
Page 4: Chapter One:how Your Corken Compressor Works
CHAPTER ONE HOW YOUR COMPRESSOR WORKS Cross Section of a Typical Corken Oil-Free Vertical Compressor Head Unloader Assembly (Optional) Discharge Valve Assembly Suction Valve Assembly Piston Assemblies Outlet Cylinder Packing set (Upper) Oil Deflector Ring Intercooler (2-Stage Only) Inspection Plate (Model and Distance Piece Serial Number) -
Page 5: Running Gear
1.2 RUNNING GEAR Figure 1.2A). Sturdy iron crossheads transmit reciprocating motion to the piston. Corken gas compressors are mounted on sturdy oil- lubricated crankcases. Crankshafts are supported by Corken's automatically reversible oil pump design heavy-duty roller bearings. The connecting rods ride allows the machine to function smoothly in either the crankshaft on journal bearings. -
Page 6: Piston/Piston Rings
Distance Piece (‘D’ Style) Gas flows down from cylinder Piston Ring Groove Gas Pressure Forces Cylinder Wall Ring Against Wall V-Ring Piston Ring Packing Expander Piston Ring Deflector Ring Figure 1.4A Packing 1.5 VALVES Spring The typical Corken compressor valve consists of a seat, bumper, spring and valve disk, as shown in Figure 1.5A. - Page 7 arrangement for your machine. If the valve/unloader The unloaders are controlled by devices which number for your machine is 3 or 4, proceed to control the flow of gas into and out of the unloader chapter 2 (your machine has no unloaders). cylinder.
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Page 8: Chapter Two:installing Your Corken Compressor
CHAPTER TWO INSTALLING YOUR CORKEN COMPRESSOR 2.1 LOCATION Recommended Foundation Details for Corken Compressors Corken compressors designed manufactured for outdoor duty. For applications in which the compressor will be subjected to extreme Hex Nut conditions for extended periods, such as hot boiler Compressor 2”... -
Page 9: Liquid Traps
Piping Details Mechanical Trap Outlet Vacuum Breaker Valve Flexible Connectors Rigid Piping Rigid Piping Ball Float Support Support Inlet Drain Valve Figure 2.3A Figure 2.4A On oil-field gas compressors, "heavy ends" such as compressible fluid in this situation, high-impact pentane, hexane, heptane, etc., may accumulate stresses are created that will result in serious beneath the piston over a period of time. - Page 10 Automatic Liquid Trap ASME Automatic Trap Relief Valve Outlet Outlet Pressure Gauge Liquid Level Float Switch Mist Pad Inlet Baffle High-Liquid-Level Shutdown Switch Liquid-Level Alarm Switch Inlet Drain Drain Valve Drain Figure 2.4C Figure 2.4B rises above the inlet, the float will plug the level switch will open and disconnect the power to compressor suction.
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Page 11: Driver Installation / Flywheels
when running and cool when stopped, can draw Wiring Diagram moist air into the motor. This moist air will condense, and may eventually add enough water inside the motor to cause it to fail. To prevent this, make a Level Switch #2462 Start practice of running the motor at least once a week on... -
Page 12: Crankcase Lubrication
2.6 CRANKCASE LUBRICATION pieces are equipped with tapped holes to purge, vent and drain. Proper connections to and from Non-detergent oil is recommended for Corken these tapped holes are essential for optimum compressors. Detergent oils tend to keep wear compressor performance. particles and debris suspended in the oil, whereas non-detergent oils let them settle to the bottom of the Since some oil will pass the bottom packing set,... -
Page 13: Relief Valves
PURGING. Purging without buffering can only be HIGHLY CORROSIVE GASES. The compressor performed units with “A”-Style packing should be blocked from the system via valves on arrangements. Purge gas at a lower pressure than the suction and discharge piping, then purged with the suction pressure fed into the distance piece dry inert gas before being shut down. -
Page 14: Chapter Three:start Up Of Your Corken Compressor
CHAPTER THREE STARTING UP YOUR CORKEN COMPRESSOR NOTE: Read entire chapter before going to start- The flywheel is mounted on the shaft via a split, up checklist. tapered bushing and three bolts (Figure 3.2A). These bolts should be tightened in an even and progressive 3.1 INSPECTION AFTER EXTENDED manner until torqued as specified below. -
Page 15: Crankcase Oil Pressure Adjustment
CRANKCASE PRESSURE ADJUSTMENT • Check crankcase oil level at the oil bayonet. (Re- install the inspection plate and gasket.) Your Corken compressor Model FD151 is equipped with automatically reversible • Follow any other pre-start-up procedures that may geartype oil pump. Ensure that the pumping be necessary in your application. -
Page 16: Startup Check List
3.5 STARTUP CHECK LIST 17.Carefully check for any loose connections or bolts. Please verify all of the items on this list before starting your compressor! Failure to do so may 18.Remove all stray objects (rags, tools, etc.) from result in a costly (or dangerous) mistake. vicinity of unit. -
Page 17: Chapter Four:routine Maintenance Chart
CHAPTER FOUR ROUTINE MAINTENANCE CHART ITEM TO CHECK First Week Daily Weekly 1000 2000 6000 Only Hours Hours Hours Hours Crankcase oil pressure Compressor suction pressure Compressor discharge pressure Compressor discharge temperature Crankcase oil level Drain liquid from system accumulation points Drain / check distance piece Check V-belts for correct tension Retorque valve holddown screws... -
Page 18: Chapter Five: Routine Service And Repair Procedures
CHAPTER FIVE ROUTINE SERVICE AND REPAIR PROCEDURES Compressor Model FD151 Suction: Discharge: Specification 4 All Specifications Valve Cap O-rings* Corken Wrench Head Head * Older Units may have a metal gasket instead of the o-ring. Figure 5.1A 5.1 VALVES A) with the special wrench supplied with the compressor. Valves may then be removed. -
Page 19: Cylinder And Head
The metal valve gasket should always be replaced When reassembling the compressor, make sure the when the valve is reinstalled. Make sure suction and bolts are retightened as shown in Appendix C. discharge valves are in the right slots, as shown in 5.3 PISTON RINGS AND PISTON RING the illustrations. -
Page 20: Piston Rod Packing Adjustment
Piston Cross-Section Packing-Adjusting Nuts Model FD151 (Second Stage) “X” Piston Piston Ring Piston Ring Clearance Expander Tighten 1/4 turn Cylinder Pistons Piston Rod Shim Washer Figure 5.5A Figure 5.4B 5.3A). Next, remove the roll pin with needle nose leakage approaches an unacceptable level. pliers. -
Page 21: Wrist Pin Bushing Replacement
5.6.1 WRIST-PIN BUSHING REPLACEMENT removing the semicircular inserts. Make sure the indentations in the connecting-rod bearing and To replace the wrist-pin bushing, remove the retainer connecting rod line up when installing the new rings that position the wrist pin in the crosshead. bearings. -
Page 22: Oil Pump Inspection
contaminated crankcase oil. To check the oil pump, To check the crankshaft end play, first remove the oil unbolt the pump cover and remove the oil pump, pump (see Section 5.7). Press the end of shaft spring guide, spring and oil-pump shaft, as shown in towards the crankcase;... -
Page 23: Chapter Six: Extended Storage Procedures
CHAPTER SIX EXTENDED STORAGE PROCEDURES Following a few simple procedures will greatly minimize the risk of the unit becoming corroded and damaged. Corken recommends the following precautions to protect the compressor during storage: 1. Drain the crankcase oil and refill with rust- inhibiting oil. -
Page 24: Material Specifications
APPENDIX A MATERIAL SPECIFICATIONS STANDARD OPTIONAL PART SIZE MATERIAL SIZE MATERIAL HEAD, CYLINDER FD151 DUCTILE IRON ASTM A536 MC1002 COATED DISTANCE PIECE, CROSSHEAD GUIDE DUCTILE IRON ASTM A536 NONE CRANKCASE, FLYWHEEL BEARING CARRIER VALVE SEAT AND BUMPER FD151 17-4 PH STAINLESS STEEL NONE VALVE PLATE FD151... -
Page 25: Mechanical Specifications And Bolt Torque Valves
APPENDIX B MECHANICAL SPECIFICATIONS Cylinder Bore Piston Displacement Model Inches (cm) Stroke CFM (lit/min) First Stage Second Stage Inches (cm) Min. at 400 RPM Max at 825 RPM FD151 2-1/2” (6.35) 1-1/4” (3.17) 2.5 (6.35) 2.8 (79) 5.8 (164) Max Allow Rod Min Inlet Pressure Max Pressure Max. -
Page 26: Clearance And Dimensions, Purging And Draining Of Distance Piece
APPENDIX C CLEARANCES AND DIMENSIONS Dimensions in inches. Model Clearance: Conrod Clearance: Wrist Cylinder Bore Cylinder Piston Ring FD151 Bearing to Crankshaft Pin to Wrist Pin Diameter (Max) Finish (RMS) Radial Thickness Journal Bushing* (Max) (Min) Stage 1 0.0005 0.0025 0.0009 2.504 0.082... -
Page 27: Piston Details
APPENDIX D PISTON ASSEMBLIES Model FD151 Stage 1 Stage 2 “X” Piston Clearance Piston Rod Cylinder Piston Rod Cylinder TWO-STAGE MODEL FD151 Piston Assembly No. 1981-1X 5201-XC Piston Diameter 2-1/2” (6.35 cm) Stage 1 1-1/4” (3.17 cm) Stage 2 Ref. No. Part Name Part No. -
Page 28: Distance Piece / Packing Details
APPENDIX E DISTANCE PIECE DETAILS MODEL FD151 COMPRESSOR Packing Spec. A PART NO. PART NAME 5200C 1192 Locking Device TFE 1/8” dia. x 1/4” long 1387 Adjustment Screw 4395C 1452-1 Female Packing Ring 1714 1453-1 Male Packing Ring 5000-125 1454 Packing Ring 1714 1628... -
Page 29: Head / Valve Details
APPENDIX F HEAD ASSEMBLY DETAILS FD151 ALL MODELS FD151 HEAD VALVE REMOVAL Suction Discharge Specification 4 All Specifications Suction Discharge Valve Valve HEAD HEAD IDENTIFICATION OF VALVE UNLOADER SPEC. Example: Model No. FD151M FD151M 78 FBAB FD151M Valve Unloader Spec. VALVE DETAILS Suction Valve Discharge... - Page 30 Appendix F Refer to diagram on previous page. REF NO. PART NO. DESCRIPTION 4371-3 Head Model FD151 (ANSI Flange) Coated 3483-X Suction Valve Assy, Spec 4,7,78,8,9 3483-X1 Same as above but with Copper Gaskets 3483-X2 Same as above but with Iron-Lead Gaskets 3483 Suction Valve Seat 3484...
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Page 31: Connecting Rod And Crosshead Assembly Details
Appendix G CONNECTING ROD AND CROSSHEAD ASSEMBLY DETAILS All Specifications Model FD151 3, 4 Model 1. Crosshead 2. Crosshead 3. Conn. Rod 4. Connecting 5. Conn. Rod 6. Bolt Assembly Guide Assembly Bearings FD151 1132-X3 4383 1889-X 1889 1367 1599 1132-X4 (c) Model 7. -
Page 32: Crankcase Details
Appendix H CRANKCASE DETAILS – FD151 IDENTIFICATION OF VALVE/UNLOADER SPEC. Example: Model No. FD151AM Valve/Unloader Spec. Crankcase Assembly No. 2955-X1 (M3, 4, 8, 9) 2549-X1 Flywheel Assembly Not Shown (16”) Optional Flywheel Assembly 3271-X1 Not Shown (14”) Caution: Always relieve pressure in the units before attempting any repairs. - Page 33 Appendix H PART NO. PART NAME ASSEMBLY ASSEMBLY NAME 1273 Bearing Adjustment Shim (0.005”) 1273-1 Bearing Adjustment Shim (0.007”) 1279-X Breather Cap Assembly with 1279, 2-111A 1273-2 Bearing Adjustment Shim (0.020”) 1341 -X1 Crankshaft Assembly with 1284 (2),1286,1341, 1275 Oil Filter Screen 1501,2590,2719 1276 Filter Screen Washer...
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Page 34: Parts List Fd151
Appendix I MODEL FD151 PARTS LIST GAS COMPRESSOR - FLANGED - DUCTILE IRON DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Packing: ‘D’ Style A - Inlet Pressure >0 psig (V-V) O-ring Material J - H.D. Viton Crankcase: 191-491 M - Std Pressure Lube Intercooler - ANSI Two Stage F - No Intercooler Valves... - Page 35 Appendix I Component Quantity Component Quantity Number Description Required Number Description Required 2956 Bearing Carrier - 19 4383-X Crosshead Guide Assy 2957 Bearing Cover 4395 Packing Cartridge 2958 Crankcase Inspection 4397 Cartridge Spacer 2961 Air Release Valve Body 4398 Cartridge Holddown Screw 2962 Air Release Valve Ball 4943...
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Page 36: General
APPENDIX J GENERAL COMPRESSOR TROUBLESHOOTING GENERAL In most cases problems with your Corken Gas Compressor can along with a list of possible causes. If you are having a problem be solved quite simply. This chart lists some of the more which is not listed or if you cannot find the source of problem, frequent problems that occur with reciprocating compressors consult the Factory. -
Page 37: Compressor Startup Log Sheet
APPENDIX K CORKEN COMPRESSOR LOG SHEET Compressor Model No. Serial No. Package No. Motor BHP , Frame , RPM , F.L. Amps , Manuf. Installation Date Startup Date Customer Location Field Contact Telephone No. Make and Grade of Oil Pressure Switch Settings Stage 1 Stage 2 Suction Pressure... - Page 40 9201 North I-35 Service Road, Oklahoma City, OK. 73131 Phone (405) 946-5576 • Fax (405) 948-7343 E-mail cocsalesdept@idexcorp.com Web address www.corken.com Printed in U.S.A. April 1999...