Diaphragm compressor is positive displacement compressor of special structure with excellent sealing performance and the medium doesn' t contact with any lubricants. Those advantages enable diaphragm compressor to compress the extremely high purity gas, the toxic, highly corrosive, flammable, explosive, radioactive gas. The diaphragm compressor is wildly employed in the field of industrial gas, food, petrochemical, nuclear power, military and scientific examination etc.
1.1 After-sales commissioning and maintenance card：
For initial commission or maintenance record card during operation, the maintenance personnel will make record and signature, please properly keep it.
1.2 Quick-wear part-diaphragm：
The material of diaphragm is 00Cr15Ni5, which is made from Fushun special steel Co., The diaphragm became to be finished after 18 process,such as cut ,surface treatment, heat setting.The service life is about up to 4000-16000 hours. Diaphragm is complete in specifications with good price, warmly welcome calls 010-60701278/80 for consultation and purchase.
1.3 Sales and service network ：
General safety requirement
1.1The operators must be trained.They must familiar with the compressor’s structure, working principle and master
the operation manual. Otherwise they would not be allowed to operate the compressor.
Before checking the compressor carefully, it is forbidden to start the compressor.
Any improper operation will cause the compressor damage or person injure.It is very danger to rebuild any part of compressor, without manufacturer's permission.
1.1The operators must be trained.They must familiar with the compressor’s structure, working principle and master
the operation manual. Otherwise they would not be allowed to operate the compressor.
Before checking the compressor carefully, it is forbidden to start the compressor.
Any improper operation will cause the compressor damage or person injure.It is very danger to rebuild any part of compressor, without manufacturer's permission.
1.3 Fire-proof,explosion-proof requirements
The installation, operation and maintenance of the compressor which is for compressing the inflammable, easy explosive or toxic gas, must be satisfied with the relative regulations.The measures should be taken to prevent leaked gas accumulated in the compressor room.The release ports (such as safety valve, cooler drain valve etc.) should be lead to the outside of the room.The electric elements must be satisfied with the requirements of the explosion-proof.
1.4 Regulations for lubricant
Only the compressor manufacturer recommended brand lubricant can be allowed to use. t is forbidden to mix different brand lubricants.
The lubricant must be changed regularly.
1.5 Regulations for cooling water
The cooling water should be clear, soft and not easy to scale.
The cooling water should be:
1.5.1 The impurity and suspended matters is not more than 100mg/L, and remain oil is less than 5mg/L:
1.5.2 PH value is between 6.5~9;
1.5.3 The hardness of the water is less than 10°( note: 1 means in 1leter water, it contains 10mg Ca0 or 19mg MgO)If the quality of the water is not satisfied with the above requirements, it should be filtered.
1.6 Protection for person
When compressor is running, the person shouldn't contact the rotating parts (such as belt, chain, coupling and fan etc.). cylinder wall and discharge pipes to prevent injure.
1.7 Requirements for electric elements
The installation and maintenance of the electric equipment should be satisfied with the local concerned regulations. The operator must have operating license. Before service the electric elements, ensure the power is cut off.Meanwhile put an alarm sign or arrange a person for monitoring.
1.8 Lifting requirement
The capacity of lifting equipment should be satisfied the requirements. When lifting, the safety of the person and machine should be cared. Lifting can refer to drawing 1-1:
The lifting angle must not less than 45°. lf the lifting angle less than 45°, a strengthen beam will be needed.
2.1 General information of structure
Diaphragm compressor mainly consists of crankcase, connecting rod, cross-head, piston, cylinder body, cooler and its pipeline, base plate, instrumentation, electric motor etc. The compressor structure is divided into 4 types-..L.Z.V and P,according to cylinder body arrangement.
L type diaphragm compressor's vertical and horizontal cylinders form L. (Please refer to the picture)
Z type diaphragm compressor only consists of vertical cylinders, and this structure looks like the letter "Z”. (Please refer to the picture)
V type diaphragm compressor's left and right cylinders form V. (Please refer to the picture)
P type diaphragm compressor is the balanced opposed frame, the cylinder body number can be 2, 3 or 4. (Please refer to the picture. This is the 4 cylinders type)
Cylinder body part has the similar structure including cylinder cover, cylinder body, diaphragm etc. There's a special shape curved face on cylinder cover and cylinder body, and a set of metal diaphragms are clamped between these two curved face. which forms two cavities. The cavity on cylinder cover side is gas cavity, and the other one that locates on cylinder body side and connects with the space between the piston through many small holes on the cylinder body is the oil cylinder. Cylinder jacket is needed inside cylinder body and the piston makes reciprocating movement inside the jacket. Suction and discharge valve port are located on cylinder cover. The discharge valve port is on the center of cylinder cover and the other 1 or 2 ports are suction port. The suction and discharge valves are in the suction and discharge valve port on the cylinder cover, and the valves are tightened with pressure tube.
2.2 Working principle
Diaphragm compressor is positive displacement compressor of special structure. The electric motor drives the crankshaft through belt or coupling: as the crankshaft rotation, the connecting rod makes plane movement, which drives the cross-head and piston installed on small end of connecting rod makes linear movement. The movement amplitude equals twice of crank throw radius, and this is one stroke, The movement frequency is the crankshaft rotation frequency.
Taking the upper dead point of the piston as the starting point, the piston begins to move downward when crankshaft starts to rotate. Under the function of the oil level falling and self elastic force, the diaphragms restore to the balance position. Whereas, the cylinder volume increases gradually, consequently the gas remained in the clearance expands and then gas is inhaled through the cylinder suction valve. When the piston reaches to the lower dead point, the diaphragms also reach their lower limit position, which finishes the cylinder suction process.
After that, the piston begins to move upward to drive the hydraulic oil that has even effects on the diaphragm through the small holes on the oil distributing plate to push it move upward. At this time, the cylinder begins to compress gas. In case the gas pressure is higher than the one of the gas discharge pipe, the discharge valve opens automatically to discharge gas. Whereas the oil pressure keeps rising to force the diaphragm tightly touch the cylinder cover curved face to exhaust all the gas. Thus the discharge process ends.
The reciprocating pistons drive the oil to make the diaphragm vibrate up and down. Under the help of the suction and discharge valve, each vibration period of the diaphragm is one complete circulation process of suction.compression and discharge of cylinder, which increases the gas delivery pressure.
A part of oil in the cylinder would leak into the crankcase through the gaps between the piston ring and cylinder wall as well as ring groove, the compensating oil pump is installed in order that the diaphragms tightly touch the cylinder cover curved face at the end of compression stroke to discharge the entire compressing medium. During suction process, the compensating oil pump fills the oil into the oil cylinder, thus the oil volume is larger than the leakage volume. The excess oil returns to the crankcase at the end of process through pressure regulating valve used to pressure.
The diaphragms totally separate the gas cylinder and oil cylinder and function as piston because of its self reciprocating vibration. So it's unnecessary to put any lube into the gas cylinder and the compressing medium only touches the metal diaphragm, which guarantees the purity of the medium. The cylinder consists of cylinder cover curved face and diaphragm and is a closed cavity with excellent sealing performance.Those advantages enable diaphragm compressor to compress the extremely high purity gas to reach the purity of 99.999%. The diaphragm compressor is especially suitable to compress, deliver, fill bottle of the precious noble gas. As for the toxic, highly corrosive, flammable, explosive, radioactive gas, the diaphragm compressor is also suitable. Thanks for the perfect heat-sinking capability of the cylinder and higher compression ratio, the available pressure range is from very low pressure to 200Mpa. The diaphragm compressor is employed in the field of industrial gas, food, petrochemical nuclear power, military and scientific examination etc.
2.3 Application
Diaphragm compressor could be used to compress air, hydrogen, nitrogen, oxygen, inert gas, carbon dioxide carbon monoxide, methane, natural gas, ethane, TFE, HFP, ammonia gas etc. but different gas requires different compressor arrangement. And the compressor should be operated in accordance with technical agreement.
3.1 Cylinder
All the cylinders comprise upper plate, diaphragms, and cylinder body etc. The diaphragms are clamped between the cylinder cover and cylinder body. The cylinder cover and cylinder body each has a concave recess hollowed out in their contacting faces. The gas cylinder is formed between cylinder cover concave recess and diaphragms. Both suction valve and discharge valve are fitted on the upper plate. Among of them, the discharge valve is located on the center of the upper plate. The evenly located small oil holes are on the cylinder body to deliver the oil pressure inside the oil cylinder to the diaphragms.
3.2 Pressure Regulating Valve
The oil pressure of oil cylinder is regulated by the tension of the valve spring.In case the oil pressure is higher than the regulated value, turn the regulating bolt counter-clockwise to loosen the spring tension, but turn the regulating bolt clockwise to tighten the spring, when the oil pressure is lower than there gulated value. When the oil pressure meets the required value, the regulating bolt must be locked with a lock-nut. The oil pressure of the oil cylinder shall always be higher than the discharge pressure by 15~20%. But the oil and gas differential pressure shall not be lower than 0.3MPa or higher than 1.5MPa.
3.3 Cooler
The cooler structure is the double-wall pipe type. The circular space between the outer and inner pipe is the cooling water passage and the inner pipe is the gas passage. Normally the water inlet port is at the lower side and the water outlet port is at the upper side. The flow direction of cooling water and gas is on the contrary.
3.4 Oil Pressure Measuring Device
The measuring device of oil cylinder discharge pressure consists of shock-proof pressure gauge, check valve and unloading valve. The case of the pressure gauge is totally airproof and filled with damping liquid. The inner devices of gauge is immersed in the liquid, which makes the pressure gauge hands stable through the function of the viscosity of damping liquid. The unloading valve is fitted under the gauge to discharge the remained air in the oil pipeline and to unload the oil pressure gauge. Also the check valve connecting with oil cylinder through pipeline is fitted under the unloading valve.
3.5 Oil pipes
Oil pipes consist of lube oil pipe and oil pressure secure system.
The lubrication for the driving device adopts gear oil pump circulation pressure lubricating. The lube oil stored in the frame oil tank enters into the gear oil pump after being filtered and is pressed into the oil holes in the crankshaft through the gear oil pump to lubricate the crankshaft friction surface. At the same time, part of the lube oil reaches the crosshead pin and crosshead along the oil holes in the connecting rod to lubricate the friction surface. The oil pressure of gear oil pump shall be kept between 0.3~0.5Mpa, and the bearings at the two ends of crankshaft is splash lubricated.
Oil pressure secure system consists of oil compensating pipe, pressure-measuring pipe and oil return pipe. The oil output from the oil compensating pump will supplement oil for compressor cylinders through the oil compensating pipe and the excess oil returns to the crankcase through the pressure-regulating valve.
3.6 Gas pipes
The gas enters into compressor through inlet port to be compressed and enters into the clients' system after cooling by the cooler.
4.1 Check
On receiving delivery, the client should dismantle the box to check if there are shortage or damage of the products according to packing list. Please take notes for any problem and contact the manufacturer immediately. There must have special staff to keep the relative documents with delivery and spare parts.
4.2 Preservation
4.2.1 Indoor safekeeping;
4.2.1.1 Dry, ventilation, with no corrosion;
4.2.1.2 Temperature is not lower than -15 C;
4.2.1.3 When relative humidity is >85%，please put an exsiccator in the package box;
4.2.1.4 Use a wood stopper to caulk the open port of machinery;
4.2.1.5 Charge dry nitrogen into the pipe when necessary；
4.2.2 Safekeeping outdoor for a short time；
4.2.2.1 Put a shield for the package box in case of wind, rain and sunshine;
4.2.2.2 Put the compressor on a higher place to prevent water;
4.2.2.3 Check the compressor weekly and amend the problem；
The valid period of preservation is 12 months after coming out from the factory, Please contact our company incase the expiration of the valid period and make maintenance if necessary.
5.1 Foundation
The foundation should be a convex concrete terrace that is to be constructed by user according to the foundation drawing supplied by manufacturer and the on-site conditions. Please consider the water discharge and drainage system.
The foundation should be built respectively which can't use the former foundation and must separate from the system border equipment by using soil.
5.2 Installation
5.2.1 The compressor should be installed in a environment of dry, ventilation, without dust and non-corrosive;
5.2.2 A passage of 1.5m wide at least is required around the machine;
5.2.3 A bridge crane that is removable and capable of lifting the compressor is required;
5.2.4 After installing the diaphragm compressor on foundation, the horizontal error should less than 5%o, andwithout any warping for the foundation seat when the compressor is fixed；
5.3 Gas pipes connected outside
The pipelines connected with the inlet and outlet port of compressor and the sewage pipelines should be designed and installed by users. For large diaphragm compressor, the metal hose could be used for the suction and discharge pipe in order to eliminate the vibration. If the compressor is not equipped with suction filter, the client should install according to the site conditions. If any liquid in the source gas, a suction buffer separation tank must be installed on the suction pile.
The compressor should be equipped with gas return pipe, if not the client should design and equip the pipe. The gas return pipe should be used at the time of compressor start up or stop to realize under-loading start up or stop,in this way the compressor is effectively protected.
5.3.1 Requirements for pipelines
o、Pressure testing should be proceeded for all the gas transporting pipelines and the testing pressure should be 1.5 times as large as the highest allowable pressure;
b、The welding bead and connecting parts of the gas pipeline should be inspected for the leak tightness；
C、Air vent and the outlet of unloading valve should be equipped with pipe and the air should be transported to the safety area to recycle or discharge;
d、Suspended long pipelines should be supported by ancillary shoring but without subsidiary stress;
e、There must have some measures to damp the vibration and eliminate the heat expansion of pipelines connected with compressor;
f、No welding slag, rust and sewage exist inside the pipeline and blow the inside pipeline by using the dry and compressed air before installation;
g、The suction pipelines should be equipped with release hole to unload in case of the suction pressure is higher than rating suction pressure. The discharge pipelines should be equipped with check valve to prevent the return of gas and blow-down valve to facilitate the starting of compressor with light load。
5.3.2 Accessories of pipelines
At the preliminary running period of compressor, a filter or screen with 80 mesh should be installed at the suction port to prevent welding slag, dust, and the like.
5.33 Requirements for water pipelines
A water supervisor should be installed in pipes to facilitate the inspection for the flowing condition of the cold water.
5.4 Installation for instrument
Check the pressure gauge before installation and send the pressure gauge to the relative department to be adjusted.
Please assemble instrument according to the nameplate and drawing. The pressure gauge should be installed toward the operating surface of diaphragm compressor, Tight the compressor and if the direction is wrong, just loosen the locking nut under the gauge seat or add the sealing pad under the gauge seat to adjust.
6.1 Filling crankcase with oil
Before running, loosen the plunger on the crankcase and fill certain amount of lube oil into the crankcase, and the oil level shall be above the calibration line. The lube oil should be used in accordance with technical agreement.
6.2 Filling cross-head and cross-head bushing with oil
The distance piece window should be dismantled before initial operation, and appropriate amount of lube oil should be sprayed into the oil return hole on cylinder body with oil gun. Then the window should be re-installed and the belt pulley should be rotated with hand to ensure that the lube oil evenly distribute on cross-head guide.
6.3 Fill the oil tank with oil
In order to meet the normal operating requirement of diaphragm compressor, the oil chamber between the oil cylinder piston and diaphragms must be filled with oil and there shall have no remained gas. Because the compressibility of gas, the remained gas could make the working stroke of diaphragm reduce resulting the discharge capacity reduction during operating.
Different oil filling method for oil tank with separate oil pump station and without separate oil pump station.
A、The method for oil tank with separate pump station
6.3.1 Turn the belt wheel to make the piston move to the upper dead point.
6.3,2 Open the oil discharge valve under the cylinder body and connected with oil supply system.
6.3.4 Open the unloading valve under the oil pressure gauge.
6.3.5 Start the oil supply system electric motor, When the oil is full, the piston will move to the lower dead point and drive the big belt wheel to close the oil supply system electric motor power.
6.3.6 Close the oil discharge valve on cylinder body During oil filling: lube oil is filled for cylinder through oil supply system after filter and cooler.
The diverting valve picture (the picture on the right)
B、The method for oil tank without separate pump station
6.3.1 Open the unloading valve under the oil pressure gauge. if there's oil return pipe, open the valve on the return pipe.
6.3.2 Start the electric motor.
6.3.3 Close the unloading valve under the oil pressure gauge.
6.3.4 Regulate oil pressure regulating valve and close the compressor electric motor power when the oil cylinder pressure gauge starts move. (Notes: because oil compensatory pump oil intake amount is little, so the time is little longer)The diverting valve picture (the picture on the right).
6.3.5 Evacuate excess oil
Notes: When compressor is running normally, the diaphragms must be curved concavely downwards with the piston at BDC. Nevertheless, after the oil filing the diaphragms are mounted flat in the compressor and remain stable without any deformation when the piston is at lower dead point, There is consequently a half-cylinder of oil in excess in the space beneath diaphragms which must be released from oil cylinder or the compressor can not be started up.To evacuate the excess oil proceed as follows:
Turn flywheel, bring the piston in oil cylinder towards upper dead point and meantime open the unloading valve under the oil pressure gauge, and turn the belt wheel at least 2 times.
6.4 Check the oil volume of crankcase
Recheck the oil, if the oil level is lower than the lower scale line, it should be added to the crankcase.
6.5 Check and adjust oil pressure
In order to ensure the diaphragms tightly touch the cylinder cover concave recess to discharge all the gas at the end of discharge process during operating, the oil discharge pressure(start-up pressure of pressure-regulating valve) must suitable be higher than the cylinder gas discharge pressure by 5-25%but the oil and gas pressure difference should be not lower 0.3MPa or higher than 1.5MPa.
Caution: it's forbidden to vacuumize the compressor during the time of oil regulating, and it's necessary to supply certain pressure gas at the suction port or directly connected with open air.
In case the compressor operates under the pressure that is lower than the nominal discharge pressure, please reduce the oil discharge pressure of oil cylinder pursuant to the above requirements, so the pressure difference on diaphragms shall not be too high and the service life is extended.
The start-up pressure of the compressor pressure-regulating valve has been adjusted when delivered at the factory according to the nominal discharge pressure, but the client shall check or adjust the start-up pressure of the valve in accordance with the practical operating conditions to ensure the normal operating.
6.6 Leak check
Prior to the compressor operation it is necessary to check the bolts and nuts of compressor for tightness and check the flange connections between compressor and suction/discharge piping, if necessary.
7.1 Preparation before starting
When on the condition that it's a initial starting or restarting after replacing diaphragm or inspection, the following procedures are to be followed:
7.1.1 Check all valves whether in the condition of cut-off;
7.1.2 Remove all the maintenance accessories for safety and the sign board for maintenance;
7.1.3 Check the system and remove the material coming from outside;
7.1.4 Barring at least on circle and make sure that there is no mechanical failure;
7.1.5 Make sure that the rotation direction of motor and crankshaft is correct;
7.1.6 Check and make sure that all the protective device are in good condition;
7.1.7 Check if the pressure gauge hand backs to "zero"
7.1.8 Check if the lube oil inside the crankcase meets the requirement and if the oil level is between the upper and lower scale mark;
7.1.9 (With separate oil pump station) check if the oil pipe block valve under the cylinder body is on close condition;
7.1.10 (with separate oil pump station) check the oil pipe diverting valve position, and check if the valve on the oil supply pipe open.
7.2 Starting
Never start the compressor with load. Compressor can be loaded only after the normal sped has been reached:
7.2.1 Connect the cooling water pipes;
7.2.2 Open the unloading valve under oil pressure gauge;
7.2.3 (with oil return pipe) Open valve on oil return pipe;
7.2.4 Turn off the valve on suction and discharge pipeline; if the suction pressure is lower than 0.5MPa, don't close the valve on the suction pipe;
7.2.5 (With separate oil pump station) start the oil pump electric motor and after the lube oil pressure is stable;
7.2.6 Start the electric motor;
7.2.7 Close the unloading valve under the oil pressure gauge and when the oil tank pressure reaches the setting value;
7.2.8 Open the gas suction and gas discharge valves;
7.2.9 (With oil return pipe) close the vale on oil return pipe;
7.2.10 Check the panel of oil and air pressure;
7.2.11 Check the sound and vibration of compressor.
7.3 Stopping
7.3.1 (With oil return pipe) open the valve on oil return pipe;
7.3.2 Close the gas suction and discharge valves; if the suction pressure is lower than 0.5MPa, don't close the valve on the suction pipe;
7.3.3 Open the unloading valve;
7.3.4 Turn off the compressor main motor;
7.3.5 (With separate oil pump station) when flywheel stops rotation, turn off the oil pump motor power;
7.3.6 Close the cooling water suction and discharge valve;
7.3.7 If there's nitrogen displacement pipe, please make nitrogen displacement.If the compressor is equipped with automatic unloading start up and close, the compressor will operate automatically in accordance with electric control design.
7.4 Emergency stopping
Whenever abnormal noise is heard or extraordinary phenomena are observed, shut down the compressor immediately
7.5 Please discharge all the cooling water inside the compressor when the compressor is stopped for a long period of time in winter.
8.1 Daily maintenance
When the compressor is running, pay attention to gas discharge pressure and oil release pressure in both compression stages. Be sure that no extraordinary noise is heard, lt is also necessary to check oil level in crankcase.
After 3000-4000 hrs' operation, completely changes oil in crankcase. During the initial service of compressor it is advisable to reduce the oil change time interval to a proper extent, generally within 1000hrs, The lube oil pollution condition at the oil scale mark is also used to decide whether to change the oil.
8.2 Changing the diaphragms
when a diaphragm has been found punctured or cracked, immediately shut down compressor and change the diaphragm in the order given:
8.2.1 According to the failure to tell which diaphragm is broken:
8.2.2 (With separate oil pump station) open the valve under the cylinder, and turn the diverting valve to the oil sucking position. Open the oil discharge valve (unloading valve) under oil gauge, start the oil pump motor and extract the hydraulic oil in the oil tank back to the crankcase through oil pump.
8.2.3 Dismantling
8.2.3.1 Dismantle the cylinder suction and discharge pipe;
8.2.3.2 Dismantle the cooling water pipe connected with cylinder cover;
8.2.3.3 Take out the suction and discharge valve with valve removal tool;
8.2.3.4 Dismantle all the bolts on the cylinder cover except the three guide bolts (the bolts on the outside surface of cylinder body with fastening screws);
8.2.3.5 Lift the cylinder to 15-20mm with 3 cylinder cover handles;
8.2.3.6 Take out the diaphragm set;
8.2.3.7 if necessary, lift the cylinder cover with hoisting equipment;
8.2.3.8 Cautions during the removal of the diaphragm:
a、 Before dismantling, mark the relative position between the cylinder cover and body to avoid mistake;
b、 Don't damage the screw on the bolt during dismantling or it's difficult to install again;
C、Please make sure to protect the cured face on the cylinder cover and body as well as the diaphragm surface, no damage, bruise or scratch allowed;
d、It's forbidden to hit the parts during dismantling to avoid any damage or deformation of the sealing surface or cylinder damage, bruise or scratch allowed.curved face, then leakage or diaphragm rupture during compressor operation will occur.
8.2.4 Cleaning
NY.190 solvent gasoline is used as cleaning agent. First cylinder cover and curved surface the cylinder, suction and exhaust valve as well as diaphragm shall be brushed with hairbrush, and then cleaned by cloths, care shall betaken to prevent fire during cleaning, and below points shall be followed.
a、Any source of fire surrounding the site shall be prohibited;
b、All power shall be cutoff, and well earthed;
C、Wearing of clothes may cause sparkling and shoes with iron nail shall be prohibited:
d、Sufficient fire extinguishing tools shall be prepared;
e、Sufficient fire extinguishing tools shall be prepared;
f、Safety personnel monitoring and inspection shall be presented at site.
8.2.5 Assembling
8.2.5.1 Requirements prior to assembly:
a、Curved surface of cavity and diaphragm shall be kept clean, any scratch, indentation, rusty and dirt is not allowed, if any defects may cause non-use or leakage etc., it shall be repaired or replaced.
b、it shall wait after clean agent on surface of the parts is completely volatilized then assembly can begin.
8.2.5.2 Assembly
a、Lift the cylinder cover, confirm the correct position, put the cover through 3 pieces of guiding screws, then slowly slides to cylinder body, but no contact of these two at the time;
b、 Turning into 3 pieces of cover handle to jack-up the cover, with 15-20 mm distance from the body;
C、Insert diaphragm groups between cover and body;
d、During assembly of diaphragm, care shall be taken on sequence of it, there are 3 pieces of diaphragms, are air side, middle and oil side diaphragm respectively, at edge of each diaphragm there are 2 positioning holes,diaphragm for oil side and air side are the same,better put the one with best surface quality at air side. There are 3 small grooves on one side of middle diaphragm,towards the oil side, on the other side towards the gas side, there is 1 groove on it;
e、Turing anti-clockwise the cover handles, slowly lower down the cover and make it contact with body,then examine around the circle, make sure cover is tightly contact with diaphragm,and O ring on the cover is staying in O ring groove;
f、Put through all bolts, and tum on the nuts. Attention: before turning on the nuts, one thin layer of lubricant oil shall be painted on thread of bolts and bottom side of nuts, so that scratch of thread and cylinder cover can be avoided while tightening Tightening of nut shall be made symmetrically and even, and please refer to below table for torque. Tightening of nut shall at least in 3 steps, so that stress on the bolts shall be even. After all nuts have been tightened, torque value of each bolt shall be once more checked, till it can not be turned further with maximum torque;
g、 Install the suction and discharge valve onto the cylinder cover with valve removal tool and tightened the valve with suction and discharge pipe; install the suction and discharge pipe and cooling water pipe. Please refer to the below picture for the torque wrench's usage.
8.3 Inspection of compensating pump
In case of inadequate capacity of pump or when the pump cease to supply oil, the efficiency of compressor becomes lower and the compressor may even stop delivering gas. To check the pump for normal work operator touches the pump oil outlet pipe with hand. when the pump functions property, the pulsation of oi is felt on the oil outlet pipe. Operator can also loosen the oil outlet pipe connection and observe whether the pump is discharging oil.
Check the oil inlet and outlet valve port of compensating pump, and clean the dirty valves or replace the damaged valves.
8.4 Type for servicing compressor
When dismantling or assembling the parts and components of compressor pay particular attention to cleanliness of parts and components, since a small particle of dust or metal results in improper function of valves or oil cylinder.may even cause the failure of diaphragms.
lf the compressor does not work properly, inspect various parts in following order.
8.4.1 Check the oil level in crankcase;
8.4.2 Check the pressure of oil cylinders; if the pressure is beyond the rated range, check the oil pressure regulating valves, compensating pump or ascertain whether the diaphragms are punctured;
8.4.3 Check the gas discharge pressure; if abnormal, inspect the gas suction and gas discharge valves or check the diaphragms;
8.4.4 If the discharge temperature rises abruptly, check the cooling water or gas valve.
For trouble shooting, please refer to below table and ensure the compressor normal operation.
The types, causes and troubleshooting methods of common faults in compressors.
|
Failures |
Main causes |
Trouble shooting |
|
Lube oil pressure suddenly drop, and is lower than0.2MPa
|
1.Not enough lube oil inside the crankcase. 2.Blockage of the filter and filtering components 3.Oil pressure gauge malfunction Oil pump piping blockage or rapture 5.Oil supply system malfunction 6.Oil viscosity declines 7.Oil pipe connection loosens 8.Bearing or cooper sleeve of driving mechanism severely wears out 9.Gear pump is damaged 10.Sealing parts wear out |
1.Fill oill immediately 2.Cleaning 3.Replace the oil pressure gauge 4.Replace the oil pressure gauge 5.Check oil supply system 6.Replace lube oil 7.Tighten the nut or add washer 8.Check and repair the bearing or sleeve 9.Replace gear pump 10.Replace sealing part |
|
Compensating oil pump don' t supply oil |
1.Oil inlet and outlet valve port loosens 2.Oil inlet and outlet valve don’t close tightly 3.Gear pump oil pressure is lower than0.3MPa. 4.Oil inlet and outlet valve position and direction are wrong |
1.Replace 2.Dismantle and clean the valve 3.Check oil pressure caus 4.Check carefully and install again |
|
Excessive high temperature of lube oil |
1.Not enough lube oil supply 2.Low quality lube oil with bad heat radiation 3.Dirty lube oil that increase mechanical wear 4.Movement parts failure 5.Bad lube oil cooling |
1.Check the oil piping leakage and add lube oil 2.Replace it with qualified lube oil 3.Clean the oil tank and replace lube oil 4.Check and repair the failure parts 5.lncreasing cooling water |
|
Cooling water system leakage or other failures |
1.Piping water leakage 2.Excessive water scale and excessive high gas discharge temperature |
1.Repair and replace 2.Get rid of the water scale |
|
Safety valve failures |
1.Fail to start upon time 2.Fail to start up to the biggest power 3.Fail to close tightly |
1.Readjust 2.Readjust 3.Clean the valve and repair, |
|
Main shaft bush excessive heat |
1.Contact surface problem of the shaft radius and shaft bush 2.Too small clearance of radial fitting 3.Oil supply problem |
1.Check and repair 2.Check and repair 3.Check and repair lubrication system |
|
Pressure regulating valve malfunction |
1.Valve seat and valve port loosen 2.Spring loses elasticity 3.The gasket under the valve malfunction |
1.Replace 2.Replace 3.Replace the gasket or add the thickness of the gasket |
|
Slave valve malfunction |
1.Diaphragm rupture or the sealing loosens 2.Oil pipe blockage 3.Valve seat port damage |
1.Replace 2.Clean 3.Repair or replace |
|
Abnormal sound |
1.Slapping the cylinder 2.Connecting rod and crankshaft counterweight clashes each other 3.Improper fitting ellipticity of the belt wheel and crankshaft or the belt wheel loosens 4.Gas valve loosen 5.Improper bearing surface or damage 6.Connecting rod nuts loosen 7.Connection of Crosshead and piston rod loosen 8.Over big ellipticity of the crankshaft main shaft neck crank neck or crosshead pin 9.Crosshead guide damaged |
1.Not enough on in the ail tank,check the oil pressure 2.Adjust the clearance and tighten 3.Change belt wheel to make the conical contactabove 70%then tighten the belt wheel. 4.Tighten the valve nuts 5.Replace 6.Tighten and lock 7.Tighten and lock 8.Check clearance and ellipticity,repair or replace 9.Repair or replace |
|
Not enough discharge capacity |
1.Suction and discharge valve port loosen er block 2.Excessive suction and discharge clearance 3.pressure abnormal 4.Leakage on some parts 5.Diaphragm clamp force unevenly distrilbuted or force on the diaphragm |
1.Repair or replace 2.Reduce the clearance 3.Repair 4.Seal the leakage part 5.Evenly tighten the cylinder bolt |
|
Non oil pressure after start up |
1.Not enough oil in the oil tank 2.Compensating oil pump malfunction 3.Regulating valve (slave valve)malfunction 4.Pressure gauge unloading valve is open |
1.Check and supply crankcase oil 2.Check and repair 3.Check and repair 4.Close the valve |
|
Oil cylinder pressure abnormal |
1.Pressure regulating valve abnormal 2.Compensating oil pump abnormal 3.Diaphragm rupture 4.Cylinder sealing loosens 5.Check valve and damper under the oil gauge malfunction, and the hand violently swings |
1.Check and repair 2.Check and repair 3.Replace 4.Check and repair 5.Replace or clean |
|
Cylinder sealing oil or gas leakage |
1.Insufficient or unevenly tighten force on cylinder cover bolt 2.Fault on the sealing face 3.0 ring damage 4.Pipe connection sealing loosen |
1.Tighten the bolt 2.Repair the sealing face 3.Replace the O ringO 4.Repair or replace |
Notes: Other failures difficult to solve, please call the service number and contact the professional service personnel.
Diaphragm compressor is positive displacement compressor of special structure with excellent sealing performance and the medium doesn' t contact with any lubricants. Those advantages enable diaphragm compressor to compress the extremely high purity gas, the toxic, highly corrosive, flammable, explosive, radioactive gas. The diaphragm compressor is wildly employed in the field of industrial gas, food, petrochemical, nuclear power, military and scientific examination etc.
1.1 After-sales commissioning and maintenance card：
For initial commission or maintenance record card during operation, the maintenance personnel will make record and signature, please properly keep it.
1.2 Quick-wear part-diaphragm：
The material of diaphragm is 00Cr15Ni5, which is made from Fushun special steel Co., The diaphragm became to be finished after 18 process,such as cut ,surface treatment, heat setting.The service life is about up to 4000-16000 hours. Diaphragm is complete in specifications with good price, warmly welcome calls 010-60701278/80 for consultation and purchase.
1.3 Sales and service network ：
General safety requirement
1.1The operators must be trained.They must familiar with the compressor’s structure, working principle and master
the operation manual. Otherwise they would not be allowed to operate the compressor.
Before checking the compressor carefully, it is forbidden to start the compressor.
Any improper operation will cause the compressor damage or person injure.It is very danger to rebuild any part of compressor, without manufacturer's permission.
1.1The operators must be trained.They must familiar with the compressor’s structure, working principle and master
the operation manual. Otherwise they would not be allowed to operate the compressor.
Before checking the compressor carefully, it is forbidden to start the compressor.
Any improper operation will cause the compressor damage or person injure.It is very danger to rebuild any part of compressor, without manufacturer's permission.
1.3 Fire-proof,explosion-proof requirements
The installation, operation and maintenance of the compressor which is for compressing the inflammable, easy explosive or toxic gas, must be satisfied with the relative regulations.The measures should be taken to prevent leaked gas accumulated in the compressor room.The release ports (such as safety valve, cooler drain valve etc.) should be lead to the outside of the room.The electric elements must be satisfied with the requirements of the explosion-proof.
1.4 Regulations for lubricant
Only the compressor manufacturer recommended brand lubricant can be allowed to use. t is forbidden to mix different brand lubricants.
The lubricant must be changed regularly.
1.5 Regulations for cooling water
The cooling water should be clear, soft and not easy to scale.
The cooling water should be:
1.5.1 The impurity and suspended matters is not more than 100mg/L, and remain oil is less than 5mg/L:
1.5.2 PH value is between 6.5~9;
1.5.3 The hardness of the water is less than 10°( note: 1 means in 1leter water, it contains 10mg Ca0 or 19mg MgO)If the quality of the water is not satisfied with the above requirements, it should be filtered.
1.6 Protection for person
When compressor is running, the person shouldn't contact the rotating parts (such as belt, chain, coupling and fan etc.). cylinder wall and discharge pipes to prevent injure.
1.7 Requirements for electric elements
The installation and maintenance of the electric equipment should be satisfied with the local concerned regulations. The operator must have operating license. Before service the electric elements, ensure the power is cut off.Meanwhile put an alarm sign or arrange a person for monitoring.
1.8 Lifting requirement
The capacity of lifting equipment should be satisfied the requirements. When lifting, the safety of the person and machine should be cared. Lifting can refer to drawing 1-1:
The lifting angle must not less than 45°. lf the lifting angle less than 45°, a strengthen beam will be needed.
2.1 General information of structure
Diaphragm compressor mainly consists of crankcase, connecting rod, cross-head, piston, cylinder body, cooler and its pipeline, base plate, instrumentation, electric motor etc. The compressor structure is divided into 4 types-..L.Z.V and P,according to cylinder body arrangement.
L type diaphragm compressor's vertical and horizontal cylinders form L. (Please refer to the picture)
Z type diaphragm compressor only consists of vertical cylinders, and this structure looks like the letter "Z”. (Please refer to the picture)
V type diaphragm compressor's left and right cylinders form V. (Please refer to the picture)
P type diaphragm compressor is the balanced opposed frame, the cylinder body number can be 2, 3 or 4. (Please refer to the picture. This is the 4 cylinders type)
Cylinder body part has the similar structure including cylinder cover, cylinder body, diaphragm etc. There's a special shape curved face on cylinder cover and cylinder body, and a set of metal diaphragms are clamped between these two curved face. which forms two cavities. The cavity on cylinder cover side is gas cavity, and the other one that locates on cylinder body side and connects with the space between the piston through many small holes on the cylinder body is the oil cylinder. Cylinder jacket is needed inside cylinder body and the piston makes reciprocating movement inside the jacket. Suction and discharge valve port are located on cylinder cover. The discharge valve port is on the center of cylinder cover and the other 1 or 2 ports are suction port. The suction and discharge valves are in the suction and discharge valve port on the cylinder cover, and the valves are tightened with pressure tube.
2.2 Working principle
Diaphragm compressor is positive displacement compressor of special structure. The electric motor drives the crankshaft through belt or coupling: as the crankshaft rotation, the connecting rod makes plane movement, which drives the cross-head and piston installed on small end of connecting rod makes linear movement. The movement amplitude equals twice of crank throw radius, and this is one stroke, The movement frequency is the crankshaft rotation frequency.
Taking the upper dead point of the piston as the starting point, the piston begins to move downward when crankshaft starts to rotate. Under the function of the oil level falling and self elastic force, the diaphragms restore to the balance position. Whereas, the cylinder volume increases gradually, consequently the gas remained in the clearance expands and then gas is inhaled through the cylinder suction valve. When the piston reaches to the lower dead point, the diaphragms also reach their lower limit position, which finishes the cylinder suction process.
After that, the piston begins to move upward to drive the hydraulic oil that has even effects on the diaphragm through the small holes on the oil distributing plate to push it move upward. At this time, the cylinder begins to compress gas. In case the gas pressure is higher than the one of the gas discharge pipe, the discharge valve opens automatically to discharge gas. Whereas the oil pressure keeps rising to force the diaphragm tightly touch the cylinder cover curved face to exhaust all the gas. Thus the discharge process ends.
The reciprocating pistons drive the oil to make the diaphragm vibrate up and down. Under the help of the suction and discharge valve, each vibration period of the diaphragm is one complete circulation process of suction.compression and discharge of cylinder, which increases the gas delivery pressure.
A part of oil in the cylinder would leak into the crankcase through the gaps between the piston ring and cylinder wall as well as ring groove, the compensating oil pump is installed in order that the diaphragms tightly touch the cylinder cover curved face at the end of compression stroke to discharge the entire compressing medium. During suction process, the compensating oil pump fills the oil into the oil cylinder, thus the oil volume is larger than the leakage volume. The excess oil returns to the crankcase at the end of process through pressure regulating valve used to pressure.
The diaphragms totally separate the gas cylinder and oil cylinder and function as piston because of its self reciprocating vibration. So it's unnecessary to put any lube into the gas cylinder and the compressing medium only touches the metal diaphragm, which guarantees the purity of the medium. The cylinder consists of cylinder cover curved face and diaphragm and is a closed cavity with excellent sealing performance.Those advantages enable diaphragm compressor to compress the extremely high purity gas to reach the purity of 99.999%. The diaphragm compressor is especially suitable to compress, deliver, fill bottle of the precious noble gas. As for the toxic, highly corrosive, flammable, explosive, radioactive gas, the diaphragm compressor is also suitable. Thanks for the perfect heat-sinking capability of the cylinder and higher compression ratio, the available pressure range is from very low pressure to 200Mpa. The diaphragm compressor is employed in the field of industrial gas, food, petrochemical nuclear power, military and scientific examination etc.
2.3 Application
Diaphragm compressor could be used to compress air, hydrogen, nitrogen, oxygen, inert gas, carbon dioxide carbon monoxide, methane, natural gas, ethane, TFE, HFP, ammonia gas etc. but different gas requires different compressor arrangement. And the compressor should be operated in accordance with technical agreement.
3.1 Cylinder
All the cylinders comprise upper plate, diaphragms, and cylinder body etc. The diaphragms are clamped between the cylinder cover and cylinder body. The cylinder cover and cylinder body each has a concave recess hollowed out in their contacting faces. The gas cylinder is formed between cylinder cover concave recess and diaphragms. Both suction valve and discharge valve are fitted on the upper plate. Among of them, the discharge valve is located on the center of the upper plate. The evenly located small oil holes are on the cylinder body to deliver the oil pressure inside the oil cylinder to the diaphragms.
3.2 Pressure Regulating Valve
The oil pressure of oil cylinder is regulated by the tension of the valve spring.In case the oil pressure is higher than the regulated value, turn the regulating bolt counter-clockwise to loosen the spring tension, but turn the regulating bolt clockwise to tighten the spring, when the oil pressure is lower than there gulated value. When the oil pressure meets the required value, the regulating bolt must be locked with a lock-nut. The oil pressure of the oil cylinder shall always be higher than the discharge pressure by 15~20%. But the oil and gas differential pressure shall not be lower than 0.3MPa or higher than 1.5MPa.
3.3 Cooler
The cooler structure is the double-wall pipe type. The circular space between the outer and inner pipe is the cooling water passage and the inner pipe is the gas passage. Normally the water inlet port is at the lower side and the water outlet port is at the upper side. The flow direction of cooling water and gas is on the contrary.
3.4 Oil Pressure Measuring Device
The measuring device of oil cylinder discharge pressure consists of shock-proof pressure gauge, check valve and unloading valve. The case of the pressure gauge is totally airproof and filled with damping liquid. The inner devices of gauge is immersed in the liquid, which makes the pressure gauge hands stable through the function of the viscosity of damping liquid. The unloading valve is fitted under the gauge to discharge the remained air in the oil pipeline and to unload the oil pressure gauge. Also the check valve connecting with oil cylinder through pipeline is fitted under the unloading valve.
3.5 Oil pipes
Oil pipes consist of lube oil pipe and oil pressure secure system.
The lubrication for the driving device adopts gear oil pump circulation pressure lubricating. The lube oil stored in the frame oil tank enters into the gear oil pump after being filtered and is pressed into the oil holes in the crankshaft through the gear oil pump to lubricate the crankshaft friction surface. At the same time, part of the lube oil reaches the crosshead pin and crosshead along the oil holes in the connecting rod to lubricate the friction surface. The oil pressure of gear oil pump shall be kept between 0.3~0.5Mpa, and the bearings at the two ends of crankshaft is splash lubricated.
Oil pressure secure system consists of oil compensating pipe, pressure-measuring pipe and oil return pipe. The oil output from the oil compensating pump will supplement oil for compressor cylinders through the oil compensating pipe and the excess oil returns to the crankcase through the pressure-regulating valve.
3.6 Gas pipes
The gas enters into compressor through inlet port to be compressed and enters into the clients' system after cooling by the cooler.
4.1 Check
On receiving delivery, the client should dismantle the box to check if there are shortage or damage of the products according to packing list. Please take notes for any problem and contact the manufacturer immediately. There must have special staff to keep the relative documents with delivery and spare parts.
4.2 Preservation
4.2.1 Indoor safekeeping;
4.2.1.1 Dry, ventilation, with no corrosion;
4.2.1.2 Temperature is not lower than -15 C;
4.2.1.3 When relative humidity is >85%，please put an exsiccator in the package box;
4.2.1.4 Use a wood stopper to caulk the open port of machinery;
4.2.1.5 Charge dry nitrogen into the pipe when necessary；
4.2.2 Safekeeping outdoor for a short time；
4.2.2.1 Put a shield for the package box in case of wind, rain and sunshine;
4.2.2.2 Put the compressor on a higher place to prevent water;
4.2.2.3 Check the compressor weekly and amend the problem；
The valid period of preservation is 12 months after coming out from the factory, Please contact our company incase the expiration of the valid period and make maintenance if necessary.
5.1 Foundation
The foundation should be a convex concrete terrace that is to be constructed by user according to the foundation drawing supplied by manufacturer and the on-site conditions. Please consider the water discharge and drainage system.
The foundation should be built respectively which can't use the former foundation and must separate from the system border equipment by using soil.
5.2 Installation
5.2.1 The compressor should be installed in a environment of dry, ventilation, without dust and non-corrosive;
5.2.2 A passage of 1.5m wide at least is required around the machine;
5.2.3 A bridge crane that is removable and capable of lifting the compressor is required;
5.2.4 After installing the diaphragm compressor on foundation, the horizontal error should less than 5%o, andwithout any warping for the foundation seat when the compressor is fixed；
5.3 Gas pipes connected outside
The pipelines connected with the inlet and outlet port of compressor and the sewage pipelines should be designed and installed by users. For large diaphragm compressor, the metal hose could be used for the suction and discharge pipe in order to eliminate the vibration. If the compressor is not equipped with suction filter, the client should install according to the site conditions. If any liquid in the source gas, a suction buffer separation tank must be installed on the suction pile.
The compressor should be equipped with gas return pipe, if not the client should design and equip the pipe. The gas return pipe should be used at the time of compressor start up or stop to realize under-loading start up or stop,in this way the compressor is effectively protected.
5.3.1 Requirements for pipelines
o、Pressure testing should be proceeded for all the gas transporting pipelines and the testing pressure should be 1.5 times as large as the highest allowable pressure;
b、The welding bead and connecting parts of the gas pipeline should be inspected for the leak tightness；
C、Air vent and the outlet of unloading valve should be equipped with pipe and the air should be transported to the safety area to recycle or discharge;
d、Suspended long pipelines should be supported by ancillary shoring but without subsidiary stress;
e、There must have some measures to damp the vibration and eliminate the heat expansion of pipelines connected with compressor;
f、No welding slag, rust and sewage exist inside the pipeline and blow the inside pipeline by using the dry and compressed air before installation;
g、The suction pipelines should be equipped with release hole to unload in case of the suction pressure is higher than rating suction pressure. The discharge pipelines should be equipped with check valve to prevent the return of gas and blow-down valve to facilitate the starting of compressor with light load。
5.3.2 Accessories of pipelines
At the preliminary running period of compressor, a filter or screen with 80 mesh should be installed at the suction port to prevent welding slag, dust, and the like.
5.33 Requirements for water pipelines
A water supervisor should be installed in pipes to facilitate the inspection for the flowing condition of the cold water.
5.4 Installation for instrument
Check the pressure gauge before installation and send the pressure gauge to the relative department to be adjusted.
Please assemble instrument according to the nameplate and drawing. The pressure gauge should be installed toward the operating surface of diaphragm compressor, Tight the compressor and if the direction is wrong, just loosen the locking nut under the gauge seat or add the sealing pad under the gauge seat to adjust.
6.1 Filling crankcase with oil
Before running, loosen the plunger on the crankcase and fill certain amount of lube oil into the crankcase, and the oil level shall be above the calibration line. The lube oil should be used in accordance with technical agreement.
6.2 Filling cross-head and cross-head bushing with oil
The distance piece window should be dismantled before initial operation, and appropriate amount of lube oil should be sprayed into the oil return hole on cylinder body with oil gun. Then the window should be re-installed and the belt pulley should be rotated with hand to ensure that the lube oil evenly distribute on cross-head guide.
6.3 Fill the oil tank with oil
In order to meet the normal operating requirement of diaphragm compressor, the oil chamber between the oil cylinder piston and diaphragms must be filled with oil and there shall have no remained gas. Because the compressibility of gas, the remained gas could make the working stroke of diaphragm reduce resulting the discharge capacity reduction during operating.
Different oil filling method for oil tank with separate oil pump station and without separate oil pump station.
A、The method for oil tank with separate pump station
6.3.1 Turn the belt wheel to make the piston move to the upper dead point.
6.3,2 Open the oil discharge valve under the cylinder body and connected with oil supply system.
6.3.4 Open the unloading valve under the oil pressure gauge.
6.3.5 Start the oil supply system electric motor, When the oil is full, the piston will move to the lower dead point and drive the big belt wheel to close the oil supply system electric motor power.
6.3.6 Close the oil discharge valve on cylinder body During oil filling: lube oil is filled for cylinder through oil supply system after filter and cooler.
The diverting valve picture (the picture on the right)
B、The method for oil tank without separate pump station
6.3.1 Open the unloading valve under the oil pressure gauge. if there's oil return pipe, open the valve on the return pipe.
6.3.2 Start the electric motor.
6.3.3 Close the unloading valve under the oil pressure gauge.
6.3.4 Regulate oil pressure regulating valve and close the compressor electric motor power when the oil cylinder pressure gauge starts move. (Notes: because oil compensatory pump oil intake amount is little, so the time is little longer)The diverting valve picture (the picture on the right).
6.3.5 Evacuate excess oil
Notes: When compressor is running normally, the diaphragms must be curved concavely downwards with the piston at BDC. Nevertheless, after the oil filing the diaphragms are mounted flat in the compressor and remain stable without any deformation when the piston is at lower dead point, There is consequently a half-cylinder of oil in excess in the space beneath diaphragms which must be released from oil cylinder or the compressor can not be started up.To evacuate the excess oil proceed as follows:
Turn flywheel, bring the piston in oil cylinder towards upper dead point and meantime open the unloading valve under the oil pressure gauge, and turn the belt wheel at least 2 times.
6.4 Check the oil volume of crankcase
Recheck the oil, if the oil level is lower than the lower scale line, it should be added to the crankcase.
6.5 Check and adjust oil pressure
In order to ensure the diaphragms tightly touch the cylinder cover concave recess to discharge all the gas at the end of discharge process during operating, the oil discharge pressure(start-up pressure of pressure-regulating valve) must suitable be higher than the cylinder gas discharge pressure by 5-25%but the oil and gas pressure difference should be not lower 0.3MPa or higher than 1.5MPa.
Caution: it's forbidden to vacuumize the compressor during the time of oil regulating, and it's necessary to supply certain pressure gas at the suction port or directly connected with open air.
In case the compressor operates under the pressure that is lower than the nominal discharge pressure, please reduce the oil discharge pressure of oil cylinder pursuant to the above requirements, so the pressure difference on diaphragms shall not be too high and the service life is extended.
The start-up pressure of the compressor pressure-regulating valve has been adjusted when delivered at the factory according to the nominal discharge pressure, but the client shall check or adjust the start-up pressure of the valve in accordance with the practical operating conditions to ensure the normal operating.
6.6 Leak check
Prior to the compressor operation it is necessary to check the bolts and nuts of compressor for tightness and check the flange connections between compressor and suction/discharge piping, if necessary.
7.1 Preparation before starting
When on the condition that it's a initial starting or restarting after replacing diaphragm or inspection, the following procedures are to be followed:
7.1.1 Check all valves whether in the condition of cut-off;
7.1.2 Remove all the maintenance accessories for safety and the sign board for maintenance;
7.1.3 Check the system and remove the material coming from outside;
7.1.4 Barring at least on circle and make sure that there is no mechanical failure;
7.1.5 Make sure that the rotation direction of motor and crankshaft is correct;
7.1.6 Check and make sure that all the protective device are in good condition;
7.1.7 Check if the pressure gauge hand backs to "zero"
7.1.8 Check if the lube oil inside the crankcase meets the requirement and if the oil level is between the upper and lower scale mark;
7.1.9 (With separate oil pump station) check if the oil pipe block valve under the cylinder body is on close condition;
7.1.10 (with separate oil pump station) check the oil pipe diverting valve position, and check if the valve on the oil supply pipe open.
7.2 Starting
Never start the compressor with load. Compressor can be loaded only after the normal sped has been reached:
7.2.1 Connect the cooling water pipes;
7.2.2 Open the unloading valve under oil pressure gauge;
7.2.3 (with oil return pipe) Open valve on oil return pipe;
7.2.4 Turn off the valve on suction and discharge pipeline; if the suction pressure is lower than 0.5MPa, don't close the valve on the suction pipe;
7.2.5 (With separate oil pump station) start the oil pump electric motor and after the lube oil pressure is stable;
7.2.6 Start the electric motor;
7.2.7 Close the unloading valve under the oil pressure gauge and when the oil tank pressure reaches the setting value;
7.2.8 Open the gas suction and gas discharge valves;
7.2.9 (With oil return pipe) close the vale on oil return pipe;
7.2.10 Check the panel of oil and air pressure;
7.2.11 Check the sound and vibration of compressor.
7.3 Stopping
7.3.1 (With oil return pipe) open the valve on oil return pipe;
7.3.2 Close the gas suction and discharge valves; if the suction pressure is lower than 0.5MPa, don't close the valve on the suction pipe;
7.3.3 Open the unloading valve;
7.3.4 Turn off the compressor main motor;
7.3.5 (With separate oil pump station) when flywheel stops rotation, turn off the oil pump motor power;
7.3.6 Close the cooling water suction and discharge valve;
7.3.7 If there's nitrogen displacement pipe, please make nitrogen displacement.If the compressor is equipped with automatic unloading start up and close, the compressor will operate automatically in accordance with electric control design.
7.4 Emergency stopping
Whenever abnormal noise is heard or extraordinary phenomena are observed, shut down the compressor immediately
7.5 Please discharge all the cooling water inside the compressor when the compressor is stopped for a long period of time in winter.
8.1 Daily maintenance
When the compressor is running, pay attention to gas discharge pressure and oil release pressure in both compression stages. Be sure that no extraordinary noise is heard, lt is also necessary to check oil level in crankcase.
After 3000-4000 hrs' operation, completely changes oil in crankcase. During the initial service of compressor it is advisable to reduce the oil change time interval to a proper extent, generally within 1000hrs, The lube oil pollution condition at the oil scale mark is also used to decide whether to change the oil.
8.2 Changing the diaphragms
when a diaphragm has been found punctured or cracked, immediately shut down compressor and change the diaphragm in the order given:
8.2.1 According to the failure to tell which diaphragm is broken:
8.2.2 (With separate oil pump station) open the valve under the cylinder, and turn the diverting valve to the oil sucking position. Open the oil discharge valve (unloading valve) under oil gauge, start the oil pump motor and extract the hydraulic oil in the oil tank back to the crankcase through oil pump.
8.2.3 Dismantling
8.2.3.1 Dismantle the cylinder suction and discharge pipe;
8.2.3.2 Dismantle the cooling water pipe connected with cylinder cover;
8.2.3.3 Take out the suction and discharge valve with valve removal tool;
8.2.3.4 Dismantle all the bolts on the cylinder cover except the three guide bolts (the bolts on the outside surface of cylinder body with fastening screws);
8.2.3.5 Lift the cylinder to 15-20mm with 3 cylinder cover handles;
8.2.3.6 Take out the diaphragm set;
8.2.3.7 if necessary, lift the cylinder cover with hoisting equipment;
8.2.3.8 Cautions during the removal of the diaphragm:
a、 Before dismantling, mark the relative position between the cylinder cover and body to avoid mistake;
b、 Don't damage the screw on the bolt during dismantling or it's difficult to install again;
C、Please make sure to protect the cured face on the cylinder cover and body as well as the diaphragm surface, no damage, bruise or scratch allowed;
d、It's forbidden to hit the parts during dismantling to avoid any damage or deformation of the sealing surface or cylinder damage, bruise or scratch allowed.curved face, then leakage or diaphragm rupture during compressor operation will occur.
8.2.4 Cleaning
NY.190 solvent gasoline is used as cleaning agent. First cylinder cover and curved surface the cylinder, suction and exhaust valve as well as diaphragm shall be brushed with hairbrush, and then cleaned by cloths, care shall betaken to prevent fire during cleaning, and below points shall be followed.
a、Any source of fire surrounding the site shall be prohibited;
b、All power shall be cutoff, and well earthed;
C、Wearing of clothes may cause sparkling and shoes with iron nail shall be prohibited:
d、Sufficient fire extinguishing tools shall be prepared;
e、Sufficient fire extinguishing tools shall be prepared;
f、Safety personnel monitoring and inspection shall be presented at site.
8.2.5 Assembling
8.2.5.1 Requirements prior to assembly:
a、Curved surface of cavity and diaphragm shall be kept clean, any scratch, indentation, rusty and dirt is not allowed, if any defects may cause non-use or leakage etc., it shall be repaired or replaced.
b、it shall wait after clean agent on surface of the parts is completely volatilized then assembly can begin.
8.2.5.2 Assembly
a、Lift the cylinder cover, confirm the correct position, put the cover through 3 pieces of guiding screws, then slowly slides to cylinder body, but no contact of these two at the time;
b、 Turning into 3 pieces of cover handle to jack-up the cover, with 15-20 mm distance from the body;
C、Insert diaphragm groups between cover and body;
d、During assembly of diaphragm, care shall be taken on sequence of it, there are 3 pieces of diaphragms, are air side, middle and oil side diaphragm respectively, at edge of each diaphragm there are 2 positioning holes,diaphragm for oil side and air side are the same,better put the one with best surface quality at air side. There are 3 small grooves on one side of middle diaphragm,towards the oil side, on the other side towards the gas side, there is 1 groove on it;
e、Turing anti-clockwise the cover handles, slowly lower down the cover and make it contact with body,then examine around the circle, make sure cover is tightly contact with diaphragm,and O ring on the cover is staying in O ring groove;
f、Put through all bolts, and tum on the nuts. Attention: before turning on the nuts, one thin layer of lubricant oil shall be painted on thread of bolts and bottom side of nuts, so that scratch of thread and cylinder cover can be avoided while tightening Tightening of nut shall be made symmetrically and even, and please refer to below table for torque. Tightening of nut shall at least in 3 steps, so that stress on the bolts shall be even. After all nuts have been tightened, torque value of each bolt shall be once more checked, till it can not be turned further with maximum torque;
g、 Install the suction and discharge valve onto the cylinder cover with valve removal tool and tightened the valve with suction and discharge pipe; install the suction and discharge pipe and cooling water pipe. Please refer to the below picture for the torque wrench's usage.
8.3 Inspection of compensating pump
In case of inadequate capacity of pump or when the pump cease to supply oil, the efficiency of compressor becomes lower and the compressor may even stop delivering gas. To check the pump for normal work operator touches the pump oil outlet pipe with hand. when the pump functions property, the pulsation of oi is felt on the oil outlet pipe. Operator can also loosen the oil outlet pipe connection and observe whether the pump is discharging oil.
Check the oil inlet and outlet valve port of compensating pump, and clean the dirty valves or replace the damaged valves.
8.4 Type for servicing compressor
When dismantling or assembling the parts and components of compressor pay particular attention to cleanliness of parts and components, since a small particle of dust or metal results in improper function of valves or oil cylinder.may even cause the failure of diaphragms.
lf the compressor does not work properly, inspect various parts in following order.
8.4.1 Check the oil level in crankcase;
8.4.2 Check the pressure of oil cylinders; if the pressure is beyond the rated range, check the oil pressure regulating valves, compensating pump or ascertain whether the diaphragms are punctured;
8.4.3 Check the gas discharge pressure; if abnormal, inspect the gas suction and gas discharge valves or check the diaphragms;
8.4.4 If the discharge temperature rises abruptly, check the cooling water or gas valve.
For trouble shooting, please refer to below table and ensure the compressor normal operation.
The types, causes and troubleshooting methods of common faults in compressors.
|
Failures |
Main causes |
Trouble shooting |
|
Lube oil pressure suddenly drop, and is lower than0.2MPa
|
1.Not enough lube oil inside the crankcase. 2.Blockage of the filter and filtering components 3.Oil pressure gauge malfunction Oil pump piping blockage or rapture 5.Oil supply system malfunction 6.Oil viscosity declines 7.Oil pipe connection loosens 8.Bearing or cooper sleeve of driving mechanism severely wears out 9.Gear pump is damaged 10.Sealing parts wear out |
1.Fill oill immediately 2.Cleaning 3.Replace the oil pressure gauge 4.Replace the oil pressure gauge 5.Check oil supply system 6.Replace lube oil 7.Tighten the nut or add washer 8.Check and repair the bearing or sleeve 9.Replace gear pump 10.Replace sealing part |
|
Compensating oil pump don' t supply oil |
1.Oil inlet and outlet valve port loosens 2.Oil inlet and outlet valve don’t close tightly 3.Gear pump oil pressure is lower than0.3MPa. 4.Oil inlet and outlet valve position and direction are wrong |
1.Replace 2.Dismantle and clean the valve 3.Check oil pressure caus 4.Check carefully and install again |
|
Excessive high temperature of lube oil |
1.Not enough lube oil supply 2.Low quality lube oil with bad heat radiation 3.Dirty lube oil that increase mechanical wear 4.Movement parts failure 5.Bad lube oil cooling |
1.Check the oil piping leakage and add lube oil 2.Replace it with qualified lube oil 3.Clean the oil tank and replace lube oil 4.Check and repair the failure parts 5.lncreasing cooling water |
|
Cooling water system leakage or other failures |
1.Piping water leakage 2.Excessive water scale and excessive high gas discharge temperature |
1.Repair and replace 2.Get rid of the water scale |
|
Safety valve failures |
1.Fail to start upon time 2.Fail to start up to the biggest power 3.Fail to close tightly |
1.Readjust 2.Readjust 3.Clean the valve and repair, |
|
Main shaft bush excessive heat |
1.Contact surface problem of the shaft radius and shaft bush 2.Too small clearance of radial fitting 3.Oil supply problem |
1.Check and repair 2.Check and repair 3.Check and repair lubrication system |
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Pressure regulating valve malfunction |
1.Valve seat and valve port loosen 2.Spring loses elasticity 3.The gasket under the valve malfunction |
1.Replace 2.Replace 3.Replace the gasket or add the thickness of the gasket |
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Slave valve malfunction |
1.Diaphragm rupture or the sealing loosens 2.Oil pipe blockage 3.Valve seat port damage |
1.Replace 2.Clean 3.Repair or replace |
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Abnormal sound |
1.Slapping the cylinder 2.Connecting rod and crankshaft counterweight clashes each other 3.Improper fitting ellipticity of the belt wheel and crankshaft or the belt wheel loosens 4.Gas valve loosen 5.Improper bearing surface or damage 6.Connecting rod nuts loosen 7.Connection of Crosshead and piston rod loosen 8.Over big ellipticity of the crankshaft main shaft neck crank neck or crosshead pin 9.Crosshead guide damaged |
1.Not enough on in the ail tank,check the oil pressure 2.Adjust the clearance and tighten 3.Change belt wheel to make the conical contactabove 70%then tighten the belt wheel. 4.Tighten the valve nuts 5.Replace 6.Tighten and lock 7.Tighten and lock 8.Check clearance and ellipticity,repair or replace 9.Repair or replace |
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Not enough discharge capacity |
1.Suction and discharge valve port loosen er block 2.Excessive suction and discharge clearance 3.pressure abnormal 4.Leakage on some parts 5.Diaphragm clamp force unevenly distrilbuted or force on the diaphragm |
1.Repair or replace 2.Reduce the clearance 3.Repair 4.Seal the leakage part 5.Evenly tighten the cylinder bolt |
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Non oil pressure after start up |
1.Not enough oil in the oil tank 2.Compensating oil pump malfunction 3.Regulating valve (slave valve)malfunction 4.Pressure gauge unloading valve is open |
1.Check and supply crankcase oil 2.Check and repair 3.Check and repair 4.Close the valve |
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Oil cylinder pressure abnormal |
1.Pressure regulating valve abnormal 2.Compensating oil pump abnormal 3.Diaphragm rupture 4.Cylinder sealing loosens 5.Check valve and damper under the oil gauge malfunction, and the hand violently swings |
1.Check and repair 2.Check and repair 3.Replace 4.Check and repair 5.Replace or clean |
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Cylinder sealing oil or gas leakage |
1.Insufficient or unevenly tighten force on cylinder cover bolt 2.Fault on the sealing face 3.0 ring damage 4.Pipe connection sealing loosen |
1.Tighten the bolt 2.Repair the sealing face 3.Replace the O ringO 4.Repair or replace |
Notes: Other failures difficult to solve, please call the service number and contact the professional service personnel.