活塞式空压机缩机操作规程

活塞式空压机缩机操作规程1.开机前1.1检查“交接班记录”。

1.2检查空压机地脚螺母（移动式除外），各吸排气阀的阀盖螺母等紧固件的紧固情况。

1.3检查电源电压是否正常。

1.4检查三角皮带的的松紧程度和联轴器安装是否正常。

1.5检查空压机的安全防护装置是否可靠，仪表上是否正常，各种管路阀门是否完好。

1.6检查机身油池及注油器油位上否正常。

1.7打开进水及排水阀门，启动循环水泵（风冷除外），使水路畅通，并检查各连接处是否有漏水现象。

1.8关闭减荷阀（或找开排气管旁通放气阀门），减少空压机启动负荷。

1.9检查电器各空压机电动机启动手柄是否在启动位置。

如无问题方可接通电源开车。

2.开车运行2.1先将电动机启动开关间断点动，察听空压机的各运动部件有无异常声响，确认正常后方能启动电动机。

2.2电动机启动后，空压机应空载运行5-6分钟，然后逐步打开进气阀门，投入负荷运行。

2.3空压机运行时应经常注意检查机身油池面高度和注油器的油位和油滴数上否正常。

2.4随时注意和检查各压力表、温度表所示读数，使其在允许的规定范围内。

2.5随时注意电动机的温升及电流、电压表的所示读数应在允许规定的范围内。

2.6当储气罐内压力达到规定数值时，应注意安全阀和压力调节器的动作是否灵敏、可靠，定期对安全阀作手动或自动放气试验。

2.7空压机运行时，每工作2小时须将油水分离器的油水排放一次，储气罐内的冷凝油水每班应排放一次，空气温度大时应增加排放次数。

2.8空气机在下列情况下应紧急停车，并找出原因，，排除后方可能开机。

2.8.1一、二级排气压力表突然超过规定数值；2.8.2冷却水突然中断供给，若断水后开车时间较长，则切不可立即向气缸水套注入新的冷却水，应待气缸自行冷却后再供水开机；2.8.3空压机任何部位的温度超过允许值；2.8.4空压机发出异常响声；2.8.5润滑油突然中断供给时；2.8.6空压机发生严重漏气、漏水时；2.8.7电动机的滑环和刷子间以及线路接头处有严重火花时；2.8.8发生其它严重故障时；2.8.9检修空压机设备时，应先切断电源，排尽设备及气管道内的余气后才能进行，清洗气缸阀部件时要用煤油（不允许用汽油），洗净后须待煤油全部挥发后方可装配。

检修拆装时木片、皮块、棉纱等杂物不得落入气缸或储气罐及气管道内，以免堵塞起火，造成事故。

2.8.10空压机开车运行时，应将运行情况、设备巡回点检情况填写在运行和点检记录薄上。

3.停机3.1逐步关闭减荷阀门（或打开排气管旁通放气阀门）使空气机进入空载运转状态。

3.2切断电源。

3.3空压机停车15分钟后，才能停止循环水泵，关闭冷却水进入水阀。

3.4放出中间冷却器和储气罐中冷凝的油水。

在冬季低温下应将各级水套和中间冷却器内的存水全部放尽，以免冻裂机器。

3.5进行日常维护保养。

进排气阀，滤器，油底壳，冷凝器。

3.6填写“交接班记录”，做好交接班工作。

1. ORDERING REPLACEMENT PARTSA. COMPRESSOR TYPEB. COMPRESSOR SERIAL NUMBERC. PART NUMBER AND DESCRIPTIOND. QUANTITY ORDEREDE. RA TED WORKING PRESSURE OF COMPRESSORThe type designation (A) and serial number (B) are shown on the rating plate which is fixed to the crankcase.The rating plate is shown in Fig. 1.2. DESCRIPTION OF COMPRESSOR2.1 DesignThe machine coverded by this instruction book is a single cylinder, 2-stage single-acting watercooled air compressor. The design principle is shown in the cross-sectional drawing Fig. 2.The first stage of the compressor is the low-pressure stage (LP) and the second is the high-pressure stage (HP).Air circulation through the compressor cooler:A. Suction filteB. LP suction valveC. LP delivery valveD. LP safety valveE. LP coolerF. HP suction valveG. HP delivery valveH. HP coolerI. HP safety valveThe big-end bearing is a two-shell plain bearing and the gudgeon pin bearing is an undivided press-fitted plain bearing. The big end and gudgeon pin bearings are pressure-lubricated from a gear pump mounted on the end ofthe crankshaft. The crankshaft bearings are two-row ball bearings.Vertical cooling tubes are rolled into the compressor cylinder block. These serve to cool the air after first-stage compression and again after second-stage compression. The cooling water intake and outlet are located so thatthe water circulates through the cylinder block and ensures efficient cooling of the air and compressor cylinder walls. The compressor compresses air from atmospheric pressure to rated pressure, with an upper limit of 35 bars.The compressor is designed for installation together with an electric motor or other drive unit on a well-stiffended base, with a flexible coupling between compressor and motor.Every compressor is tested before delivery from the factory, and all compressor sets supplied with motor are aligned before dispatch. See chapters 3.1. and 5.6.This compressor is designed to supply compressed air for engine starting, and for the operation of air power equipment and instruments. It complies with the requirements specified by the classification institutions. Instruction manual for Water-cooled Air Compressor HV1/140 & HV1/140A- 2 -2.2. Safety equipmentThe compressor is fitted with two safety valves, one after the first-stage compression and the other after second- stage compression.The safety valves, which are set at the factory in accordance with the working pressure specified by the customer, ensure that the pressure does not exceed the limit for which the compressor and the compressed air system are dimensioned.The cylinder block cooling jacket is fitted with a safety plate which will be blow out if the cooling water is subjected to excessive pressure. Use only manufacturer's genuine safety plates to replace blown plates.The compressors automatic control equipment normally comprises a pressostat that shuts down the compressorif the lube oil pressure falls below the minimum limit.3. INSTALLATION AND OPERA TION3.1. Installation instructionsEvery compressor unit is supplied complete with drawings and specifications showing its dimensions andattachment points.The compressor unit should be installed in a location where the air is not excessively warm. Warm intake airreduces the capacity of the compressor. Normally, the ambient temperature for electrical equipment should notexceed 45C. The compressor unit bedplate should lie plane to its foundation. After the unit is installed, checkthe alignment of compressor and motor. The procedure is shown in Fig.4.Use vernier callipers or inside micrometer callipers to check the distance (W). This should be the samearound the whole circumference of the coupling.Using a micrometer (A), check the radial misalignment between the coupling halves. The maximum micrometer reading (A) should be as illustrated3.2. Cooling water systemsIt is of the greatest importance to the operation and life of the compressor that a good and reliable supply ofcooling water is ensured. The quantities of cooling water required according instruction book. These specifications apply to both seawater and freshwater cooling.Whether the compressor is connected to a central cooling system or has its own separate cooling water pump, itis important to ensure that the cooling water is circulating properly. In this connection it is not sufficient simply tocheck that the compressor pressure gauge is registering cooling water pressure.If the cooling water feed temperature is too low, increased internal condensation may result. If this is the case,the cooling water temperature should be increased. If the temperature cannot be increased by recirculation, condensation can be reduced by reducing the supply of cooling water.The cylinder block cooling jacket is equipped with a thermometer for the monitoring of cooling water temperature. Recommended cooling water temperatures according instruction book- 3 -3.3. Starting upBefore initial starting up and after long periods out of use, carry out he following operations:A. Check the oil level.B. Check that the quality of the oil has not been impaired by water or other foreign matter.C. Check compressor valves and lubricate the cylinder with oil.D. Turn over the compressor by hand, with the suction valve relieved by means of the manual valve opener.E. Check cooling water circulation.F. Check that the air line cock between the compressor and the air reservoir is open.G. Open the manual drain cocks on the water trap.H. Start the compressor.I. If everyhing is operating normally, close the drain cocks and set the valve opener in the operating position.Allow the compressor to run for a few minutes before loading it to maximum working pressure.3.4. OperationDuring normal operation, pressures and temperatures should be normally. Some of the values, which are directly affected by local conditions,.Operation of the compressor is normally monitored by the automatic features of the starting equipment, e.g. thermostat monitoring of cooling water temperature. However, additional regular checking of operation andautomatic functions is recommended.Some water form the air will always condense in the system.The compressor oil and water traps should be regularly drained by hand, unless this function is performed by an automatic draining system.3.5. StoppingStopping the compressor manually for short periods:A. Operate the manual valve opener to relieve the LP suction valve.B. Open the water trap drain cocks.C. Stop the compressor.If the compressor is to be shut down for a long period, e.g. when a ship is to be laid up, the procedure is as follows:AA. Lubricate compressor valves, non return valves, cylinder wallsand exposed crankshaft surfaces withcorrosin-inhibiting oil, suitable for the envisaged period of shutdown.BB. If there is any risk of frost, drain the cooling water from the compressor.CC. Drain off old oil, clean the sump and refill with new oil.DD. Set the manual valve opener in the horizontal position to relieve he load on the suction valve.EE. Turn over the compressor manually once a month.FF. The starter cabinet and other electrical equipment should also be protected from damage by corrosion.4. FAULT TRACINGThe following are some of the faults that may arise in operation.A. Compressor capacity is low and/or compressor not supplying full pressure. Dirty intake air Check suction filter. Possible cause Remedy Inferior lube oil --Change the lube oil type. See list ofDirty, damaged orClean and check all valves. recommended types in worn valves Replace defective parts. this handbook. Manufactorer can Sticking piston rings Dismantle rings.supply further Clean grooves and rings.information. Replace defecive parts.When reinstalling,Incorrect tightening ofTighten valvelubricate cylinder wallscompressor valves clamping screwswith oil. to specified torque.Leaking safety valves --Overhaul safety valves, adjust to correctE. Overheating or knocking in crankcase.lifting pressure.Possible causeRemedy Defective gasket ---Replace gasket. between crankcaseDefective bearings ----Inspect bearings, check and sylinder block clearances.Air filter blocked----Clean filter.Insufficent lube oil orDrain sump, clean and add lube oil contaminated new oil. with waterB. LP safety valve blows.Binding crankshaft Check bearing clearances.Possible cause Remedy bearing Replace defective parts.HP valves damaged or dirty Check and clean valves.Replace defective parts.F. Overheating and scoring of piston.Possible causeRemedyC. HP safety valve blows.Piston or gudgeon pin Replace defectivePossible cause Remedybearing incorrectly parts fitted , check piston Clearances, piston ringAir line shut-off Open shut-off cock.clearances and cock closed.gudgeon pin bearing.Non-return valveRemove and cleanDeficient coolingCheck coolingblockedon-return valve.water circulationReplace defective parts.and temperatures.D. Valves require maintenance too frequently.G. Excessive lube oil consumption.Possible causesRemedyOverheating Check cooling waterPiston rings worn outReplace piston rings.circulation and temp.Inspect coolers andDefective crankcaseReplace breather valve.clean if necessary.breather valveInstruction manual for Water-cooled Air Compressor HV1/140 & HV1/140A- 5 -5. INSPECTION AND MAINTENANCEIMPORTANT: PERSONAL SAFETYBefore starting any kind of work on the compressor, the electricity supply must be switched off at the starters and also at the main switchboard. Hang a notice on the switch on the main switchboard to show that repairs are in progress 5.1. Maintenance scheduleChange the lube oil after approximately the first 200 hours of running in. Drain off the oil while it is warm, clean the crankcase before refilling with new oil. When cleaning, it is important not to use rags that may leave threadsor fluff in the crankcase.The following maintenance schedule is intended as a guideline for normal maintenance. However, compressor operating conditions vary widely from installation to installation and it is therefor important to adapt the maintenance schedule to the experience of the individual operator.Maintenance- Cylinder through valve apertures- Pipe connectionsIntervals routine Overhaul:- LP delivery valve DailyA- HP delivery valve Every 500 hoursB Every 1000 hoursC Replace:- Lube oil after cleaning crankcase Every 3000 hoursD- Lube oil filterEvery 9000 hoursEEvery 12000 hoursFRoutine DOverhaul:- LP delivery valveRoutine A- HP delivery valve- Lube oil filter (clean)Check:- Lube oil pressure- Lube oilReplace:- Lube oil after cleaning- Cooling water circulation and crankcase temperatures- Automatic functionsRoutine E- Drain condensateCheck:- Coolers (clean)Routine BRoutine FCheck:- LP delivery valve- HP delivery valveCheck:- Main bearings- Compressor bedplate bolts- Piston, gudgeon pin and rings- Gudgeon pin bearing- Lub oil pumpRoutine CBefore ordering replacement parts, please read theCheck:- LP suction valveinstructions for ordering parts.- HP suction valveInstruction manual for Water-cooled Air Compressor HV1/140 & HV1/140A-5.2. ValvesIn the parts list and drawings each valve is shown complete, with its own part number, and also dismantled withthe part numbers of the individual components.After overhaul or replacement of parts, assemble the valves in sequence as shown in the drawing of the dismantled valve. When assembling valves, lubricate the nut and valve bolt and tighten to the torques (in kpm) given below: DimensionMinimumMaximumM81.01.2IMPORTANT:Before attempting to check compressor valves, loosen the clamping screw on the valve cover before removing the cover. After inspecting and overhauling valves, it is essential that the clamping screw, which bears against the valveclamping piece and which keeps the valve in place on its seat, should be tightened with an unbrako key to thetorque shown in Table T.3.Overhaul and mainenance of valvesRegular and careful maintenance of valves is essential to the capacity and reliability of the compressor. Wetherefore recommend overhaul in accordance with the following guidelines:A. When cleaning and dismantling the valve, never clamp the valve directly in a vice to loosen the centre boltnut. A special clamping jig for this purpose, suitable for all valves, is available from the factory on request. Asimple makeshift for clamping the valve is to set it in a vice between two pins which fit into the outermostseat slots of the valve.B. Clean the valve components and check them carefully.IMPORTANT: Never use sharp implements on sealing surfaces and plate parts.C. Replace all parts that are worn or even slightly scored. Check that all guide pins are in order. Maximumwear limit is 10% of the total thickness of components.D. If a valve spring or spring plate shows signs of weak-ness, all springs must be replaced at the same time, because damage can result if some springs operate longer than others. Replacement of all valve springs is recommended after about 5000 hours running time, even if the springs do not look worn.E. If there are signs of abrasion or scoring of the valve seat sealing ledges, these must be machined. Most valves are drilled for guide pins, with spare holes for new pins. Guide pins can be driven out by means of a suitable tool. If it proves impossible to remove a broken pin, use one of the spare holes.F. To remove the valve centre bolt, mark the centre of the pin with a centre punch and then drill out the pin. Remove the centre bolt. After refitting the bolt, drill a hole for the safety pin, drive the pin securely into place and peen the end to prevent it from falling out.G. After completion of machining and careful replacement of guide pins in their respective holes in the valve seating and/or catch plate, check that the ends of the pins do not but against the bottom of the holes in the matching parts.Use only genuine replacement pins and parts.Assembly of valves demands precision, care and forethought. Make sure that the various parts are correctly located and that the right numbers are installed. Compare with the lists and drawings of parts to ensure that the right number of parts is present. Total lifting heights of valve plates are given in Table T.4.Instruction manual for Water-cooled Air Compressor HV1/140 & HV1/140A- 7 -5.3. Lubricating oil systemThe lube oil pump is a gear pump which is normally capable of operating for long periods without maintenance. The pump is driven direct from the end of the crankshaft, and the lube oil pressure is controlled by means of aby-pass valve in the pump. When maintenance is to be performed, loosen the pump flange, disconnect the oil pipes and withdraw the pump.On the suction side of the pump there is a filter which can be easily dismantled for cleaning.* For the lubrication of the LP side of the piston, the compressor is fitted with a small piston pump, driven by an eccentric from the crankshaft. The oil for the piston pump is taken from a separate reservoir mounted on the side of the compressor. The type of oil used in the compressor crankcase should also be used in the separate reservoir. The quantity of oil fed into the LP suction valve can be adjusted by means of a regulating valve, fitted on the suction side of the pump. When the compressor is warm, the normal feed should be 3-5 drops per minute. * NOTE! Old HV1/156-models only ( HV1/156A-models has no cylinder lubrication system fitted) IMPORTANT: Accumulation of condensate in the crankcase may present a serious problem under certain operating conditions, and it is important that the operator should check from the very beginningwhether condensate in the lubricating oil is liable to become a problem.Unless the condensed water emulsifies with the lubricating oil, it will separate out and there is a risk that the compressor will be lubricated with water.The choise of lube oil is of great importance to the reliable operation of the compressor. The manufactorers have performed extensive tests of lube oils for the oil companies, and the following is a list of lubricants recommended on the basis of these tests.Following syntetic lubricants are tested and recommended by Sperre:Syntetic oilBP ENERSYN RX 100CASTROL AIRCOL SN 100CHEVRON HD COMPR. OIL 100DAPHNE MARINE COMPRESSOR 100ELF PRIMERIA SG 100ESSO/EXXON SYNTESSTIC 68MOBIL RARUS 827NIPPON OIL CO. FAIRCOL SA100STA TOIL COMPW AY S 100TEXACO SYN STAR DE 100Further information about lubricants is available on application to the manufacturer.5.4. BearingsThe compressor has replaceable, two-shell plain big-end bearings. The crankshaft bearings are two-row ball bearings.The gudgeon pin bearings are single shell plain bearings, press-fitted into the little ends. Tolerances and clearances for connecting rod, crankshaft and gudgeon pin bearings are given in Table T.4.All plain bearings are pressure lubricated.After inspection or replacement of the big-end bearings it is important to ensure that the bearing does not bind on the crankshaft. It must be possible to turn over the compressor manually.New two-shell bearings are coated with a running-in compound at the factory.Dismantling the gudgeon pin bearing from the connecting rod:A. Use a hydraulic press or extractor to remove the old bearing shell.B. Press in the new bearing shell.C. Adjust the fit of the bearing to the gudgeon pin in accordance with Table T.4.Instruction manual for Water-cooled Air Compressor HV1/140 & HV1/140A- 8 -5.5. Piston and piston ringsDismantle the piston as follows:A. Remove the cylinder head without dismantling the valves.B. Unscrew the big-end bearing bolts and remove the lower bearing shell.C. Withdraw piston and connecting rod.Reassemble in the opposite sequence.5.6. Flexible couplingThe compressor flywheel serves as one coupling half.Dismantle the couplingA. Loosen the nuts on each coupling half and give each one a sharp tap with a hammer before removing them completely. This will cause the bolts to loosen from their conical holes in the coupling halves.B. Remove the bolts and take out the flexible coupling. Avoid spilling oil on the flexible coupling.The coupling half on the motor is keyed and shrunk on to the axle.AlignmentThe prinsiple and values for checking alignment are shown in Fig. 4.A. Micrometer/dial indicatorB. Magnetic baseC. FlywheelD. Coupling half, motorE. Flexible couplingCheck the angle (W) by means of inside micrometer callipers or vernier callipers. The distance (W) in mm should be the same around the whole circumference of the coupling halves.Check parallel misalignment (A) between coupling halves as shown, around the circumference of the coupling halves (C). Values in mm for maximum parallel misalignment are given in Fig.4.5.7. CoolersTo ensure reliable operation of the compressor it is important to keep the LP and HP coolers free from deposesof carbon and cooling water salts etc. Insufficient cooling causes excessive air temperature and progressively increases the formation of carbon deposits.The cooling tubes are rolled (or expanded) into the cylinder block at both ends. If the cooling tubes show signs of severe corrosions or wear, the old tubes can be drilled out and new tubes rolled (or expanded) in.5.8. FilterThe air filter should be cleaned by means of a good degreasing agent. Blow the filter clean with compressed air and give it a thin coating of compressor oil.Oil filter: Clean with a good detergent and blow through with compressed air.Instruction manual for Water-cooled Air Compressor HV1/140 & HV1/140A- 9 -6. TECHNICAL DATAT.1. Coolant flowsShaft speed rpm.725-875-975-1150Coolant flow l/min. 7-10 bars................................:9-10-11-13Coolant flow l/min. 15-35 bars..............................: 11-14-15-18T.2. Recommended pressures and temperaturesRecommended minimum inlet temperature Cooling water....................:30 CRecommended maximum outlet temperature Cooling water.................:60Recommended temperature difference..................................................:10 - 15Recommended cooling water pressure..................................................:0.5 - 3.0 barsRecommended lube oil pressure, warm compressor.............................:0.8 - 2.0 barsRecommended limit switch setting for lube oil pressure/safety stop......:0.8 barsNormal working pressure one stage 0-10 bars......................................:1.5 - 4.5 barsNormal working pressure one stage 10-35 bars....................................:4.0 - 7.0 barsMaximum working pressure....................................................................:35 barsSafety valve setting over stage pressure (10)Normal temperature outlet air.................................................................:30 - 50T.3. Torque tableA - Thread diameter (mm)B - Key widthC -Torque (kpm), clean and lubricated threads* - Marker for unbrako screw** - Marker for BSP threadsComponentABCCylinder head.......................................................:M203020Valve cover LP.....................................................:M162415Valve clamping screw HP.....................................:*M201012Cap lock nut HP...................................................:M203210Big end bearing bolts............................................:**1/4229-11Bearing housing, crankcase.................................:M10174Cylinder block to crankcase.................................:M223225Hand hole ............................................................:M12198Crankcase covers.................................................:M10174Valve covers HP...................................................:M12198Valve clamping screw LP.....................................:*M1268Cap lock nut LP....................................................:M12198Instruction manual for Water-cooled Air Compressor HV1/140 & HV1/140A - 10 -T.4. ClearancesSuction valve LP Lifting height (mm)............. : 1.2Delivery valve LP Lifting height (mm)............. : 1.2Suction valve HP Lifting height (mm)............. : 1.1Delivery valve HP Lifting height mm).............. : 1.1Cylinder/piston clearance LP (mm)............. : 2,4 ¨C 2,7Cylinder /piston clearanse HP (mm)............. : 1,3 ¨C 1,5Piston/cylinder head clearance LP (mm)............. : 1.4-1.8Crankshaft bearing play (mm)............. : 0.08-0.11Gudgeon pin bearing play (mm)............. : 0.02-0.05T.5. Piston ringsSee fig. 5.T.6. General dataNumber of cylinders ..................... : 1Cylinder diameter LP (mm) ............ : 140Cylinder diameter HP (mm) ............ : 126Piston diameter LP (mm)............. : 137 +0.45/ +0.55Piston diameter HP (mm)............. : 124 +0.58/ +0.62Stroke (mm) ............ : 100Crankpin diameter (mm) ............ : 63Crankshaft diameter at bearing (mm) ............ : 70Gudgeon pin diameter (mm) ............ : 40Number of valves LP ..................... : 2Number of valves HP ..................... : 2Oil capacity of sump (litres) .......... : 4。