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INSTRUCTION MANUAL FOR

OPERATION AND MAINTENANCE OF
MODEL ZW-19/30 OXYGEN COMPRESSOR

Page 2 of 18

Table of Contents
1.

Main Technical Data

2.

General Description

3.

Requirements for Installation

4.

Trial Run of Oxygen Compressor

5.

Normal Operation of Oxygen Compressor

6.

Possible Troubles and Remedial Measures

7.

Maintenance of Oxygen Compressor

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1.

Main Technical Data

(1)

Type: Vertical, three-row, three-stage, double-action, non-lubricated cylinder, water-cooled

(2)

Discharge capacity: 1140m3/h (under suction condition)

(3)

Condition of inlet medium

) Dry oxygen
) Inlet oxygen pressure: 0.121MPa(A)
) Inlet oxygen temperature: 25
(4)

Final pressure: 3.1MPa(A)

(5)

Outlet temperature of the last stage cooler: 40

(6)

Diameter of cylinder:
The 1st stage: 400mm
The 2nd stage: 240mm
The 3rd stage: 140mm

(7)

Piston travel: 180mm

(8)

Rotational speed: 590r/min

(9)

Rotation direction of crankshaft: Counter-clockwise as viewed from oil pump

(10) Drive type: Directly connected with motor by means of inflexible coupling
(11) Shaft power: 220kW
(12) Total weight of Compr. unit: 11918kg
(13) Lube oil: oil grade L-AN 68 (GB443 eqv ISO VG 68) lubricating oil for total loss system
A filling quantity required: 260L
(14) Motor to be used:
)Type: Y2-4003-10, threephase, AC, asynchronous motor
) Power: 250kW
) Voltage / frequency: 380V / 50Hz
) Rotational speed: 590r/min
(15) Cooling water consumption: ca.20t/h (inlet temperature: 32)
(16) Size of the 1st stage inlet pipe:219 x 6
(17) Size of the last stage outlet pipe:57 x 3.5

2.

General Description
The oxygen compressor is comprised of such main parts as crankcase, main body, crankshaft,

connecting rod, cross head, cylinder, piston, valve, sealer, cooler, safety valve, gear oil pump, oil cooler,
suction strainer, oil filter, check valve, local instrument panel, electric control cabinet, electric motor etc.
The crankcase as the upper part joins the main body as the lower parts at the centerline of
crankshaft to constitute the machine pedestal.

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The crankshaft made of rare-earth nodular cast iron is supported on four bearings located in
crankcase. The three cranks are differentiated from each other by an angle of 120 degrees. One end of
crankshaft is connected with electric motor by means of inflexible coupling while the other end powers the
geared oil pump by means of overdrive clutch. In crankshaft, holes for delivery of oil are drilled and they are
the only passageway for lubricating oil to flow to the main bearing and to the bearing in the major head of
connecting rod.
The connecting rod body is made of rare-earth nodular cast iron. To the minor end of connecting
rod the bronze bush bearing is pressed while the major head bearing is provided with bearing metal bush.
The crosshead is monoblock type and made of rare-earth nodular cast iron. It is connected with the
piston rod by means of the oblique pin and connected with the bronze bush bearing in the minor head of
connecting rod by means of cross head pin.
The 1st and 3rd cylinders are integrated by casting while the 2nd cylinder is separately cast as one
workpiece so that the concentricity of cylinder with cross head sliding passage can be easily adjusted. All
cylinder bodies are lined with cylinder sleeves made of corrosion-resistant 3Cr13. In the cylinder head and
cylinder body water will flow for cooling.
The piston is of double-action type and comprised of piston body, piston rod, piston ring, guide ring
and oil catch plate. The 1st stage piston body is the aluminum alloy casting and the surface is treated by
anodic oxidation. The 2nd stage piston body is the gray iron casting and the surface is copper coated. The
3rd stage piston body is made of corrosion-resistant 3Cr13. The guide ring and piston ring are made of
PTFE with compounds which is wear-resisting and self-lubricates. The guide ring is provided with T-shaped
open ends so that it can be easily replaced.
The suction & discharge valves are reticular valves without guiding and relative wear, and all of
their parts are made of stainless steel and can be replaced each other. The sealer at each stage has the
same structure and consists of one spoiler ring, five groups of seal box and last end seal ring. The spoiler
ring serves the function of equalization of pressure by throttle and reduction of gas flow pulsation. There
are three different rings in each group of seal box. The first one is a radial notched ring, the second one is a
tangential notched ring and both of them are seal rings. The third one is a supporting ring without notch
which is used to prevent the cold flow from side and corner when the 1st and 2nd seal rings are under the
pressure. All seal rings are made of PTFE with compounds. The sealer is provided with connector for gas
filling so that the quality of the delivered oxygen is maintained.
The oil scraper at each rank of piston rod has the same structure, and It is comprised of oil scraper
body, oil scraper ring and oil catch ring etc. The oil scraper rings are made of phosphor bronze and oil
scraper rings are made of PTFE with compounds. The oil scraper is used to prevent the liquid oil and oil fog
from being brought into the sealer along with the up-and-down movement of piston rod.

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All of the gas coolers are of vertical, shell-tube and floating-head type. The cooling tube is finned
tube which is rolled with copper tube, and the shell is made of stainless steel. The oxygen flows inside the
shell side and the cooling water flows inside the tube side.
All the oxygen pipes are of seamless pipes which are made of stainless steel. It insure that the
machine can safely run with the suction & discharge globe valves which are made of stainless steel, the
check valve and the 1st,2nd & 3rd stage safety valves.
The cooling water system for the compressor is in closed circulation. Regulate the female thread
stop valves to control the outlet temperature of cooling water not exceed 40.
The lubricating of moving mechanism is provided forced lubrication by the gear oil pump at the end
of crankshaft providing the pressure oil, and a reserve gear oil pump is equiped. The lube oil is sucked by
the gear oil pump from crankcase through the oil filter. The pressure oil is fed into two parts, one into
crankshaft to lubricate the main bearing and the major head bearing of connecting rod and also through the
connecting rod to lubricate the minor head bearing, while the other to lubricate the crosshead guide and
also to the minor head bearing.
The compressor is provided with local instruments/electric control cabinet, and most of pressure
gauges and temperature indicators are mounted on it. There is signal alarm or interlock stop when the 1st
stage suction pressure, 3rd stage discharge pressure, discharge temperature for each stage, oil supply
pressure, oil supply temperature and cooling water flow go beyond the normal range. The others
measuring points are only as ordinary indication. The detailed parameters are listed below:

Measuring Point Name

1.The 1st stage suction
pressure

Normal Indication
Value
Pressure Temp.
MPa

0.023

2.The 1st stage discharge

pressure

0.20~0.30

3.The 2nd stage discharge

pressure

0.90~1.00

4.The 3rd stage discharge

pressure

3.0

5.The 3rd stage pressure

after cooling

3.0

6.Pumping pressure for the

gear oil pump

0.25~0.30

Measuring Point
Position
Suction pipe 1st
stage
(M1Y02C.100)
Discharge pipe 1st
stage
(M1Y02.200)
Discharge pipe
2nd stage
(M1Y02.500)
Discharge pipe 3rd
stage
(M1Y02.900)
Discharge pipe 3rd
stage
(M1Y02A.700)
Moving
mechanism
(W3Z3.5N)

Instrument
Installation Site

Remarks

Local instr.
panel

Alarm at
10kPa

Local instr.
panel
Local instr.
panel
Local instr.
panel
Local instr.
panel
Local

Alarm at
3.2MPa

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(Continued from last list)
7. Lubricating oil pressure
8.Cooling water supply
pressure

Moving
mechanism
(W3Z3.5N)

0.20~0.30
~0.30

9.The 1st stage suction

temperature

25

10.The 2nd stage suction

temperature

40

11.The 3rd stage suction

temperature

40

12.The 3rd stage

temperature after cooling

40

13.The 1st stage discharge

temperature

160

14.The 2nd stage discharge

temperature

170

15.The 3rd stage discharge

temperature

170

16.Each of the cooling water

outlet temperatures

40

17. cooling water flow

20 t/h

Water supply pipe

(M1Y02.1600)
Suction pipe 1st
stage
(M1Y02C.100)
Suction pipe 2nd
stage
(M1Y02.400)
Suction pipe 3rd
stage
(M1Y02A.500)
Discharge pipe 3rd
stage
(M1Y02A.700)
Discharge pipe 1st
stage
(M1Y02.200)
Discharge pipe
2nd stage
(M1Y02.500)
Discharge pipe 3rd
stage
(M1Y02.900)
Water watcher
device
(M3Y03.000)
Water return pipe

Local instr.
panel

Alarm at
0.18MPa,
stop at
0.15MPa

Local instr.
panel
Local instr.
panel
Local instr.
panel
Local instr.
panel
Local instr.
panel
Local instr.
panel

Alarm at
170

Local instr.
panel

Alarm at
170

Local instr.
panel

Alarm at
170

Local
Local instr.
panel

Alarm at
15t/h,
stop at
12t/h

3. Requirements for Installation

3.1 Preparations to be made before installation
3.1.1 Eliminate the oil seal from the machine and clean the machine. But this compressors moving
mechanism W3Z3.5N have been assembled in the manufacturer, and the fitting-up clearances have been
adjusted to the design requirements, the connecting parts have been screwed tight and locked. The
machining surface already spray the anti-salt spray pickling oil 2377 (this pickling oil is compatible with the
lubricating oil of the compressor). Therefore the user not need to assemble the moving mechanism again,
but direct hoisting the moving mechanism on the foundation at Installing.
When user open the packing case to install should inspect the oil seal quality, spot-check the
fitting-up clearances, and turn the flywheel coupling, examines the moving mechanism whether freely. If
the storage time is excessively long, has surpassed the oil seal term of validity, the packing case is
leakage, the components surface has been corroded, in the crankcase filled with water, dirt and so on, then
the use should disassemble, repair, adjust, re-assembles and meets the design requirements.

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3.1.2 All the components to be in contact with Oxygen should be degreased and cleaned with
trichloroethylene, and the oil residual adsorption be not exceed 125 mg/m2.
3.1.3 Pre-anneal the copper washers.
3.1.4 The foundation has undergone a certain period of concrete curing and the spacers for adjustment are
prepared.
3.2 Fitting-up clearance
Before the compressor is delivered from the manufacturer, the fitting-up clearances at main
locations are adjusted in pre-installation to those required by the design. In reassembly, the fitting-up
should be done according to the numbering and the fitting-up clearances should be rechecked.
3.2.1 Diameter of crankshaft: 100 mm
Radial clearance between crankshaft and main bearing shell: 0.08 to 0.15 mm
Radial clearance between crankshaft and thrust bearing shell: 0.08 to 0.15 mm
Axial clearance between crankshaft and thrust bearing shell: 0.20 to 0.40 mm.
3.2.2 Diameter of crank:100 mm
Radial clearance between crankshaft and connecting rod bearing: 0.08 to 0.15 mm
Axial clearance between crankshaft and connecting rod bearing: 0.15 to 0.25 mm.
3.2.3 Diameter of cross head pin: 55 mm
Radial clearance between cross head pin and minor bush on connecting rod: 0.05 to 0.08 mm.
3.2.4 Diameter of cross head: 160 mm
Clearance between cross head and guide track: 0.12 to 0.22 mm.
3.2.5 Dead center for cylinder:
Top dead center: 2.0 to 2.5 mm
Bottom dead center: 2.0 to 2.5 mm.
3.2.6 Guide ring:
- Radial thickness (in initial installation):
1st stage: 12c10mm, 2nd stage: 12c10 mm, 3rd stage: 12c10 mm
- Allowable value of min. radial thickness:
It is not exceed 0.5mm that the top circle of ring than the top circle of piston body.
- End face axial clearance:
1st stage: 0.30 to 0.35 mm, 2nd stage: 0.30 to 0.35 mm, 3rd stage: 0.25 to 0.30 mm
- Round junction point clearance (in initial installation):
1st stage: 11 mm, 2nd stage: 7 mm, 3rd stage: 4 mm.
3.2.7 Piston ring:
- Radial thickness (in initial installation):
1st stage: 18, 2nd stage: 14, 3rd stage: 12 mm

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- Allowable value of min. radial thickness:
1st stage: 12 mm, 2nd stage: 8 mm, 3rd stage: 8 mm
- End face axial clearance:
1st stage: 0.20 to 0.30 mm, 2nd stage: 0.20 to 0.30 mm, 3rd stage: 0.15 to 0.20 mm
- Round junction point clearance (in initial installation):
1st stage: 11 mm, 2nd stage: 7 mm, 3rd stage: 4 mm.
3.3 Installation of machine body and electric motor
3.3.1 Adjust the levelness of compressor and motor base tracks with spacers (prepared by the User) to a
range of 0.11000 mm. Deviations should be in the same direction.
3.3.2 Align the compressor shaft with motor shaft. Put the magnetic dial gauge seat on plane A shown in
Figure 1. Use the dial gauge to rectify plane B on the basis of periphery and the required dial gauge error
should not be greater than 0.04 mm. The plane C is measured simultaneously. Four points are measured in
cross direction and the error should not be greater than 0.04 mm.

Figure 1
3.3.3 Tighten the screws on coupling.
3.3.4 Only when the secondary poured grout in foundation is solidified can the test run is carried out.
3.3.5 when moving mechanism is installed, use the taper liners adjust the level of the frame, then
cross-tighten the anchor bolts evenly to prevent the crankcase from distortion such that which affect the
clearances of the bearings and crosshead.

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3.4 Installation of piston
3.4.1 For the assembly of pistons refer to the drawings(Y325CK.30000, Y325CK.40000, Y325CK.50000).
Before installation, use trichloroethylene to thoroughly clean the assembled piston and dry it by blowing.
The clearance for piston ring groove is checked in the meantime. If the clearance does not comply with the
requirement, only when the rectification is done can the assembly be performed.
3.4.2 Before the piston are put into cylinders, lay the tools No. 0231P.50001, 0231M.60002, Y204.60001
for mounting of pistons respectively on each stage cylinders in order for the pistons to go smoothly into the
cylinders. Meanwhile, screw in the eye bolt for piston No. 0332B.350004 at the top of piston. Mount the
tool No. 0332B.350007 for mounting of piston at the end of piston rod to help the piston rod enter sealer.
3.4.3 Pay attention to the notch of piston ring escaping from passing the port of valve antrum.
3.4.4 Put the piston rod in crosshead and use wedge for fixation. Measure and rectify the top & bottom
dead centers and use the regulating piece to adjust them to the required value.
3.5 Installation of valve
3.5.1 For the assembly of valves refer to the drawings (0231.60000, 70000, 80000A, 90000A, 100000A,
110000A).

When the valve is assembled, take care to get the concave side of the spring arm of valve

plate faced to the valve seat and to keep the sloped grooves of valve plate and buffer plate in the same
direction. Pay attention to the assembly of springs and holes of damper disks. The bolts and nuts of valves
shall be tightened and fixed. Do not mix the springs and the spacers, or the valves shall not be normally
operated.
3.5.2 After assembly, cleaning by use of trichloroethylene and dry by blowing should be done again.
3.5.3 When mounting each stage valve on cylinder and dismounting each stage valve from cylinder, the
tools No.0231.220100, 0231.220200 and 0231.220300 for mounting and dismounting valves can be
respectively used.
3.6 Installation of sealer (0332B.100000)
3.6.1 When the sealer is assembled, pay attention to the locations for installation of different types of seal
rings. The seal ring with radial notch should be mounted in front sealing box i.e. towards the pressure side.
The seal ring with tangential notch is then mounted in the middle of three different types of seal rings. The
integral supporting ring is mounted in the very rear of sealing box. Such a group of seal rings must not be
wrongly positioned, otherwise, the service effect will be reduced.
3.6.2 When the sealer is assembled, make sure that the sharp angles on the edge of seal ring must not be
damaged and it is absolutely not allowed to scrape or repair them with a knife or file.
3.6.3 Check the total axial clearance of each box of seal ring to the sealing box. If non-conformity is found,
rectification must be made can it be installed.

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3.6.4 Clean the assembled sealer further by use of trichloroethylene and only when it is dried by blowing
can it be installed.
3.7 Installation of oil scraper (W3Z3.5.90000A)
The scraper ring (W3Z3.5.90002) is available for maintaining, the wedge angle of cutting edge
without damaging. The hole of oil catch ring (W3Z3.5.90004) is bellmouth, and it should be upward when
mounting. Install 3 sets of oil scrapers according to the numbers.
3.8 Installation of gas cooler (G7Y04, G7Y05, G7Y06) and piping
After the secondary grouting is done for the main machine and electric motor, such accessories as
cooler and piping can be installed. The height and levelness of cooler are firstly rectified and then
pre-install the piping. When every thing is acceptable, the anchor bolts of cooler are grouted.
All the oxygen pipes are made of 0Cr18Ni9 steel. Few interfaces of the pipes have been welded by
spot welding in the workshop and they shall be welded after site installation. Adjustment on and welding of
them shall be in accordance with the specification specified in the drawing. The welding slag and
mechanical impurity must be removed in the pipes after welding.
The oxygen pipes shall be welded and mounted in the field acc. to JB/T 5902-2001, Specification for
Oxygen Piping of Air Separation Plant.
Adjust the locations of supports or increase extra supports if there is some abnormal vibration in the
pipe when running of the compressor.

4.

Trial Run of Oxygen Compressor

Trial run of the oxygen compressor shall be done after installation. After repairing the oxygen

compressor or replacing the wearing parts, the oxygen compressor shall not be operated with load till it is
tested. But the gas for trial run of oxygen compressor must be oil-free dry air or nitrogen.
4.1 Preparations to be made before test run
4.1.1 All the parts, pipes, piping fittings, valves and coolers which contact oxygen must be cleaned and
degreased. Do not fix the suction and discharge valves temporarily.
4.1.2 Check the oil & water piping system and instrument to see whether they are in correctly connected
position and whether the instrument is in good order.
4.1.3 Before the electric motor is coupled with crankshaft, perform the test run of electric motor separately
and complete the regulation of rotational direction. The rotation is anti-clockwise as motor is viewed from oil
pump.
4.1.4 Recheck the assembling quality of all fasteners, especially that of moving parts. Check the oil catch
ring to see whether it is properly positioned.
4.1.5 Turn the crankshaft coupling several times in order to see whether the machine is rotating with or
without obstruction.

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4.1.6 Pour lubricating oils for total loss systems L-AN68 into the cleaned crankcase with the oil level
located at three fourths of oil level mirror. Dont get the crankcase fully filled with oil.
4.1.7 Open the cooling water valve on each piping until a greater flowrate is obtained.
4.1.8 Open the atmospheric valve at the end.
4.1.9 Start the reserve gear oil pump so that the oil can be supplied to each lubricating point in case the
machine lacking of oil when staring up.
4.2 Steps in test run
4.2.1 Inch the motor to check the compressor for running. If it is normal, start the motor again to let the
compressor begin running and adjust the oil pressure in time going up to the value of 0.25 MPa.
4.2.2 Stop the motor to check the main bearing and major/minor bearings of connecting rod for their
temperatures by hand after running 10 minutes. After maintaining the running for one hour, stop the motor
and

check the temperatures of each bearing, sliding path of crosshead should be less than 40 and the

temperature of piston rod should be less than 80.

If abnormality is found during test run, stopping must be immediately done for inspection. When
abnormality is eliminated, the test run can be continued.
4.3 Unload test running of oxygen compressor
After the test run of oxygen compressor is accepted, carry out the unload running continuously for 4
hours in order that the moving parts can be in a good state of running-in and the possible defect can be
found and rectified at the same time. The unload continuous running, which is particularly important to the
running-in of plastic seal ring, piston ring and guide ring, cannot be neglected.
4.4 Blow-off of oxygen compressor
4.4.1 Close the oxygen inlet globe valve, open air by-pass valve or nitrogen by-pass valve (If this valve is
not provided, disconnect the 1st stage suction pipe to enter air).
4.4.2 Mount the inlet & outlet valves (0231.60000, 70000) of the 1st stage cylinder and disconnect the
flange on the 2nd stage suction pipe. Run the oxygen compressor for about 10 minutes in order to purge
the 1st stage cylinder, the 1st stage cooler and piping. Following stopping, dismount and clean the 1st
stage inlet & outlet valves for inspection. If no abnormality is found, remount them at once to the cylinder.
4.4.3 Mount the suction pipe and inlet & outlet valves (0231.80000A, 90000A) of the 2nd stage cylinder and
disconnect the flange on the 3rd stage suction pipe. Run the oxygen compressor for about 10 minutes in
order to purge the 2nd stage cylinder, the 2nd stage cooler and piping. Following stopping, dismount and
clean the 2nd stage inlet & outlet valves for inspection. If no abnormality is found, remount them at once to
the cylinder.
4.4.4 Mount the suction pipe of the 3rd stage cylinder, the 3rd stage discharge pipe and the 3rd stage inlet
& outlet valves (0231.100000A110000A). Run the oxygen compressor for about 20 minutes in order to

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purge the 3rd stage cylinder and piping. Following stopping, dismount and clean the 3rd stage inlet & outlet
valves for inspection. If every is normal, remount them at once to the 3rd stage cylinder.
4.5 Load test running of oxygen compressor
4.5.1 After the oxygen compressor is cleaned by purging, the pressure can be increased gradually. The
nitrogen or oil-free dry air shall be used for the pressurization acc. to the suction condition of oxygen
compressor. Start the compressor and close the atmospheric valve at the end and regulate the globe valve
at the end to let the discharge pressure at each stage go up gradually. Within 4 hours the pressure goes up
gradually to 3.0 MPa, during which one hour is needed for the pressure to increase respectively from the
initial value to 1.0 MPa and from 1.0 MPa 2.0 MPa, and 2 hours are needed for the pressure to increase
from 2.0 MPa to 3.0 MPa. During the period of gradual increase of pressure, attention must be paid
to such matters as oil pressure, water pressure and temperature, each stage outlet temperature and
the abnormal knocking sounds.
4.5.2 Full load running of oxygen compressor
After the end discharge pressure goes up to 3.0 MPa, run the compressor continuously for 1 hour.
Attention must be paid to the following during full load running:
-

Whether the oil and water pressures are normal.

Whether the discharge pressures of each stage are normal.

The temperature of gas coming from each stage cooler should be less than 40.

Check the sealing effect of sealer.

Check the oil scraping effect of oil scraper.

Check the oil scraping effect of oil scraper.

Check the leak tightness of the whole system.

Monitor the working condition of valve.

Check the vibration condition of machine and piping.

Pay close attention to the indication condition of instrument and test the instrument to see
whether the alarm is sensitive and reliable.

When instrument gives the alarm, the cause must be immediately ascertained and regulation
must be made at once.

Pay attention to the temperature rise and electric current of electric motor.

Record the operational data every half an hour and check whether they meet the requirements.
If every thing is ok in the test run of oxygen compressor with full load, the compressor can be put in

normal production.

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5.

Normal Operation of Oxygen Compressor

5.1 Start-up
5.1.1 Turn the crankshaft several times and check to see whether the machine is running smoothly.
5.1.2 Open cooling water valve and regulate properly the water flowrate in each piping.
5.1.3 Start the reserve gear oil pump so that the oil can be supplied to each lubricating point.
5.1.4 Open the atmospheric valve at the end.
5.1.5 Start the electric motor according to the procedures explained in the service manual for the motor.
Open the 1st suction globe valve and run the oxygen compressor for a few minutes to replace the air or
nitrogen inside the compressor system by oxygen.
5.1.6 Close the atmospheric valve at the end gradually while regulating the discharge globe valve. The
opening of the discharge globe valve shall be properly regulated in order that the discharge pressure is up
to the rated value or the pressure required by the piping.
5.1.7 Check the running of compressor. The compressor shall not be put into normal operation till it is
normal in running.
5.2 Operations in normal running of oxygen compressor
5.2.1 The main parameters are listed below when the oxygen compressor is in normal operation:
Item

Normal Value

Remarks

The 1st stage suction pressure PIA811

23 kPa

The 1st stage discharge pressure PI812

0.20~0.30 MPa

Action of safety valve at 0.35 MPa

The 2nd stage discharge pressure PI822

0.90~1.00 MPa

Action of safety valve at 1.16 MPa

The 3rd stage discharge pressure PI832

3.0 MPa

The 3rd stage pressure after cooling PI801

3.0 MPa

Lubricating oil pressure PIAS803

0.20~0.30 MPa

Pumping pressure for the gear oil pump PI805

0.25~0.30 MPa

Cooling water pressure PIAS806

The 1st stage suction temperature TI811

Alarm at 10 kPa

Alarm at 3.2 MPa,

action of safety valve at 3.3 MPa
Alarm at 0.18 MPa,
stop at 0.15 MPa

~0.30 MPa
25

The 2nd & 3rd suction temperature TI821,TI831

40

The 1st stage discharge temperature TIA812

160

Alarm at 170

The 2nd stage discharge temperature TIA822

170

Alarm at 170

The 3rd stage discharge temperature TIA832

170

Alarm at 170

The 3rd stage temperature after cooling TI801

Each of the cooling water outlet temperatures
TI871~876

40
40

Page 14 of 18
(Continued from last list)
Lubricating oil temperatures TIA803
cooling water flow FIAS801

40
20 t/h

Alarm at 50
Alarm at 15 t/h,
stop at 12 t/h

5.2.2 Record every one hour the actual operational readings on instrument.
5.2.3 If the instrument gives the alarm signal, it must be done immediately to ascertain the cause and make
timely regulation.
5.3 Normal stop of oxygen compressor
5.3.1 Open the atmospheric valve slowly so as to unload the cylinder, and then close the globe valve at the
end and the 1st suction valve.
5.3.2 Stop the electric motor.
5.3.3 When the electric motor stops running, close the atmospheric valve.
5.3.4 Close the water inlet valve. Drain the cooling water from each stage cylinder, cooler and all water
piping completely. Especially, the machine will encounter cracking in freezing area in winter if the water is
not completely drained away.
5.4 Emergency stop of oxygen compressor
In the event of accident, the first thing to do is to stop the electric motor. Then open the atmospheric
valve at the end immediately and close the globe valve at the end and the 1st globe valve.
5.5 Long stop
5.5.1 Before the long stop of oxygen compressor, the temporary stop should be firstly carried out. Close the
oxygen suction valve to cut off oxygen flow and start the compressor again by means of the connected
passage for Dry Nitrogen to make which filled with all cylinders and the gas piping system. After that, stop
the machine formally and thus the inner of compressor can be prevent from rusting.
5.5.2 During the stop, start the oxygen compressor once a week at least and use dry nitrogen to run it for
10 minutes.

6. Possible Troubles and Remedial Measures

Cylinder
6.1.1 Abnormal gas suction & discharge pressure and temperature
-

Leakage and abnormal resistance are found at any stage of oxygen compressor so as to cause
the abnormal pressure at this stage.

Blockage occurs so that the outlet pressure at this stage goes up and the gas discharge
temperature goes up too.

Gas discharge valve is unsealed so as to cause the temperature to go up due to intake,

compression and discharge of leaking gas.

Page 15 of 18
The leaking component should be replaced and blockage should be eliminated in order to remedy the
above troubles.
6.1.2 Leakage of gas
-

Valve plate is cracked or spring breaks off so that filings fill the valve.

There is excessive wear in piston ring and cylinder sleeve so that the sealing is out of function.

There is excessive wear in sealer and seal ring so that the sealing is out of function.

Safety valve and atmospheric valve are not tightly closed.

Valve seat is not tightly fitted against the fitting surface.

For remedy of these troubles, such vulnerable parts as valve plate, piston ring and seal ring should

be replaced and the fitting surface should be abraded.

6.1.3 Water in cylinder
-

Crack occurs because the cylinder cover and cylinder are damaged.

There is leakage of water from the previous stage cooler.

6.2 Lubricating oil system

6.2.1 Low oil pressure
-

Oil level in crankcase is lower than the required height.

Oil filter is blocked.

Pump or pressure regulating valve is damaged.

Leakage takes place on oil inlet and outlet piping.

6.2.2 High oil pressure

-

Setting value for pressure regulating valve is too great.

Oil outlet piping is obstructed.

Oil is poor in quality or the brand of oil is wrong.

Oil temperature is low.

In order to remedy these troubles, the oil should be added or replaced and the oil filter as well as oil
pipeline should be cleaned, and the clearances of gear oil pump should be regulated.
6.3 Knock
6.3.1 Oxygen compressor body
-

Excessive clearance is caused by the wornout main bearing or connecting rod bearing.

Clearance between crosshead and guide track is excessive.

Crosshead pin is wornout.

Screws on connecting rod work loose.

6.3.2 Cylinder
-

Dead center is too small.

Connecting parts for piston work loose.

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-

Foreign matters enter cylinder.

Valve plate is cracked or spring is damaged.

Clearance between piston ring and groove is excessive.

Regulation of clearance, tightening of screws, elimination of foreign matters and specification of

operating are the measures to remedy these troubles.

7.

Maintenance of Oxygen Compressor

In order to guarantee the normal running of oxygen compressor and to avoid unexpected damage of

parts, daily check and periodical inspection and maintenance must be maintained. Generally, overhaul
should be done once a year and intermediate inspection & maintenance should be done once half a year
or in shorter time.
7.1 Daily check
7.1.1 Each stage discharge temperature and pressure are normal or not.
7.1.2 Supply of cooling water is normal or not.
7.1.3 Oil pressure and quantity are normal or not.
7.1.4 Listen to the valve regularly in order to know whether it works with a normal sound or not.
7.1.5 Check moving parts in order to know whether there is any knock sounded or not.
7.1.6 Check the sealer and oil scraper in order to know whether they are working well or not.
7.1.7 Check the machine and piping in order to know to what extent the vibration comes up.
7.2 Intermediate inspection and maintenance
7.2.1 Inspect each stage valve to know whether there are any damaged parts. The spare parts can be used
if necessary.
7.2.2 Inspect each instrument for its accuracy and each stage safety valve for its reliability.
7.2.3 Clean the suction strainer or replace strainer core. Clean oil filter and the breather valve located on
machine body.
7.2.4 Inspect the piston ring and guide ring for wear and tear. The new rings can be replaced if necessary.
7.2.5 Inspect and clean the sealer and oil scraper.
7.2.6 Clean the crankcase and change the lube oil.
7.2.7 Inspect each bearing and the clearance between crosshead and guide track. Make adjustment
according to the requirements if necessary.
7.3 Overhaul
Dismantle and clean every component of the whole machine and also carry out the inspection and
maintenance. In addition to the items, which are the same as those inspected and maintained in
intermediate inspection and maintenance, should be completed, the electric motor should be cleaned
according to the requirements shown in the operation instruction supplied by the motor manufacturer. In

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inspection, maintenance and assembly, do as follows:
7.3.1 the dismantled parts should be put into their right positions according to the marks made by the
manufacturer for assembly. It should be particularly noted that the 3 ranks of connecting rods should not be
wrongly exchanged with each other or reversely mounted.
7.3.2 All parts and components, contact with Oxygen must be carefully de-greased and cleaned before
general assembling.
7.4 Inspection and maintenance of important parts
7.4.1 Valves
The valves must be examined after 3000 hrs of continuous operation. The examination time shall be
shortened properly if the running period is irregular. The valves shall be taken apart and cleaned upon the
examination. The damaged parts shall be replaced if any. Refer to 3.5 for the assembling of valves.
7.4.2 Piston
Examine the wearing of the piston ring after running for 4000 hrs. Replace the piston ring if
necessary.
7.4.3 Sealer
Check the wearing of seal rings after running for 4000 hrs. Replace them if necessary. Refer to 3.6
for the assembling of seal ring.
7.4.4 Oil scraper
Often check the oil scraper. If the efficiency is not very well, check it as follows:
( ) Check the fit between scraper rings and piston rod. Re-abrade or replace them if necessary. The
contact height of each scraper ring with the piston rod is 3~3.5 mm. The scraper rings shall be obtained in
the scraping efficiency by abrading the lower part of the piston rod with fine abrasive paste after
dismantling piston rod. Replace the piston rod if it is dashed or worn out.
() Check the tension of spiral locking spring.
() Check the lube oil of moving parts for the specification. If it is too thin, the scraping effect shall not be
guaranteed.
7.4.5 Lube oil (L-AN 68

GB 443

eqv

ISO VG 68)

The lube oil used is the lubricating oils for total loss systems. And its kinematic viscosity is 61.2~74.8
mm2/s at 40. Change the oil every 6 months in the first year and once a year later. Clean the filters and
crankcase thoroughly when changing.
7.4.6 Check the tightness of connecting rod bols once a year.
7.4.7 Clean the cooling water piping.
If the outlet temperatures of gas and oil are up and the water outlet temperature of cooler drops, this
means the scaling exists in the water pipe. The following solution is recommended for cleaning of the pipe.

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() The deposited sand particles must be loosened mechanically and flushed out of the pipe. The leak test
of water pipe must be made after cleaning.
() Solution Formula and Handling for Descaling (at room temperature)
The preparation of 100 kg solution needs the material and ratio: citric acid 9 kg, sulphuric acid 800 g,
thiocarbamide 1 kg, ethyl alcohol 1500 ml, 0P-10 1 kg (JIANG NAN chemical plant), and water 86 kg.
Method for use: First, mix citric acid, thiocarbamide, ethyl alcohol and 0P-10 with water, and then pour
sulphuric acid into prepared solution. Never pour sulphuric acid into water directly. The solution feed to the
pipeline by liquid pump for cleaning. After clear away the scaling, the coolers will be rinsed with a large
number of water.
NB: Seal up the used solution after clear away the precipitate, it may again used at descaling next
time.