NEW INSTRUCTION MANUAL
General
The Instruction Manual (IM) is the most important document
concerning compressor handling
Every person involved with compressor handling has to read
and comprehend the IM before start working on the compressor
Every intervention on the compressor has to be done according
the IM
Keep the IM always available and near to the compressor
Consult the IM always before starting work (check list)
CTL4_Instruction Manual
Customer Training
Page 2
Chapter 1: Definitions for this Document
Safety
• General information
• Working practice
General Information
• Key to compressor type designation
CTL4_Instruction Manual
Customer Training
Page 3
Chapter 2: Elementary Safety Advice
Safety
• General information
• Warnings Sign at site
• Mechanical Hazard
• Working practice
• Gas specification
CTL4_Instruction Manual
Customer Training
Page 4
Chapter 3: Plant Configuration and Function
General description of compressor main components
• Like drive system, gas flow, cooling system, lubricating system,
safety devices, local instrument board
CTL4_Instruction Manual
Customer Training
Page 5
Chapter 4: Compressor Design and Function
General description of compressor
• Compressor outline & sectional view drawing
• Design Data
• Like crank gear, distance piece, cylinder, valves
CTL4_Instruction Manual
Customer Training
Page 6
Chapter 5:
Transport, Installation and Pre-Commissioning
Transport
Installation of compressor and piping system
Initial start-up
CTL4_Instruction Manual
Customer Training
Page 7
Chapter 5:
Transport, Installation and Pre-Commissioning
Installation
• We strongly recommend to install the compressor under supervision
of a BCA specialist
• It is important to give strong attention to the civil work corrections
later on are hardly possible
CTL4_Instruction Manual
Customer Training
Page 8
Chapter 5:
Transport, Installation and Pre-Commissioning
Commissioning
• Initial start-up
– Cooling system
– Oil system
• Blowing out of pipes
• Running-in of pistons
• Vibrations
• Preservation
CTL4_Instruction Manual
Customer Training
Page 9
Chapter 6: Operation
Remarks for Operation
Normal Operation
• Compressor control description
• Log sheet
CTL4_Instruction Manual
Customer Training
Page 10
Chapter 7: Trouble Shooting
Safety and Monitoring Devices
• pressure monitoring
• temperature monitoring
• noise monitoring
• flow monitoring
• vibration monitoring
CTL4_Instruction Manual
Customer Training
Page 11
Chapter 8: Preventive Maintenance
General advises
List of Tools
Maintenance schedule
Bolted connections and tightening torques
Cooling system
Oil change
Marking of compressor
Unit accessories
CTL4_Instruction Manual
Customer Training
Page 12
Chapter 8: Preventive Maintenance
CTL4_Instruction Manual
Customer Training
Page 13
Chapter 8: Preventive Maintenance
Crank gear
Bearings
Crankshaft seal
Connecting rod
Crosshead and crosshead bore
Crosshead - piston rod connection
Oil scrapers & guide bearing
CTL4_Instruction Manual
Customer Training
Page 14
Chapter 8: Preventive Maintenance
Piston rod packing
• trouble shooting advises
Piston and Cylinder
• clearance tables
• adjustment procedures
• tightening procedures
• SUPERBOLT®
Valves
CTL4_Instruction Manual
Customer Training
Page 15
Chapter 9:
Dismantle and Assemble Compressor Components
Prerequisites
• Lock out and tag out
• Depressurize and purge plant
Cross-reference to activities
• Such as maintenance on valve actuator, valves, piston rod gland, oil
pump
• Such as dismantle of piston, connection rod, flywheel
CTL4_Instruction Manual
Customer Training
Page 16
Chapter 10:
Clean and Degrease Plant and Compressor Components
Cleaning instruction
• Handling and Storage
• Responsibility
Working Environment
• Workplace
• Select cleansing agent
• Cleaning Methods
• Preserve Cleanliness
CTL4_Instruction Manual
Customer Training
Page 17
Chapter 11: Decommissioning or Dispose Plant
• Preserve Compressor Plant
• Maintain Plant during Decommissioning
• Dispose Components
CTL4_Instruction Manual
Customer Training
Page 18
Chapter 12: Spare Parts and Customer Support
• Order description
• Address
• Spare parts list & drawings
CTL4_Instruction Manual
Customer Training
Page 19
Chapter 13: Appendix
• P&ID Diagram
• Technical Data
• Control Description
• General Arrangement
• Foundation
• Drive system
• Lubrication system
• Instrumentation
• Compressor
CTL4_Instruction Manual
Customer Training
Page 20
Chapter 14: Index
Alphabetic order
CTL4_Instruction Manual
Customer Training
Page 21
Manual Exercise
Where can you find compressor gas data
Where can you find P&I Diagram for Gas & Coolant
Flange face alignment
Log sheet
Markings on compressor
Checklist for reporting of maintenance activities
Crank gear lubricating oil specification
Required oil quantity
Values for piston clearance
CTL4_Instruction Manual
Customer Training
Page 22
Manual Exercise
Values for piston dead clearance
Gland ring clearance (new rings)
Fitting of oil scraper rings
Checking of main bearing clearance
Permitted value of crankshaft deflection
Spare parts code no. of set of Oil scrapers
CTL4_Instruction Manual
Customer Training
Page 23