Page 1 ARIEL Heavy Duty Balanced Opposed Compressors TECHNICAL MANUAL For Models: JGW, JGR and JGJ ARIEL CORPORATION 35 BLACKJACK ROAD, MOUNT VERNON, OHIO 43050 TELEPHONE: 740-397-0311 FAX: 740-397-3856 VISIT OUR WEB SITE: www.arielcorp.com REV: 1/01 EMAIL: info@arielcorp.com...
Page 2 AND PRACTICES. THIS MANUAL MAY NOT BE APPLICABLE TO EQUIPMENT BUILT PRIOR TO THE DATE ON FRONT COVER AND IS SUBJECT TO CHANGE WITHOUT NOTICE. CONTACT ARIEL WITH ANY QUESTIONS (REFER TO “Ariel Telephone and Fax Numbers” on page 7-9).
Page 3: Table Of Contents
Piston Ring and Packing Ring Side Clearance, Inches (mm) ....... 1 - 10 Fastener Tightening Torque ................1 - 15 Tightening Torque Procedures..............1 - 19 Ariel Bolting ......................1 - 21 Optional Main Bearing Temperature Instrumentation - Alarm & Shutdown..1 - 23 Amot 4103 Temperature Valve ..............1 - 23 Electrical Instrumentation Setting..............
Page 4 : JGW, JGR ODELS ABLE ONTENTS Compressor Frame Lubricants ................4 - 4 Cylinder And Packing Lubrication Requirements..........4 - 5 Force Feed Lubrication System - Description............. 4 - 11 Force Feed Lubricator Adjustment ..............4 - 11 Blow-Out Fittings and Rupture Disks............. 4 - 12 Divider Valves .....................
Page 5 : JGW,JGR ODELS ABLE ONTENTS Chain and Sprocket Replacement ..............5 - 14 Eccentric Vernier - Chain Idler Sprocket Replacement (Self-Align Sprocket) 5 - 14 Lube Oil Pump Chain Sprocket Replacement..........5 - 15 Force Feed Lubricator Chain Sprocket Replacement ........5 - 16 Piston and Rod - Removal..................
Page 6 Other Abbreviations ....................7 - 5 Gas Analysis Common Abbreviations..............7 - 7 Technical and Service Schools on Ariel Compressors ......... 7 - 8 Ariel Customer Technical Bulletins (Formerly Ariel Newsletters)......7 - 8 Ariel Telephone and Fax Numbers ............... 7 - 9...
Page 7: General
While Ariel compressors share many similarities, each model has aspects that are unique to the particular type. If you as an operator are familiar with Ariel compressors, it is still impor- tant to review this manual to determine the differences. If you are new to Ariel compressors it is critical that you become very familiar with this manual prior to operating the compressor.
Page 8 : JGW, JGR 1 - D & D ODELS ECTION ESIGN PECIFICATIONS Specifications 1-2: A IGURE UXILIARY 1-1: JGW/JGR F ABLE RAME PECIFICATIONS MODEL JGW/2 JGW/4 JGR/2 JGR/4 Stroke, inches (mm) 4-1/4 (108) 4-1/4 (108) 4-1/4 (108) 4-1/4 (108) Speed, RPM 600 to 1200 600 to 1200 600 to 1200...
Page 9 : JGW, JGR 1 - D & D ODELS ECTION ESIGN PECIFICATIONS 1-2: JGJ F ABLE RAME PECIFICATIONS MODEL JGJ/2 JGJ/4 JGJ/6 Stroke, inches (mm) 3-1/2 (88.9) 3-1/2 (88.9) 3-1/2 (88.9) Speed, RPM 900 to 1800 900 to 1800 900 to 1800 Piston Speed, FPM (m/s) To 1050 (5.33) To 1050 (5.33)
Page 10: Product Information And Safety Plates
ARIEL LOGO NAME PLATE AND ADDRESS Information plate: Model, Frame serial number, Stroke, Maximum and minimum speed, Maximum rod load, Ariel ship- ping date, Normal lube oil pressure, Low oil pressure shutdown and Maximum lube oil temperature. IMPORTANT SAFETY INFOR-...
Page 11: Important Safety Information
COMPLETELY VENTED BEFORE LOOSENING BOLTS ON FLANGES, HEADS, VALVE CAPS, OR PACKING. CONSULT ARIEL TECHNICAL MANUAL BEFORE PERFORMING ANY MAINTENANCE. CAUTION SEVERE PERSONAL INJURY AND PROPERTY DAMAGE WILL RESULT IF SUCTION AND DISCHARGE VALVES ARE NOT INSTALLED IN THEIR PROPER LOCATION.
Page 12 The Force Feed Lubricator provides oil to the piston rod packing and the compressor pis- tons. The Lubricator Plate gives directions for adjusting the flow of oil. If this plate is missing, please contact Ariel Corporation, Mount Vernon, Ohio for a replacement or directions. NOTE: THE FORCE FEED LUBRICATOR BOX CONTAINS APPROXIMATELY 1/3 GAL- LONS (1 L) OF LUBRICANT.
Page 13 YPICAL Cylinder Identification Plates appear on each cylinder. The serial number is also stamped on the end of each cylinder. If any plate is missing, please contact Ariel Corporation, Mount Vernon, Ohio for a replacement or specific directions. NOTE: USE THE CYLINDER AND FRAME SERIAL NUMBERS IN ALL CORRESPON- DENCE.
Page 14 : JGW, JGR 1 - D & D ODELS ECTION ESIGN PECIFICATIONS CYLINDER IDENTIFICATION PLATE: Nominal Bore Diameter Inches Class Stroke Inches Rated Revolutions per Minute Maximum Allowable Working Pressure (Max- imum Relief Valve Set- Crank End ting PSIG - Pounds per Square Inch Gauge) Piston End Clearance Inches:...
Page 15: Clearances
If the feeler can be inserted more than 0.5 inches (13 mm), the assembly is not acceptable. b. If piston end clearance is not within table tolerance, crank end + head end, contact Packager or Ariel. NOTE: MEASURED CLEARANCES WILL NOT NECESSARILY AGREE BECAUSE OF OIL FILMS, ASSEMBLY TOLERANCES, WEAR, ETC.
Page 16: Piston Ring And Packing Ring Side Clearance, Inches (Mm)
: JGW, JGR 1 - D & D ODELS ECTION ESIGN PECIFICATIONS Piston Ring and Packing Ring Side Clearance, Inches (mm) The standard side clearance in inches (mm) for JGW, JGR and JGJ compressor piston rings and packing rings when new are as follows: 1-4: N (mm) ABLE...
Page 17 : JGW, JGR 1 - D & D ODELS ECTION ESIGN PECIFICATIONS 1-7: P ABLE ISTON TO LEARANCE AND ONVENTIONAL ISTON (mm) - W & R C NCHES LASS YLINDERS PISTON RING END GAP BORE PISTON TO BORE CLEARANCE DIAMETER MAXIMUM 1.75 (44) Uses Wearbands, see Table 1-9 on page 1-13 and Table 1-10 on page 1-14...
Page 18 : JGW, JGR 1 - D & D ODELS ECTION ESIGN PECIFICATIONS 1-8: P (mm) - ABLE ISTON TO LEARANCE AND ISTON IDER NCHES W, R & J C LASS YLINDERS PISTON RING END GAP BORE PISTON TO BORE CLEARANCE DIAMETER MAXIMUM 1.75 (44)
Page 19 : JGW, JGR 1 - D & D ODELS ECTION ESIGN PECIFICATIONS 1-9: P ABLE ISTON TO LEARANCE ISTON AP AND AP AND - RJ HJ C ADIAL ROJECTION NCHES LASS YLINDERS WEAR BANDS - NEW PISTON RING END GAP BORE PISTON TO BORE END GAP...
Page 20 : JGW, JGR 1 - D & D ODELS ECTION ESIGN PECIFICATIONS 1-10: P ABLE ISTON TO LEARANCE ISTON AP AND , (mm) I - RJ HJ C ADIAL ROJECTION NCHES LASS YLINDERS BORE WEAR BANDS - NEW PISTON RING END GAP DIAMETER PISTON TO BORE END GAP...
Page 21: Fastener Tightening Torque
Fastener Tightening Torque Listed in the following tables are fastener tightening torque values required for proper assembly of Ariel JGW, JGR and JGJ compressors. Refer to the section concerning a sub- ject component for detailed assembly procedures. Threads must be clean and free of burrs.
Page 22 : JGW, JGR 1 - D & D ODELS ECTION ESIGN PECIFICATIONS 1-11: F ABLE ASTENER IGHTENING ALUES NOMINAL SIZE, TORQUE, FASTENER TYPE INCH - TPI LB X FT (N·m) Valve Cap/Cylinder Head/Unloader/Gas Passage 3/8 - 16 Hex - Grade 8 or 9 or 193 lb x in.
Page 23 : JGW, JGR 1 - D & D ODELS ECTION ESIGN PECIFICATIONS STUD 1-8: D IGURE OINT TUDS 1/01 PAGE 1 - 17...
Page 24 : JGW, JGR 1 - D & D ODELS ECTION ESIGN PECIFICATIONS 1-12: H ABLE OERBIGER ALVE SSEMBLY ASTENERS IGHTENING ALUES NOMINAL SIZE TORQUE, FASTENER TYPE INCH - TPI LB X FT (N·m) 5/16 - 24 12 Point - Steel Grade 26 (35) Center Cap Screw 3/8 - 24...
Page 25: Tightening Torque Procedures
: JGW, JGR 1 - D & D ODELS ECTION ESIGN PECIFICATIONS Discharge Seat Suction Guard Bottom Views 1-9: S IGURE PIRALOCK HREADED ALVE SSEMBLY ARKED TOP - LOCKING BOTTOM HALF 1-10: D IGURE RAKE Tightening Torque Procedures Listed below are some procedures which make fastener tightening more accurate and will help ensure that the proper torque is being applied.
Page 26 : JGW, JGR 1 - D & D ODELS ECTION ESIGN PECIFICATIONS Always apply a steady slow force to a torque wrench, do not jerk it. When a torque wrench is jerked the amount of torque applied can be as much as one and a half times the amount set on the wrench.
Page 27: Ariel Bolting
Bolts have been selected that meet Ariel's strength, elongation, sealing and locking require- ments. Proper bolting must be used and tightened to the values listed in Table 1-11 on page 1-15. Figure 1-13: is provided to assist in the identification of bolts used in an Ariel compres- sor.
Page 28 : JGW, JGR 1 - D & D ODELS ECTION ESIGN PECIFICATIONS Hex head Grade 5 Hex head Grade 8 Hex head Grade 9 Hex Socket Head Grade 8 12 Point Grade 8 12 Point Grade B7M (NACE) 12 Point Interim Grade 5 12 Point Grade 5 12 Point Stainless Steel Grade B8M...
Page 29: Optional Main Bearing Temperature Instrumentation - Alarm & Shutdown
: JGW, JGR 1 - D & D ODELS ECTION ESIGN PECIFICATIONS Optional Main Bearing Temperature Instrumentation - Alarm & Shutdown Amot 4103 Temperature Valve This eutectic alloy device is selected to melt at 228°F (109°C) to vent control pressure and to provide a shutdown signal.
Page 30 : JGW, JGR 1 - D & D ODELS ECTION ESIGN PECIFICATIONS NOTES PAGE 1 - 24 1/01...
Page 31: Installation
This amount of deflection, which does not include the weight of the pulsation bottles or piping, is shown in the Ariel Application Data Book. Shims equaling the deflection value as listed on the cylinder outline drawing are to be added to the shim pack under the crosshead guide, elevating the crosshead guide to a level position.
Page 32: Setting
• Excessive wear to the bearings • And if severe, probable damage to various components • An Ariel compressor may be aligned by any of a number of acceptable methods such as: Face/peripheral • Reverse indicator • Across the disc pack •...
Page 33: Vents And Drains
: JGW, JGR 2 - I ODELS ECTION NSTALLATION When properly aligned, the forces on the connected equipment will be at a minimum. This will result in long bearing life and a smooth running unit. Consult Packager’s information for alignment requirements. Vents and Drains It is critical, for the safe operation of the compressor, to ensure that all vents and drains are open, functional and, if necessary, tubed off of the skid or out of the building.
Page 34 : JGW, JGR 2 - I ODELS ECTION NSTALLATION NOTES PAGE 2 - 4 1/01...
Page 35: Start Up
: JGW, JGR ODELS 3 - S ECTION TART General To ensure proper start up, it is important to carefully follow the Start Up Check List provided in this section. It is also important that the operator be thoroughly familiar with this manual and with the Packager’s Operating Manual.
Page 36: Start-Up Check List
Frame Oil - Make/Grade______________________ ________________________ Cylinder Oil - Make/Grade ______________________ Check List - Prior To Starting 1. Are the correct Ariel parts book, technical manual, special tools, and spares available? ______ ______ 2. Have the design limitations for the compressor model such as...
Page 37 : JGW, JGR 3 - S ODELS ECTION TART Compressor Model ______________________ Serial No. F-______________________ 12. Have piston end clearances been checked with feeler gauges? _____ _____ Record below: Throw #1 HE_______ _______ _______ _______ _______ _______ CE_______ _______ _______ _______ _______ _______ 13.
Page 38 : JGW, JGR 3 - S ODELS ECTION TART Compressor Model ______________________ Serial No. F-______________________ 36. Are the gas discharge temperature shutdowns installed, set and working? ______ ______ 37. Have the gas suction lines been blown out to remove water, slag, dirt, etc.? ______ ______ 38.
Page 39 ______ 16. Has a copy of this completed “Start-up Checklist” been mailed to Ariel at Ariel Corporation, 35 Blackjack Road, Mount Vernon, OH 43050, USA, Attention: Administrative Assistant - Sales or faxed to Ariel at 740-397-3856, Attention: Administrative Assistant - Sales? ______...
Page 40: Maximum Allowable Working Pressure
All Ariel Compressor Cylinders have a "Maximum Allowable Working Pressure (MAWP)." The MAWP, the hydrostatic test pressure, and the test date are stamped on the end of every Ariel Cylinder (see Figure 1-6: on page 1-7). CAUTION OPERATING CONDITIONS MUST NOT EXCEED CYLINDER DESIGN LIMITATIONS.
Page 41: Relief Valve Settings
SURE OF THE CYLINDER WHICH HAS THE LOWEST MAWP OF THOSE IN THE BYPASS CIRCUIT. THIS IS TO PROTECT AGAINST DISCHARGE-CHECK VALVE FAILURE WHEN OPERATING ON BYPASS. (SEE ARIEL PACKAGER’S STAN- DARDS, SECTION 4.4 “RELIEF VALVES”). 1/01 PAGE 3 - 7...
Page 42: Filling Sump & Priming A Main Oil Lube Oil System - Before Starting
Ariel Lube Specifications to match the gas operation conditions as supplied to Ariel with the compressor order. The lube sheets supplied in the Ariel Parts Book state gas conditions and list the base rate multiplier at each lube point.
Page 43: Compressor Re-Application
(see Figure 1-5: on page 1-6). When compressor location or operating conditions change, the lubrication rates should be changed according to the Ariel Lube Specifications shown in Table 4-1 on page 4-8. When two or more force-feed lubricator pumps are manifolded into one distribution block, the following procedure is recommended to adjust pump rates: Start with each pump adjusted to full open.
Page 44 : JGW, JGR 3 - S ODELS ECTION TART NOTES: PAGE 3 - 10 1/01...
Page 45: Lubrication And Venting
Oil heat rejection data for each frame are shown in the Ariel Data Book in the Frame Details section (contact your Packager or Ariel when you need this information). The cooler should be mounted as close to the compressor as possible, with piping of adequate size to mini- mize pressure drop of both the lubricating oil and the cooling medium.
Page 46: Cold Starting
: JGW, JGR 4 - L ODELS ECTION UBRICATION AND ENTING Cold Starting If a compressor is exposed to cold ambient temperatures, the oil system must be designed so the unit may be safely started with adequate oil flow to the main bearings. Temperature controlled cooler by-pass valves, oil heaters, cooler louvers and even buildings may be needed to ensure successful operation.
Page 47: Animal Fats
: JGW, JGR 4 - L ODELS ECTION UBRICATION AND ENTING enhance oil film strength to counter the affects of water, wet gases, solvents, etc. present in the gas. Animal Fats Generally acidless tallow used as a compounding additive to petroleum lubricants to improve “slipperiness”...
Page 48: Compressor Frame Lubricants
Not recommended for air compressors. Compressor Frame Lubricants Ariel recommends, for use in the compressor frame, a good quality mineral oil which pro- vides proper lubrication and heat removal, as well as oxidation inhibition, rust and corrosion inhibition, and anti-wear properties.
Page 49: Cylinder And Packing Lubrication Requirements
: JGW, JGR 4 - L ODELS ECTION UBRICATION AND ENTING Oil sampling should be performed on a regular basis to verify suitability of oil for continued service. Degradation to the next lower viscosity grade below the original viscosity or an increase in viscosity to the next higher grade requires a complete oil change.
Page 50 Ariel Lube Specifications to match the gas operation conditions as supplied to Ariel with the compressor order. The lube sheets supplied in the Ariel Parts Book state gas conditions and list the base rate multiplier at each lube point. If gas conditions were not supplied, the rates are for clean, dry, 0.65 specific gravity, sweet gas at rated speed and dis-...
Page 51 “normal” required lube rate for the break in period (set as close as possible to twice the “nor- mal” rate for 200 hours). Please contact Ariel for assistance if the existing pump is not capa- ble of the minimum flow rate required.
Page 52 : JGW, JGR 4 - L ODELS ECTION UBRICATION AND ENTING 4-1: C ABLE YLINDER ACKING ECOMMENDATIONS FOR ARIOUS TREAM OMPONENTS CYLINDER DISCHARGE PRESSURE 2000 to 3500 3500 to 5000 1000 to 2000 GAS STREAM > 5000 psig < 1000 psig psig psig psig...
Page 53 SAE 60 wt. Cylinder Oil (Bone Dry - ISO 150 ISO 150 - 220 ISO 220 ISO 320 ISO 460 - 680 Contact Ariel) Base Rate Base Rate Base Rate Base Rate Base Rate or Various or Various or Various...
Page 54 = CYCLE TIME SEC RUNNING LUBE PLATE RUNNING REFERENCE THE LUBRICATION SHEETS IN THE ARIEL “PARTS BOOK” FOR THE CYCLE TIME (SECONDS) VS. RPM (COMPRESSOR SPEED) TABLE AT VARIOUS RUNNING SPEEDS FOR YOUR UNIT, AT THE STATED GAS OPERATING CONDITIONS AND LUBRICANT.
Page 55: Force Feed Lubrication System - Description
: JGW, JGR 4 - L ODELS ECTION UBRICATION AND ENTING Force Feed Lubrication System - Description The force feed lubrication system provides oil to the compressor cylinders and the piston rod packings. Refer to Figure 4-7: on page 4-17. All cylinders have both top and bottom lubrication injection points available as an order option, except for the T class and cylinders in the larger sizes, where “both top and bottom”...
Page 56: Blow-Out Fittings And Rupture Disks
THE LUBRICATOR OIL FLOW. Blow-Out Fittings and Rupture Disks 4-2: B ABLE ITTING SSEMBLIES AND EPLACEMENT UPTURE ISKS REPLACEMENT RUPTURE DISK BLOW-OUT FITTING ASSEMBLY THICKNESS SUPPLIER ARIEL P/N COLOR RATED RATED ARIEL P/N INCHES Lincoln A-0080 3250 22.4 A-0124 Purple 0.0225 0.57...
Page 57: Divider Valves
: JGW, JGR 4 - L ODELS ECTION UBRICATION AND ENTING Divider Valves 4-3: D IGURE IVIDER ALVE ISTRIBUTION LOCK YPICAL NOTE: REFER TO PARTS BOOK FOR THE FRAME BEING SERVICED FOR ASSEM- BLY DRAWINGS, PARTS LIST AND REPAIR KITS THAT ARE AVAILABLE FOR DIVIDER VALVES.
Page 58: Description
(LED) cycle indicator to provide a positive visual indication of system operation. The Ariel DNFT includes a proximity switch. The standard DNFT is factory set for (3) three minutes from no-flow to alarm/shutdown signal and is not adjustable.
Page 59: Assembly Instructions For Divider Valves
: JGW, JGR 4 - L ODELS ECTION UBRICATION AND ENTING DNFT. Retain for partial credit return. Disassemble the magnetic housing from the switch body by loosening the (2) 1/4”-20 set screws on a new DNFT. Be sure magnet pin and spring are intact and working in the magnetic housing assembly.
Page 60 : JGW, JGR 4 - L ODELS ECTION UBRICATION AND ENTING Lubricant flow shifts piston 1 from right to left dispensing piston lube through connecting passages to outlet 1. Piston 1 shift directs flow against right side of piston 2. (See Figure 4- 5: illustration 2) Lubricant flow shifts piston 2 from right to left dispensing lube through valve ports of piston 1 and through outlet 2.
Page 61 : JGW, JGR 4 - L ODELS ECTION UBRICATION AND ENTING To Check Valve To Lube Point 4-6: O IGURE ITTING Pressure Gauge To Other Cylinders DNFT-Digital No-Flow and Packings Timer Shutdown Switch Divider Valves Distribution Block Single Ball Check Valve Sintered Bronze Filter...
Page 62: Force Feed Lubrication System And Running Conditions
1/8 inch plug on the discharge end of the lubricator pump. Priming the force feed lubrication system requires the use of a priming pump (G-7162); refer to “Ariel Optional Tools” on page 5-1.
Page 63: Force Feed Balance Valves
: JGW, JGR 4 - L ODELS ECTION UBRICATION AND ENTING In some applications, cross-porting of divider valves is used to deliver the proper proportion of lubricant to a given point. Supply Tank NOTE: The system must be designed to provide posi- tive pressure to the force feed lubricator pump.
Page 64: Setting And Maintaining Balance Valves
: JGW, JGR 4 - L ODELS ECTION UBRICATION AND ENTING Valve Cap Lock Nut 4-9: F IGURE ORCE ALANCE ALVE Setting and Maintaining Balance Valves Balance valves cannot be set prior to operating the unit. Ensure that all fittings are tight and any known leaks have been fixed.
Page 65: Checking/Adjusting Balance Valves On Subsequent Start-Up
If back-pressure on an unused balance valve is high enough, it may eventually begin to leak oil. In this case, replace the balance valve internal assembly with a plug assembly, Ariel Part Number A-10330. DO NOT RUN UNIT WITH LEAKY BALANCE VALVES. A valve seal repair kit, Ariel Part Number A-8005-K, is available.
Page 66 : JGW, JGR 4 - L ODELS ECTION UBRICATION AND ENTING From the filter, oil travels to an oil gallery cast in the crankcase and running the length of the crankcase. Drilled holes from the gallery thru the bearing saddles deliver oil to the crankshaft bearings. Passages drilled diagonally thru the crankshaft from the crank journals to the crank pins deliver oil to the connecting rod bearings.
Page 67 Lube Oil Pump Lube Oil Oil Tubing From Frame Strainer Gallery to Top and Bot- tom of Guide to Lubri- cate Crosshead Piping By Ariel Check Valve Filter Inlet Hand - Priming Pump Lube Oil Inlet to Cast-In Oil Gallery. Oil...
Page 68: Lube Oil Strainer, Filter & Filter Installation Instructions
Lube Oil Filter Ariel recommends replacing filter element when differential pressure reaches approximately 10 PSI (70 kPa) across the filter at normal operating temperatures or at six month intervals. Filter Element Installation Instructions Clean filter base surface, and be certain old gasket is removed.
Page 69: Lube Oil Pump & Lube Oil Pressure
The low oil pressure shutdown is normally mounted by the packager and is supplied to cus- tomer specifications. Ariel provides an oil pressure pickup fitting on the oil gallery located after the cooler and filter. The electric or pneumatic oil pressure switch is to be set to actuate when oil pressure falls below 35 PSIG (240 kPa).
Page 70 : JGW, JGR 4 - L ODELS ECTION UBRICATION AND ENTING DO NOT ATTEMPT TO ADD OIL TO THE CRANKCASE THROUGH THE BREATHER HOLE WHILE THE UNIT IS RUNNING. THIS WILL CAUSE OIL FOAMING AND UNNECESSARY NO FLOW SHUTDOWNS IN THE FORCE FEED LUBRICATION SYSTEM.
Page 71 : JGW, JGR 4 - L ODELS ECTION UBRICATION AND ENTING Eye Bolt Packing Lubrication (From Distribution Block) Secondary Vent Crosshead Guide Vented Space Packing Aluminum Gasket Piston Primary Vent O-Ring Seal Oil and Gas Drain Tube This Drain Off of Skid Primary Vent, Tube Off of or Out of the Building Skid or Out of the Building...
Page 72 : JGW, JGR 4 - L ODELS ECTION UBRICATION AND ENTING O-Ring Seal Packing Lubrication Seal Gasket Piston Rod Primary Vent/Drain Lubricating Gas and Oil Optional Purge Secondary Purge Gas Gas Connection Vent (Optional) Section A-A Section A-A 4-13: P IGURE ACKING UBRICATION...
Page 73: Maintenance
Contact your packager and/or Ariel Field Service for more information. To contact Ariel, refer to “Ariel Telephone and Fax Numbers” on page 7-9. 1/01...
Page 74: Connecting Rod - Removal
: JGW, JGR 5 - M ODELS ECTION AINTENANCE CAUTION TO PREVENT PERSONAL INJURY, ENSURE THAT COM- PRESSOR CRANKSHAFT CANNOT BE TURNED BY THE DRIVER OR COMPRESSOR CYLINDER GAS PRESSURE DURING MAINTENANCE: -- ON ENGINE-DRIVEN COMPRES- SORS, REMOVE THE CENTER COUPLING OR LOCK THE FLYWHEEL.
Page 75: Crank Pin Bearing & Connecting Rod Bushing Removal & Installation
: JGW, JGR 5 - M ODELS ECTION AINTENANCE AVOID PERSONAL INJURY. THE WEIGHT OF EACH CROSSHEAD IS LISTED IN THE BALANCE SHEET THAT COMES IN THE MANUAL WITH EACH COMPRESSOR.) Turn the crankshaft until the throw is at its highest point. Remove the top two connecting rod bolts and the rod bearing cap.
Page 76: Connecting Rod - Installation
: JGW, JGR 5 - M ODELS ECTION AINTENANCE should shift circumferentially during operation, oil can still travel to its inner surface and to the crosshead pin. However, during installation of a new bushing, no more than 1/3 of the oil passage hole in the rod should be covered by the bushing.
Page 77: Crosshead - Removal
: JGW, JGR 5 - M ODELS ECTION AINTENANCE Reinstall the spacer bars. All spacer bars are match-marked for proper location. They must be reinstalled in their original location. Tighten all spacer bar bolts to the value listed in Table 1-11 on page 1-15. Examine the removed top cover and side cover gaskets.
Page 78 : JGW, JGR 5 - M ODELS ECTION AINTENANCE CAUTION CROSSHEADS ARE HEAVY. CARE MUST BE TAKEN WHEN HANDLING TO AVOID PERSONAL INJURY. THE WEIGHT OF EACH CROSSHEAD IS LISTED IN THE BALANCE SHEET THAT COMES IN THE MANUAL WITH EACH COMPRESSOR. Remove crosshead guide side covers and cylinder head.
Page 79: Crosshead - Installation
: JGW, JGR 5 - M ODELS ECTION AINTENANCE Approximately 3 Tons (27 kN) Force Required Bushing Crosshead Inner Support Do Not Support Here 5-3: C IGURE ROSSHEAD USHING EPLACEMENT Crosshead - Installation NOTE: BE SURE CROSSHEADS ARE RETURNED TO THEIR ORIGINAL THROW LOCATION.
Page 80: Crankshaft - Removal
: JGW, JGR 5 - M ODELS ECTION AINTENANCE Crankshaft - Removal Sprocket Main Bearing Journals Oil Slinger Drive End Crank Pins Counterweights 5-4: C IGURE RANKSHAFT WITH LINGER AND PROCKET YPICAL Remove the coupling shim pack. Remove the coupling hub. (In order to remove the coupling hub it may be necessary to heat it.
Page 81 : JGW, JGR 5 - M ODELS ECTION AINTENANCE 5/8-11 UNC (Jack Nut) Turn this Nut to Jack Bearing Cap straight up. 7” (178 mm) Long Drill an 11/16” (17.5 mm) Hole 5/8-11 UNC Threaded Rod 16” (406 mm) Long 5/8-11 UNC Steel Bar Lock Nut...
Page 82: Crankshaft - Oil Slinger
: JGW, JGR 5 - M ODELS ECTION AINTENANCE or one of the throws and the other hand on the end of the shaft to keep the crankshaft level. Wear gloves to avoid being cut by the slinger and to achieve a good grip.
Page 83: Installation
: JGW, JGR 5 - M ODELS ECTION AINTENANCE touch the shaft with the drill. Mark the drill with tape so you do not drill through the sprocket and into the crankshaft face. The drilled hole will relieve most of the shrink, and a couple of good radial hits with a ham- mer and chisel will open the sprocket enough so it can be easily removed.
Page 84: Crankshaft - Installation
: JGW, JGR 5 - M ODELS ECTION AINTENANCE Crankshaft - Installation Move the connecting rods to their full outer position. While the crankshaft is being lowered very slowly into the crankcase (suspended by a crane with a nylon sling), one person should grasp the drive end and slowly maneuver the drive end and auxiliary end straight down into the crankcase, wearing clean gloves as during removal.
Page 85: Chain Adjustment
: JGW, JGR 5 - M ODELS ECTION AINTENANCE Replacement of any parts that can change the position of the drive sprocket on the crank- shaft (i.e. crankshaft, drive sprocket, thrust plates), and/or loss of the as built sprocket posi- tion of driven components, can require repositioning the lube oil pump and force feed lubricator sprockets.
Page 86: Chain And Sprocket Replacement
: JGW, JGR 5 - M ODELS ECTION AINTENANCE 5-2: C ABLE HAIN EFLECTION IMITS DEFLECTION LIMITS COMPRESSOR MODEL FORCE FEED LUBRICATOR TO IDLER, INCHES (mm) JGW, JGR & JGJ - 2 Throw 0.065 to 0.109 (1.65 to 2.77) JGW, JGR & JGJ - 4 Throw 0.068 to 0.114 (1.73 to 2.90) JGJ - 6 Throw 0.053 to 0.088 (1.35 to 2.24)
Page 87: Lube Oil Pump Chain Sprocket Replacement
: JGW, JGR 5 - M ODELS ECTION AINTENANCE Oil O-Ring Capscrew (2) Before Assembly Sprocket Stat-O-Seal Washer Locknut 5-8: E ) - T IGURE CCENTRIC ERNIER HAIN DLER PROCKET LIGNING PROCKET YPICAL Lube Oil Pump Chain Sprocket Replacement Refer to Figure 5-9:. Remove all piping from the pump.
Page 88: Force Feed Lubricator Chain Sprocket Replacement
: JGW, JGR 5 - M ODELS ECTION AINTENANCE 10. Re-install and adjust the chain according to the instructions in “Chain Adjust- ment” on page 5-13. 11. Reinstall all tubing to the pump. Gaskets Set Screws Woodruff No. 204 or Square Key Sprocket Pump Adapter...
Page 89 : JGW, JGR 5 - M ODELS ECTION AINTENANCE 11. Re-attach all tubing to the lubricator. Priming Pump Outlet to Stem Distribution Block 1/4-Inch Tubing Connection for a Locknut Priming Pump Lubricator Oil Fill Connection Sintered Bronze Filter Sprocket No. 204 Woodruff Setscrew Sight Glass...
Page 90: Piston And Rod - Removal
: JGW, JGR 5 - M ODELS ECTION AINTENANCE Piston and Rod - Removal CAUTION TO PREVENT PERSONAL INJURY, ENSURE THAT COMPRESSOR CRANKSHAFT CANNOT BE TURNED BY THE DRIVER OR COMPRES- SOR CYLINDER GAS PRESSURE DURING MAINTENANCE: -- ON ENGINE-DRIVEN COMPRESSORS, REMOVE THE CENTER COUPLING OR LOCK THE FLYWHEEL.
Page 91: Piston And Rod - Disassembly And Reassembly
Piston and Rod - Disassembly and Reassembly Disassembly The Piston and Rod Clamping Fixture shown in Figure 5-12: on page 5-20 will be useful for the piston and rod disassembly and reassembly operations. This fixture may be purchased from Ariel. 1/01 PAGE 5 - 19...
Page 92: Reassembly
: JGW, JGR 5 - M ODELS ECTION AINTENANCE Part Num- D-0961 Spanner bolts onto piston nut 5-12: P IGURE ISTON AND LAMPING IXTURE Clamp the piston and rod assembly in the special Clamping Fixture (D-0961), using the bushing for a 1-1/2” rod size (see Figure 5-12:). Tighten the four 12- point cap screws to prevent the rod from turning.
Page 93: Piston And Rod - Installation
: JGW, JGR 5 - M ODELS ECTION AINTENANCE Check piston rings and wear band (when used) to determine wear (see “Deter- mining Ring Wear:” on page 5-24 and “Determining Wear Band Wear:” on page 5-24). Replace piston rings and wear bands as required. Assemble the piston, rod, collar and nut by hand.
Page 94: Piston Rod Run Out
: JGW, JGR 5 - M ODELS ECTION AINTENANCE Piston Rod Run Out Check piston rod run out after installing a new unit, after relocating a unit or after any main- tenance that could affect rod run out. Verify that the crosshead guides are properly shimmed to level. Refer to “Procedure For Set- ting and Aligning”...
Page 95: Piston Rings
Seal-joint rings are available for double acting cylinders. Refer to Figure 5-13:. Seal-joint piston rings are directional and must be installed properly. To utilize the seal-joint rings in double acting cylinders, in place of angle cut rings, contact Ariel for new part numbers. Stamped Side Toward Pressure 5-13: S...
Page 96: Determining Ring Wear
AINTENANCE Determining Ring Wear: Ariel recommends replacing rings when the end gap has increased three times the new dimension. To measure the end gaps, insert the rings in the cylinders without pistons. (See Table 1-7 on page 1-11, Table 1-8 on page 1-12 or Table 1-9 on page 1-13 for new end gap dimensions.)
Page 97: Piston Rod Packing - Reassembly
10. Before reassembly be certain all parts are perfectly clean. Piston Rod Packing - Reassembly Be sure to refer to the pressure packing assembly in your parts book. Ariel sup- plies four parts books with each unit. Please contact your distributor if you do not have a parts book.
Page 98 : JGW, JGR 5 - M ODELS ECTION AINTENANCE Parts should be laid out on a work bench so that they can be installed progres- sively with each in its correct position and the rod rings with their proper faces toward the pressure.
Page 99: Types Of Piston Rod Packing Rings
: JGW, JGR 5 - M ODELS ECTION AINTENANCE Types of Piston Rod Packing Rings Type "P" Pressure Breaker This is a single ring. It is cut radially into three equal segments. Total end clearance for the ring is 0.030 to 0.036 inches (0.76 to 0.91 mm) for PEEK material and 0.015 to 0.021 inches (0.38 to 0.53 mm) for bronze and cast iron materials.
Page 100: Type "Btr" Single Acting Seal Set
: JGW, JGR 5 - M ODELS ECTION AINTENANCE Type "BTR" Single Acting Seal Set This set is made up of three rings. It seals in one direction only. The first ring (pressure side) is radially cut with an installed total end gap of 0.078 to 0.109 inches (1.98 to 2.77 mm) for Teflon material and 0.156 to 0.187 inches (3.96 to 4.75 mm) for bronze, Polyimide and PEEK materials.
Page 101: Type "Bd" Double Acting Seal Set
: JGW, JGR 5 - M ODELS ECTION AINTENANCE Type "BD" Double Acting Seal Set This set consists of two tangentially step cut rings. The rings are doweled so the tangential cuts are staggered from one ring to the other. The installed total end gap is 0.078 to 0.109 inches (1.98 to 2.77 mm) for Teflon material and 0.156 to 0.187 inches (3.96 to 4.75 mm) for bronze, Polyimide and PEEK materials.
Page 102: Type "3Rws" Oil Wiper Set
: JGW, JGR 5 - M ODELS ECTION AINTENANCE Type "3RWS" Oil Wiper Set This set uses three radial cut rings. They are doweled to provide a staggered arrangement. Their purpose is to keep crankcase oil out of the packing and cylinder. Assemble with the blank face towards the oil (crankcase) and the slotted side towards the pressure packing.
Page 103: Type "Al" Double Acting Seal Set
CTING Typical Arrangement of Piston Rod Packing Rings Ariel supplies JGW, JGR and JGJ packings in two pressure ranges. The general arrange- ment of the oil supply, seal ring and vent locations is shown below: The oil wiper rings and a seal ring set are carried on a separate diaphragm in the crosshead guide when a “two compartment distance piece”...
Page 104: Piston Rod Packing Ring Material
AINTENANCE Piston Rod Packing Ring Material In the past, bronze was the standard material for Ariel packing rings. Bronze, however, is unsatisfactory for sour gas service, (hydrogen sulfide in the gas). PEEK, cast iron and Teflon provide outstanding service with sour gas, and since they perform equally well with sweet gas, they are now the standard materials.
Page 105: Valves - Maintenance
AINTENANCE Valves - Maintenance Ariel uses valves manufactured by Hoerbiger Corporation. Before servicing any valve refer to the correct valve assembly drawing and parts list and Hoerbiger's literature in the Parts Book. On the valve assembly drawing you will notice that valves have different springing for different pressure levels.
Page 106: Bolt Tightening For Valve Caps
: JGW, JGR 5 - M ODELS ECTION AINTENANCE Valve Cap O-Ring 1/8” (3mm) Valve Cap Valve Retainer Plastic Thumb Screw Center Bolt or Stud Lock Guide Ring Guard Seat Discharge Valve Springs Suction Valve Plate Discharge Valve Plate Guard Seat “Steel”...
Page 107 : JGW, JGR 5 - M ODELS ECTION AINTENANCE high pressure applications, place a new, proper, soft metallic wire gasket on the retainer and install the valve cap. Be careful not to gouge the bore, distort or damage the wire gasket. Always use a new metallic wire gasket;...
Page 108: Vvcp - Variable Volume Clearance Pocket Head End Unloader
Disconnect the VVCP packing vent. Remove the VVCP from the cylinder using similar pro- cedures as when removing a cylinder head. The approximate weights of VVCP’s for han- dling purposes can be found in the Ariel Data Book. Disassembly Unsnap the thread protector bellows from the slot in the hand wheel. With the locking handle locked, remove locknut and hand wheel.
Page 109: Maintenance
Packager’s instructions regarding where to set the VVCP. Also reference the VVCP data sheet in the Ariel Technical Manual Parts Book. The VVCP piston ring is designed not to be gas tight, to allow a nearly balanced gas pres- sure for ease of VVCP adjustment with the cylinder pressurized.
Page 110 : JGW, JGR 5 - M ODELS ECTION AINTENANCE the VVCP can be adjusted when the cylinder is pressurized, but difficult to turn when the cyl- inder is vented. This problem is corrected by disassembling the VVCP and cleaning. To adjust the volume, loosen the stem locking handle, so that stem is free to turn. Turn the stem by use of the hand wheel on the outboard end of the shaft.
Page 111: Water-Cooled Compressor Rod Packing
All cylinders with water-cooled packing must be connected to a circulating water cooling sys- tem that will provide the required flow, pressure drop, inlet temperature and heat rejection, unless prior approval is obtained from Ariel to leave it unconnected. 1/01...
Page 112: Ethylene Glycol Contamination
A qualified chemical disposal service should be used. Cleaning Non-Lube Compressor Cylinder Components Complete non-lube cylinders ordered and shipped from Ariel are provided cleaned and pro- tected to non-lube service requirements. Internal parts shipped loose, contaminated internal surfaces and all repair parts are to be cleaned prior to installation, thus providing long life of non-lube compressors and extending life of rings.
Page 113 Use only a thin film of oil for the valve cap O-rings and bolt holes. Cleaned parts are to be assembled immediately to avoid contamination and corrosion. If cyl- inder is not to be put into immediate service, contact Ariel (see “Ariel Telephone and Fax Numbers” on page 7-9) for preservation instructions to ER-34.
Page 114 : JGW, JGR 5 - M ODELS ECTION AINTENANCE NOTES PAGE 5 - 42 1/01...
Page 115: Technical Assistance
First and foremost on the preventative maintenance list is the completion and compliance with the Ariel Corporation Packagers Standard and Compressor Start Up Check List. All items must be adhered to, both before and after start up.
Page 116: Monthly (In Addition To Daily Requirements)
: JGW, JGR 6 - T ODELS ECTION ECHNICAL SSISTANCE Check shutdown set points. Low oil pressure shutdown is 35 psi (240 kPa) minimum. 10. High temperature shutdown to be set within 25°F (14C) of actual operating tem- perature. 11. High-low pressure shutdowns set as close as practical. Consideration should be given to rod load capacity of machine.
Page 117: Every 2 Years Or 16,000 Hours (Plus Daily/Monthly/6 Months/Yearly)
(0.001m/m of cylinder diameter) out of round or tapered. NOTE: REBORING REMOVES NITRIDED SURFACE OF CYLINDER BORE. CONTACT ARIEL FOR RE-NITRIDING. Inspect piston ring end gap. Replace rings that are outside the maximum limit listed in Table 1-7, Table 1-8, Table 1-9 and Table 1-10.
Page 118: Every 6 Years Or 48,000 Hours
Replace DNFT. Trouble Shooting Minor problems can be expected during the routine operation of an Ariel compressor. These troubles are most often traced to liquid, dirt, improper adjustment or to operating personnel being unfamiliar with Ariel compressors. Difficulties of this type can usually be corrected by cleaning, proper adjustment, elimination of an adverse condition, replacement of a relatively minor part or proper training of the operating personnel.
Page 119 : JGW, JGR 6 - T ODELS ECTION ECHNICAL SSISTANCE Problem Possible Causes Excessive Packing Worn packing rings. Improper lube oil and or insufficient lube rate. Leakage Dirt in packing. Packing rings assembled incorrectly. Improper ring side or end gap clearance. Plugged packing vent system.
Page 120 : JGW, JGR 6 - T ODELS ECTION ECHNICAL SSISTANCE NOTES PAGE 6 - 6 1/01...
Page 121: Appendices
ECTION PPENDICES Ariel Tools Ariel Furnished Tools Ariel provides one tool box with each unit with tools included in the box as listed below (see Figure 7-1:). Peg Wrench for Round Crosshead Nuts 1" Diameter (A-0324) • Open End Wrench for Hex Crosshead Nuts 3" (C-0195) •...
Page 122: Minimum Hand Tools Required
PPENDICES Minimum Hand Tools Required The following hand tools are normally all that is required to work on Ariel JGW, JGR and JGJ compressors. These are in addition to the Ariel furnished and optional tools listed above. Please contact Ariel if you have any questions about tools for Ariel units.
Page 123: Terms, Abbreviations And Conversion To Si Metric
: JGW, JGR 7 - A ODELS ECTION PPENDICES Ratchet Extension Valve Tool Peg Wrench Support B-1240 A-0135 A-0324 A-0409 A-0626 Open End Wrench for Hex Piston Nut Spanner Crosshead A-0424 Nuts C-0195 7-1: A IGURE RIEL OOLS Terms, Abbreviations and Conversion to SI Metric Area or square inch x 0.00064516 = meter...
Page 124: Flow - Liquid
: JGW, JGR 7 - A ODELS ECTION PPENDICES Flow - Liquid GPM or US gallons per minute x 0.0630902 = liter/second, or L/s = dm GPM or US gallons per minute x 0.227125 = meter /hour, or m Force lbf or pound (force) x 4.44822 = Newton, or N Heat BTU or British Thermal Units x 1.05506 = kilojoule, or kJ...
Page 125: Speed
: JGW, JGR 7 - A ODELS ECTION PPENDICES bar x 100 000 = Pascal, or Pa Pa x 0.00001 = bar bar x 100 = kPa kPa x 0.01 = bar psi x 68.94757 = mbar or millibar mbar x 0.0145 = psi psi x 0.06894757 = bar bar x 14.5 = psi Speed...
Page 126 : JGW, JGR 7 - A ODELS ECTION PPENDICES CL. = Clearance CU = Cubic CYL = Cylinder = Centerline DNFT = Digital No-Flow Timer Switch ESNA = Registered Trade Mark of Elastic Stop Nut Division, Harvard Industries HE = Head End HEX = Hexagon MAWP = Maximum Allowable Working Pressure MAX.
Page 127: Gas Analysis Common Abbreviations
: JGW, JGR 7 - A ODELS ECTION PPENDICES Gas Analysis Common Abbreviations 7-1: G ABLE NALYSIS OMMON BBREVIATIONS COMPONENT NAME COMMON ABBREVIATION CHEMICAL FORMULA (SYNONYM) Methane Ethane C2H6 Propane C3H8 Iso-Butane (2-Methyl Propane) C4H10 N-Butane C4H10 Iso-Pentane (2-Methyl Butane) C5H12 N-Pentane C5H12...
Page 128: Technical And Service Schools On Ariel Compressors
Technical Manual for Packagers and End Users. Be sure to refer to this material before operating or servicing the equipment. A complete listing of these Bulletins is available at the Ariel Website, and copies may be obtained from the Packager or from Ariel.
Page 129: Ariel Telephone And Fax Numbers
: JGW, JGR 7 - A ODELS ECTION PPENDICES Ariel Telephone and Fax Numbers Switchboard 740-397-0311 Weekdays 8 am - 5 pm Eastern Time, except holidays General Fax 740-397-3856 Field Service 740-393-5052 Emergency from 5 pm - 8 am, weekends and holidays...
Page 130 : JGW, JGR 7 - A ODELS ECTION PPENDICES NOTES PAGE 7 - 10 1/01...
Page 131 Ariel Recommended Spares Page 1 of 4 ARIEL CORPORATION Recommended Spares Start-Up Wed Sep 15 17:42:16 EDT 2010 F28585 Project: Part Number Description Your Price Net Amount JGJ FRAME CLASS C-0159 GSKT,RET,27-1/2 X15-1/8X1/32 $0.0000 $0.00 B-0419 GSKT,RET,12-1/4 X 8-1/8X1/32 $0.0000 $0.00...
Page 132 Ariel Recommended Spares Page 2 of 4 ARIEL CORPORATION Recommended Spares Consumables Wed Sep 15 17:42:16 EDT 2010 F28585 Project: Part Number Description Your Price Net Amount JGJ FRAME CLASS C-0159 GSKT,RET,27-1/2 X15-1/8X1/32 $0.0000 $0.00 B-0419 GSKT,RET,12-1/4 X 8-1/8X1/32 $0.0000 $0.00...
Page 133 $0.0000 $0.00 Sub Total $0.00 Insurance Grand Total $0.00 All amounts are in US dollars and price is subject to change at any time. ARIEL CORPORATION, 35 BLACKJACK ROAD, MOUNT VERNON, OHIO 43050 USA PHONE: 740-397-0311 FAX: 740-397-3856 https://www.arielcorp.com/members/reports/cust/recspr/recspr_strup1.asp?ordnum=45671... 9/15/2010...
Page 134 Ariel Recommended Spares Page 4 of 4 Printed: Wed Sep 15 17:42:17 EDT 2010 © 2010 ARIEL CORPORATION https://www.arielcorp.com/members/reports/cust/recspr/recspr_strup1.asp?ordnum=45671... 9/15/2010...

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Ariel JGW Series Technical Manual

Design Specifications & Data

Installation

Start up

Lubrication and Venting

Maintenance

Technical Assistance

Appendices

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