Instruction manual

Piston compressor

L90 - L140 - L160 - L190

To Introduction
 Type Instruction manual

L90-L140-L160-L190 Piston Compressors

INTRODUCTION:
This Instructions Manual contains a brief technical description and important instructions
on commissioning, maintenance and servicing of the compressor.
We recommend to read this manual carefully in order to be able, in case of trouble, to
detect the cause quickly and care for remedy and, in case of repairs, to make provisions for
proper mounting acc. to the instructions.
This manual assumes a general technical knowledge of piston compressors and does not
claim to be complete. If repairs become necessary, only original HATLAPA spare parts
must be used in order to maintain the operational reliability and efficiency of the machine.
For identification and supply of spare parts, an order must contain the following
information:

1. Serial No. and type designation (see name plate).

2. Ident No. from the spare parts list.
3. Method of the required dispatch, as well as consignee and address for the invoice.
4. Name of the vessel (ex-name), Yard No., and Shipyard.

In order to receive spare parts with the least possible delay, get in touch direct with

Uetersener Maschinenfabrik GmbH & Co.

Tornescher Weg 5-7 · D-25436 Uetersen / Germany
D-2549 Uetersen / Germany
Phone: (+49) 4122 / 711- 0
Telex: 218510 htlu d
Cable: HATLAPA Uetersen
Fax: (+49) 4122 / 711 - 330
E-mail: info@hatlapa.de
Internet: http://www.hatlapa.de

or with our accredited agents, after-sales service stations or licensees/co-operators as per

attached list.
We wish to point out that repairs and/or modifications to the compressor which are carried
out without our approval during the guarantee period, will release us from our guarantee
obligations. The manufacturer cannot be rendered liable for damage to the compressor
which can be shown to have been caused by the use of unsuitable lubricants or failure to
comply with the operating instructions.
Reprint of the text or illustrations, or even extracts therefrom is prohibited.
Subject to alterations at all times due to technical development.

To Table of Contents

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TABLE OF CONTENTS:
Page:

Introduction ................................................................................................................2

1 Description ...............................................................................................................4
1.1 Design.....................................................................................................................4
1.2 Specifications..........................................................................................................5
1.3 Working method .....................................................................................................5
1.4 Cooling....................................................................................................................5
1.5 Lubrication of Working Parts ..................................................................................6
1.6 Condensate Separation ..........................................................................................6
1.7 Starting without Back-Pressure...............................................................................6

2 Setting-up and Installation......................................................................................7

3 Commissioning........................................................................................................8
3.1 Safety References ..................................................................................................8
3.2 Before Starting........................................................................................................9
3.3 After Starting...........................................................................................................9
3.4 During Operation ....................................................................................................9
3.5 After Stopping .........................................................................................................9

4 Servicing and Maintenance...................................................................................10

4.1 General Servicing Instructions ..............................................................................10
4.2 Servicing Schedule ...............................................................................................11
4.3 Overhaul of Valves ...............................................................................................13
4.4 Overhaul of Pistons and Cylinders........................................................................13
4.5 Overhaul of crankshaft and connecting rod ..........................................................14
4.6 Protection against Corrosion during prolonged Shut-Down ..................................15

5 Trouble Shooting ...................................................................................................16

6 Spare Parts.............................................................................................................17

7 Instructions for Correctly Ordering Spare Parts.................................................18

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1 Description

1.1 Design

Three-stage, single acting, air-cooled, 3-cylinder trunk piston machine with 60° W
cylinder arrangement.

The equalization of mass of the crank mechanism and the special arrangement of
the three cylinders together with the use of trunk pistons guarantee low vibrations
during operation. They enable a 3-point resilient mounting without any problems..

The large-dimensioned and force-feed lubricated slide bearings of the crankshaft

and connecting rods, make the machine insensitive to internal and external vibration
loading in both standstill and operating modes.

The use of trunk pistons at all stages guarantees low wear and safe lubrication with
high service life expectancy for pistons and cylinders.

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1.2 Specifications

Typ L90 L140 L160 L190

Number of Cylindersr 3 3 3 3
Cylinder Bore 1st Stage [mm] 155 155 185 185
Cylinder Bore 2nd Stage [mm] 85,5 85,5 110 110
Cylinder Bore 3rd Stage [mm] 48 48 60 60
Piston Stroke [mm] 72 96 78 92
Crankshaft-Axial Clearance [mm] 0,3- 0,3- 0,3- 0,3-
0,4 0,4 0,4 0,4
Quantity of Lub. Oil min. [l] 4 4 4 4
Quantity of Lub. Oil max. [l] 5,5 5,5 5,5 5,5
Weight without E-Motor [approx. kg] 450 450 450 450
Setting Oil pressure at warm Machine 4 4 4 4
[approx. bar]
Setting Oil Pressure Contol Switch 1 1 1 1
[approx. bar]

1.3 Working method

The compressor compresses the ambient air sucked in through the air-intake filter
with silencer in three stages to the selected final pressure. Combined concentric
ring plate valves with large flow cross-sections control automatically the gas
exchange in the compression chambers. After every stage the heated compressed
air flows through a large-dimension cooler. To monitor the correct functioning of the
compressor a pressure gauge and a thermometer are installed after each
compression stage. Safety valves, installed after every compression stage, prevent
the pressure from rising above the admissible limit.

1.4 Cooling

The heat generated in the machine by air compression and mechanical friction is led
off to the atmosphere. An axial-flow fan fixed on the face of the crankshaft sucks
cooling air through a combined light alloy honeycomb radiator at the 1st, 2nd and
3rd stages and forces this to the cylinders installed downstream.

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1.5 Lubrication of Working Parts

Only compressor oils according to the enclosed oil specification chart may be used.
Crankshaft and conn. rod bearings are force-feed lubricated by means of a
gearwheel oil pump driven directly by the crankshaft. This pump sucks the oil from
the crankcase through a sieve and forces it to the two main bearings of the
crankshaft, as well as to the conn. rod bearings. The lubrication oil pressure is
limited by a spring-loaded pressure limiting valve and is indicated by a pressure
gauge. The lub. oil pressure is monitored by a pressure switch, which switches off
the compressor in case of insufficient oil pressure.

1.6 Condensate Separation

Together with the moist ambient air which is sucked in, water enters the compressor
in form of vapour. By compression and subsequent cooling of the compressed air,
this water vapour condenses. The water separated from the compressed air blends
with the oil which is entrained in very small quantities from the lubricated working
surfaces of the cylinders. This water-oil mixture is extracted from the compressed-
air stream in special condensate collector chambers.

At regular intervals – after every 15 min. for about 10 sec. - as well as on starting
and stopping of the compressor, the collector chambers must be drained by opening
the manual valves or optionally by automatic devices. Such condensate separation
reduces wear and tear due to corrosion in the compressor components, and in the
connected pipelines and prevents the compressor from damage due to water
shocks. Disposal of the condensate has to be carried out according to the locally
valid prescriptions.

1.7 Starting without Back-Pressure

During starting-up, the driving motor must be unloaded by opening the drain valves.
In automatically controlled compressors, unloading is effected by time-lagged
closing of these valves.

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2 Setting-up and Installation

The compressor is driven by a directly-coupled electric motor through a flexible

coupling, the shaft centres of motor and compressor must lie in exactly the same
axis. Under no circumstances may the shaft centres be offset.

In case of resilient mounting there must be sufficient room for movement. All
pipelines must then be connected to the consumer system by flexible hoses, strictly
adhering to the installation instructions.

All drain pipelines are to be laid with constant descent and must discharge into an
open funnel after the shortest possible distance. Each compression stage needs a
separate drain pipeline in order to guarantee perfect drainage of the individual
stages; stop valves are to be installed as closely as possible to the compressor.

Further instructions on the installation of valves, pipelines, and control equipment

are to be taken from the enclosed piping diagrams with their respective descriptions.

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3 Commissioning

3.1 Safety References

The compressor has been produced according to the State-of-art and is

operationally reliable.
The compressors are a source of danger if inexpertly or improperly used.

• Only authorised and trained persons are allowed to operate and repair the
machine or to do maintenance work. Make sure that these persons have read
and understood the complete operating instructions and safety instructions.
• The compressor may only be used for compressing air.
• The compressor may not be operated without safety or protecting devices.
• Only sealed safety valves may be used, readjustment is not allowed. They
have to be replaced immediately when defective.
• Before starting any maintenance work it is necessary to stop the compressor
system and to prevent it from re-starting. The system has to be voltage–free,
all parts containing compressed air have to be depressurized.
• The compressor system may only be operated in perfect working condition. It
must be free of foreign parts.
• Rebuilding or any other changes to the compressor system that may
influence the safety are strictly prohibited.

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At initial commissioning, after a several months` interruption in operation, or

after extensive repair work the operator must observe the following points (see
also 4.6 Protection against corrosion during prolonged Shut-Down).

3.2 Before Starting

• The compressor must be filled to the upper oil level mark with prescribed
compressor oil (see list of recommended oils).
• Check that the crankshaft is moving easily by turning over the flywheel by
hand; but make sure that the compressor set cannot be started
unintentionally.
• Open the shut-off valve in the pipeline leading to the compressed-air receiver.
• Open drain valves.

3.3 After Starting

• Check the direction of rotation of the shaft (see also arrow).

• Watch the pressure gauge for rise in oil pressure.
• Close the drain valves and check for leakage.

3.4 During Operation

• Once the final pressure is attained, check the safety valves for proper
functioning: Slightly turn the knurled nut until the valve blows off. After
closure, check for leakage.
• Observe the compressed-air temperature at the thermometers.
• After fitting of new working parts (repair), run in the compressor for about one
hour at low final pressure (5 to 10 bar).

3.5 After Stopping

• Open the drain valves at the condensate separators.

• Check that the automatic drain valves open properly.
• Check the non-return valve in the pipe to the compressed-air receiver for
leakage.

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4 Servicing and Maintenance

For trouble-free operation, it is necessary to check regularly and carefully the

safety devices and the wear and tear parts of the compressor as well as the
functioning of fitted valves and instruments. Regularly check the stock of spare
parts and seals which must be protected against corrosion, and stock up to the
specified quantity again after any servicing and overhaul work.
The following maintenance and overhaul instructions must be adhered to.
However, they do not claim to be complete.
Observance of the servicing intervals as mentioned below guarantees great
reliability and long service life of the compressor.
In this connection, reference is made to the requirements of the rules of the
classification societies and seafarer unions.

4.1 General Servicing Instructions

a) Check the oil level daily. Fill the crankcase with the prescribed compressor oil,
however, not exceeding the top oil level mark. Too much oil results in foaming
due to immersion of rotating parts, with the compressor at extremely inclined
position. Intense misting of the oil and uncontrolled cylinder lubrication would
result in increased oil consumption and coking of the working valves.
b) Drain off the lub. oil at the prescribed intervals - when the compressor is still hot
from running - and fill in fresh compressor oil after having cleaned the oil sieve.
c) Regularly and carefully check the oil pressure as well as the air pressure of all
stages. Varying operating pressure values indicate anomalies in the lubricating
system and valves, as well as leaks in the piping system.
d) At regular intervals dismantle and strip down the combined suction and pressure
valves and clean all parts. Packing rings between valve and cylinder head must
be replaced in sets only. For details, see „4.3 Overhaul of Valves„.
e) Check the safety valves on the compressor by slightly turning the knurled nut at
short intervals.

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4.2 Servicing Schedule

After first commissioning, after a general overhaul, and after repairs to the crank
mechanism or cylinder, the following maintenance work should be done:

After 100 working hours

1.) Change the oil.

2.) Clean the oil suction sieve.
3.) Check the safety valves.
4.) Check the bolts and nuts on crankcase, cylinders, and pipelines for tightness
(See list of tightening torques).
5.) Check the drainage system.

After that the following intervals are to be kept:

After every 500 working hours:

1.) Check the safety valves

2.) Clean the air-intake filter
3.) Check the drainage system

After every 1000 working hours (however, at least once a year):

1.) Change the oil.

2.) Clean the oil suction sieve.
3.) Replace the oil filter cartridge
4.) Clean the combined air cooler, cooler pipes, cooling fins of cylinders and fan

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After every 1500 working hours:

1.) Clean the combined suction and pressure valves and check for wear.
2.) Check parts which come into direct contact with hot compressed air, such as
valves, cylinder heads and compressed-air pipelines for carbon residues and,
if necessary, clean them with solvents.

The admissible servicing intervals of the valves are determined above all by the
operating conditions and by the properties of the lubricant used. We recommend
to reduce the servicing intervals in case of severe operating conditions.

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4.3 Overhaul of Valves

The combined suction and pressure valves of the compressor require conscientious
care and maintenance. Their springs and plates are the most intensely stressed
parts of the compressor.
For cleaning, the concentric valves have to be dismantled by removal of the fitting
bolt. Soaking of the components in paraffin facilitates removal of coked deposits.
Care should be taken that the ground sealing surfaces, and valve plates are neither
scratched nor damaged. Springs and valve plates should be checked for damage
and wear and replaced, if necessary. For reassembly, adhere strictly to the assembly
diagram (parts list). Parts of different valves must not be mixed. Tighten the fitting
bolt with the prescribed torque. After reassembling check the soft running of the
valve plates against the spring pressure using a rounded pin. Valves or valve parts
must be clamped in a vice with smooth jaws only. When fitting the valves, use new
packing rings in sets and see that they are properly positioned.
Cylinder head nuts and bolts for pipes should first be tightend by hand. Then nuts
should be initially tightened cross-wise using a torque wrench at approx. 10 Nm
(1 kpm) and then tightened securely in the same sequence to the necessary torque.

4.4 Overhaul of Pistons and Cylinders

Pistons and cylinders can be removed for cleaning and checking of wear without
dismantling the connecting rod and crankshaft. All components must first be marked
so as to maintain pairings (assignment of pistons and cylinders) and the positioning
of the parts for reassembly.

To dismantle the pistons after pulling out the cylinders, firstly remove each of the
retainer rings of the wrist pins using a pair of circlip pliers, and then push the wrist
pin out of the piston with a set bolt or other suitable device.

Heating the piston to between approx. 60°C and 80°C facilitates insertion of the wrist
pin. Piston rings should be removed and inserted only using piston-ring pliers.
Observe that the piston rings are correctly positioned (see parts list) and stagger the
joints when fitting. On inclined cylinders, the oil scraper ring joint should point
upwards when fitted.

To measure clearance and wear, first of all, all parts must be cleaned and checked
for damage. The measurement of the cylinder diameter is carried out using a
precision internal gauge applied in the operational way of the piston rings.

The nominal diameter of the piston is stamped on top of the piston head. The actual
diameter should be checked at the bottom end of the piston stem, at right angles to
the wrist pin axis. For fitting clearances and wear limits refer to the attached list.

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To check the joint clearance, the piston rings should be inserted at a right angle into
the upper cylinder aperture and positioned at a location where the cylinder liner
shows no signs of wear. The joint clearance is measured using a feeler gauge.

Before fitting the pistons and cylinders, the seat-face on the crankcase and
underside of the cylinder must be carefully cleaned. Use new cylinder gaskets. Apply
oil to pistons and cylinders. Compress piston rings with a tensioning band and slip
the cylinders over the pistons by hand.
Parts, which have reached or exceeded their service life (see List of Wear Limits),
should be replaced.

4.5 Overhaul of crankshaft and connecting rod

Crankshaft and connecting rods move in force-feed lubricated slide bearings.

Connecting rods and bearing covers are identified by punched figures. Association
and location of the covers must not be changed. Mark the individual parts to
maintain correct positions during reassembly. After disassembly, clean all parts,
check all bearings and journals for wear and damage and measure the wear. Check
the axial and radial clearance by means of a precision gauge.

Refitting of the crankshaft

Clean the oil ducts and blow through compressed air. Thoroughly oil the bearings
and journals as well as the associated components before assembly. Insert the
crankshaft in the crankcase first without shaft seals and then screw on the housing
cover with its gasket. Check wether the axial clearance of the crankshaft is within
the admissible clearance. Fit the shaft seals and tighten the housing cover screws to
the prescribed torque. When fastening the flywheel and the fan wheel, secure the
crankshaft against rotation by inserting a rod from outside through the opening of
the flywheel housing into the flywheel bore.

Refitting of the connecting rods

Oil the crank pin and bolt threads.

Place the upper part of the connecting rod with bearing shell on the crank pin and
see that the shell is correctly positioned in the connecting rod.
Put the lower part of the connecting rod with bearing shell from the opposite side,
pass through the fitting bolts and screw them into the upper part of the connecting
rod.
After pretensioning of the two bolts to approx. 30 Nm use a torque wrench to tighten
to the prescribed torque.

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4.6 Protection against Corrosion during prolonged Shut-Down

Compressors must be stored in a dry room. In case of long storage a protection
of all inner components should be carried out according to the manual at least
every 8 months. Before first commissioning, the compressors must be checked
by a trained engineer for damage which may result from long storage. A report of
inspection must be sent to HATLAPA. Noticed damage during this check are not
covered by our guarantee. The date of commissioning or supply of the vessel to
owner must be advised to us.

Compressors which will be put out of operation for several months must be
protected against corrosion.

Internal protection:
• Open drain valves of 1st and 2nd stage under pressure.
• Run the compressor without pressure while the drain valves are open.
• Close the drain valves.
• Remove the air-intake filter-and pour about 250 cm³ of anti-corrosion oil into the
air-intake socket within approx. 2 minutes.
• Shut down the compressor and open the drain valves.

External protection:
• After cleaning, apply rust-preventive paint to all parts.
• Components made of light alloy, copper or brass need no treatment.
• Finned cylinders and cylinder heads should only be given an application of
aluminium bronce.

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5 Trouble Shooting
The following details are intended to provide a brief guide to determining the
cause of abnormal operation. We do not claim that this information is complete.
It only deals with the faults most frequently encountered, as known from
experience.

a) Oil pressure too low:

Too low oil level in the crankcase (oil pressure display fluctuating).
Clogged suction sieve.
Leaking oil pressure limiting valve (dirt).
Damaged bearing (in general together with knocking noise).

b) Intermediate pressure too low and / or compressed-air delivery too low:

Combined suction/pressure valve damaged or leaking.
Leaking piston rings
Leaking cooler or compressed-air delivery line.
Still open or leaking drain valves.

c) Intermediate pressure too high and / or compressed-air delivery too low:

Combined suction/pressure valve damaged or leaking.
Clogged cooler or compressed-air delivery line.

d) Safety valve blowing off although pressure is normal:

Defective safety valve.

e) Safety valve 1st stage / 2nd stage blowing off / Intermediate pressure too high
sea c)

f) Safety valve of final stage blowing off, final pressure too high :
Closed valve on compressed-air receiver.
Non-return valve does not open.
Defective pressure control switch (of the automatic system).

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6 Spare Parts

We recommend to keep some spare parts in stock in order to allow quick remedy
of minor failures due to the natural wear and tear.

1 set of valve plates and valve springs for each stage

1 set of piston rings incl. oil scraper ring for each stage
1 set of sealing rings and gaskets for each stage

If the compressor is intended for continuous operation, in addition stock:

1 combined suction and pressure valve for each stage
1 set of crankshaft bearings and connecting-rod bearings
1 piston with wrist pin and piston rings for each stage

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7 Instructions for Correctly Ordering Spare Parts

When ordering spare parts, the following details must be given:

1.) Serial No. and type designation (see name plate).
2.) Ident. No. from the spare parts list.
3.) Method of the required dispatch, as well as consignee and address for the
invoice.
4.) Name of the vessel (ex-name), Yard No., and Shipyard.

In order to receive spare parts with the least possible delay, get in touch direct
with

Uetersener Maschinenfabrik GmbH & Co.

Tornescher Weg 5-7 · D-25436 Uetersen / Germany
D-2549 Uetersen / Germany
Phone: (+49) 4122 / 711- 0
Telex: 218510 htlu d
Cable: HATLAPA Uetersen
Fax: (+49) 4122 / 711 - 330
E-mail: info@hatlapa.de
Internet: http://www.hatlapa.de

or with our accredited agents, after-sales service stations or licensees/co-

operators as per attached list.

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