Corken F291 Instruction manual

IE101H
Installation, Operation
& Maintenance Manual
Liquid Transfer-Vapor Recovery Compressors
Warning: (1) Periodic inspection and maintenance of Corken products is essential. (2) Inspection, maintenance and installation of Corken
products must be made only by experienced, trained and qualied personnel. (3) Maintenance, use and installation of Corken products
must comply with Corken instructions, applicable laws and safety standards (such as NFPA Pamphlet 58 for LP-Gas and ANSI K61.1-1972
for Anhydrous Ammonia). (4) Transfer of toxic, dangerous, ammable or explosive substances using Corken products is at user’s risk and
equipment should be operated only by qualied personnel according to applicable laws and safety standards.

Warning
Install, use and maintain this equipment according to Corken, Inc. instructions and all applicable federal, state, local
laws and codes, and NFPA Pamphlet 58 for LP-Gas or ANSI K61.1-1989 for Anhydrous Ammonia. Periodic inspection
and maintenance is essential.
Corken One Year Limited Warranty
Corken, Inc. warrants that its products will be free from defects in material and workmanship for a period of 12
months following date of purchase from Corken. Corken products which fail within the warranty period due to defects
in material or workmanship will be repaired or replaced at Corken’s option, when returned freight prepaid to Corken,
Inc., 3805 N.W. 36th Street, Oklahoma City, Oklahoma 73112.
Parts subject to wear or abuse, such as mechanical seals, blades, piston rings, valves, and packing, and other
parts showing signs of abuse are not covered by this limited warranty. Also, equipment, parts and accessories not
manufactured by Corken but furnished with Corken products are not covered by this limited warranty and purchaser
must look to the original manufacturer’s warranty, if any. This limited warranty is void if the Corken product has been
altered or repaired without the consent of Corken.
ALL IMPLIED WARRANTIES, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR A PARTICULAR PURPOSE, ARE EXPRESSLY NEGATED TO THE EXTENT PERMITTED BY LAW AND
SHALL IN NO EVENT EXTEND BEYOND THE EXPRESSED WARRANTY PERIOD.
Corken disclaims any liability for consequential damages due to breach of any written or implied warranty on Corken
products. Transfer of toxic, dangerous, flammable or explosive substances using Corken products is at the user’s
risk. Such substances should be handled by experienced, trained personnel in compliance with governmental and
industrial safety standards.
Contacting The Factory
For your convenience, the model number and serial number are given on the compressor nameplate. Space is
provided below for you to keep a written record of this information.
ALWAYS INCLUDE THE MODEL NUMBER AND SERIAL NUMBER WHEN ORDERING PARTS.
Model No.
Serial No.
Date Purchased
Date Installed
Purchased From
Installed By
IMPORTANT NOTE TO CUSTOMERS!
CORKEN, INC. does not recommend ordering parts from general descriptions in this manual. To minimize
the possibility of receiving incorrect parts for your machine, Corken strongly recommends you order parts
according to part numbers in the Corken Service Manual and/or Installation, Operation, & Maintenance
(IOM) Manual. If you do not have the appropriate service manual pages, call or write Corken with model
number and serial number from the nameplate on your compressor.
2

Table of Contents
CHAPTER1—INTRODUCTION ............................................................ PAGE 4
1.1 LiquidTransferbyVaporDifferentialPressure...................................................5
1.2 ResidualVaporRecovery ...................................................................5
1.3 CompressorConstructionFeatures...........................................................6
CHAPTER 2—INSTALLING YOUR CORKEN COMPRESSOR.................................... PAGE 8
2.1 Location.................................................................................8
2.2 Foundation...............................................................................8
2.3 Piping...................................................................................8
2.4 Liquid Traps .............................................................................10
2.5 DriverInstallation/Flywheels...............................................................12
2.6 CrankcaseLubrication ....................................................................12
2.7 ReliefValves ............................................................................12
2.8 TruckMountedCompressors...............................................................12
2.9 Shutdown/AlarmDevices ..................................................................13
CHAPTER 3—STARTING UP YOUR CORKEN COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 14
3.1 Inspection After Extended Storage...........................................................14
3.2FlywheelandV-beltAlignment..............................................................14
3.3 Crankcase Oil Pressure Adjustment ..........................................................14
3.4 Startup Checklist.........................................................................15
CHAPTER 4—ROUTINE MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 16
CHAPTER 5—ROUTINE SERVICE AND REPAIR PROCEDURES.................................PAGE 17
5.1 Valves .................................................................................17
5.2Head ..................................................................................19
5.3 Piston Rings and Piston Ring Expanders ......................................................19
5.4 Pistons.................................................................................19
5.5 PistonRodPackingAdjustment.............................................................20
5.6 CylinderandPackingReplacement..........................................................20
5.7 Bearing Replacement for Crankcase and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.7.1 Wrist Pin Bushing Replacement ........................................................22
5.7.2 Replacing Connecting Rod Bearings ....................................................22
5.7.3 Replacing Roller Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.8 OilPumpInspection ......................................................................23
5.9 ServicingtheFour-WayValve...............................................................24
CHAPTER 6—EXTENDED STORAGE PROCEDURES......................................... PAGE 25
APPENDICES
A. Repair Kits and Gasket Sets .............................................................26–27
B. ModelNumberandMountingIdentificationCode............................................28–29
C. Operating and Material Specifications, Bolt Torque Values, Clearance and Dimensions . . . . . . . . . . . . . . 30–35
D. Compressor Selection
Mounting Selections .................................................................36
Butane............................................................................37
Propane...........................................................................38
Ammonia ..........................................................................39
E. Outline Dimensions ....................................................................40–50
F. Troubleshooting..........................................................................51
G. Model91andF91PartsDetails ..........................................................52–59
H. Model291andF291PartsDetails ........................................................60–67
I. Model 490, 491, and F491 Parts Details ....................................................68–75
J. Model691andF691PartsDetails ........................................................76–83
K. ModelD891PartsDetails...............................................................84–93
3

Chapter 1—Introduction
Threaded and ANSI flanges:
Compressors are available in either threaded NPT,
ANSI, or DIN flanged connections.
High-efficiency valves:
Corken valves offer quiet operation and high
durability in oil-free gas applications. Specially
designed suction valves which tolerate small
amounts of condensate are used in liquid transfer-
vapor recovery compressors.
O-ring head gaskets:
Easy to install O-ring head gaskets providing highly
reliable seals.
Ductile iron construction:
All cylinders and heads are ductile iron for maximum
thermal shock endurance.
Self-lubricating PTFE piston rings:
Corken provides a variety of state-of-the-art piston
ring designs to provide the most cost-effective
operation of compressors for non-lube service. The
step-cut design provides higher efficiencies during
the entire life of the piston ring.
Positively locked pistons:
Simple piston design allows end clearance to be
precisely set to provide maximum efficiency and
long life.
Self-lubricating piston rod seals:
Seals constructed of PTFE incorporating special
fillers to ensure no oil carry over and maximize
leakage control. Spring loaded seal design self
adjusts to compensate for normal wear.
Nitride-coated piston rods:
Impregnated nitride coating provides superior
corrosion and wear resistance.
Nameplate:
Serves as packing adjusting screw cover (see
figure 1.1A).
Cast iron crossheads:
Durable cast iron crossheads provide superior
resistance to corrosion and galling.
Pressure-lubricated crankcase with filter:
Self-reversing oil pump ensures proper lubrication
regardless of directional rotation to main and
connecting rod bearings. Standard 10-micron filter
ensures long-lasting bearing life (not available on
Model 91).
Construction Details—Model F291 Compressor
4

Compressor reduces
pressure in storage tank
by removing vapor
Compressor increases
pressure in tank car by
adding vapor
Pressure difference between
tanks causes liquid to flow out of
the tank car into the storage tank
Four Way Valve Position 1
Vapor Line
Vapor Line
Liquid Line
Figure 1.1A: Typical Nameplate
(Also Serves as the Packing Adjusting Screw Cover)
1.1 Liquid Transfer By Vapor
Differential Pressure
Corken LPG/NH3compressors are designed to
transfer liquefied gases such as butane/propane
mixtures (liquefied petroleum gas or LPG) and
Anhydrous Ammonia (NH3) from one tank to another.
Liquefied gases such as LPG & NH3are stored in
closed containers where both the liquid and vapor
phases are present.
There is a piping connection between the vapor
sections of the storage tank and the tank being
unloaded, and there is a similar connection between the
liquid sections of the two tanks. If the connections are
opened, the liquid will seek its own level and then flow
will stop; however, by creating a pressure in the tank
being unloaded which is high enough to overcome pipe
friction and any static elevation difference between the
tanks, all the liquid will be forced into the storage tank
(see figure 1.1B). The gas compressor accomplishes
this by withdrawing vapors from the storage tank,
compressing them and then discharging into the tank
to be unloaded. This procedure slightly decreases the
storage tank pressure and increases the pressure in
the other tank, thereby causing the liquid to flow.
The process of compressing the gas also increases the
temperature, which aids in increasing the pressure in the
tank being unloaded.
1.2 Residual Vapor Recovery
The principle of residual vapor recovery is just the
opposite of liquid transfer. After the liquid has been
transferred, the four-way control valve (or alternate
valve manifolding) is reversed so that the vapors are
drawn from the tank just unloaded and discharged into
the receiving tank. Always discharge the recovered
vapors into the liquid section of the receiving tank.
This will allow the hot, compressed vapors to condense,
preventing an undesirable increase in tank pressure (see
figure 1.2A).
Residual vapor recovery is an essential part of the value
of a compressor. There is an economical limit to the
amount of vapors that should be recovered, however.
When the cost of operation equals the price of the product
being recovered, the operation should be stopped.
For most cases in LP Gas and Anhydrous Ammonia
services, this point is reached in the summer when the
compressor inlet pressure is 40 to 50 psig (3.8 to 4.5
bars). A good rule of thumb is not to operate beyond
Figure 1.1B: Liquid transfer by vapor differential pressure
5

Vapor is
bubbled
through liquid to
help cool and
recondense it
Removing vapor from
tank causes liquid heel
to boil into vapor
Liquid line is valved closed
during vapor recovery.
Four Way Valve Position 2
Liquid Heel
Vapor Line
Vapor Line
the point at which the inlet pressure is one-fourth the
discharge pressure. Some liquids are so expensive that
further recovery may be profitable, but care should be
taken that the ratio of absolute discharge pressure to
absolute inlet pressure never exceeds 7 to 1. Further
excavation of very high value products would require a
Corken two-stage gas compressor.
Invariably, there is some liquid remaining in the tank
after the liquid transfer operation. This liquid “heel”
must be vaporized before it can be recovered, so do not
expect the pressure to drop immediately. Actually, more
vapor will be recovered during the first few minutes
while this liquid is being vaporized than that during the
same period of time later in the operation. Remember
that more than half of the economically recoverable
product is usually recovered during the first hour of
operation on properly sized equipment.
1.3 Compressor
Construction Features
The Corken liquid transfer-vapor recovery compressor
is a vertical single-stage, single-acting reciprocating
compressor designed to handle flammable gases like LPG
and toxic gases such as ammonia. Corken compressors
can handle these potentially dangerous gases because
the LPG/NH3is confined in the compression chamber
and isolated from the crankcase and the atmosphere.
A typical liquid transfer-vapor recovery compressor
package is shown in figure 1.3A.
Corken gas compressors are mounted on oil lubricated
crankcases that remain at atmospheric pressure.
Crankshafts are supported by heavy-duty roller bearings
and the connecting rods ride the crankshaft on journal
bearings. With the exception of the small size model 91
compressor, all compressor crankcases are lubricated by
an automotive type oil pressure system. An automatically
reversible gear type oil pump circulates oil through
Figure 1.3A: 107-Style Compressor Mounting
Figure 1.2A: Residual Vapor Recovery
6

Gasket
Adjusting
screw
Relief ball spring
Relief ball
Suction valve
seat
Valve plate
Spacers
Washer
Spacers
Washer
Valve spring
Suction valve
post
Suction valve
bumper
Valve gasket
Gasket
Bolt
Discharge valve
bumper
Valve spring
Valve plate
Discharge valve
seat
Valve gasket
Suction Valve
Spec 3
Discharge Valve
All Specs
passages in the crankshaft and connection rod to
lubricate the journal bearings and wrist pins (see figure
1.3B). Sturdy iron crossheads transmit reciprocating
motion to the piston.
Corken’s automatically reversible oil pump design
allows the machine to function smoothly in either
direction of rotation.
Corken compressors use iron pistons that are locked
to the piston rod. The standard piston ring material is a
glass-filled PTFE polymer specially formulated for non-
lubricated services. Piston ring expanders are placed
behind the rings to ensure that the piston rings seal
tightly against the cylinder wall.
Piston rod packing is used to seal the gas in the
compression chamber and prevent crankcase oil from
entering the compressor cylinder. The packing consists
of several PTFE V-rings sandwiched between a male and
female packing ring and held in place by a spring (see
figure 1.3C).
The typical Corken compressor valve consists of a seat,
bumper, one or more spring/s and one or more valve/s
discs or plates as shown in figure 1.3D. Special heat-
treated alloys are utilized to prolong life of the valve in
punishing non-lubricated services. The valve opens
whenever the pressure on the seat side exceeds the
pressure on the spring side.
Figure 1.3D: Suction and Discharge Valves
Figure 1.3B: Pressure Lubrication System
(Not Available on Model 91)
Figure 1.3C: Compressor Sealing System
7

2.1 Location
NOTE: Compressor must be installed in a well
ventilated area.
Corken compressors are designed and manufactured for
outdoor duty. For applications where the compressor will be
subjected to extreme conditions for extended periods such
as corrosive environments, arctic conditions, etc., consult
Corken. Check local safety regulations and building codes
to assure installation will meet local safety standards.
Corken compressors handling toxic or flammable gases such
as LPG/NH3should be located outdoors. A minimum of 18
inches (45 cm) clearance between the compressor and the
nearest wall is advised to make it accessible from all sides
and to provide unrestricted air flow for adequate cooling.
NOISE. Corken vertical compressors sizes model 91
through 891 should not exceed an 85 DBA noise level
when properly installed.
2.2 Foundation
Proper foundations are essential for a smooth running
compression system. Corken recommends the compressor
be attached to a concrete slab at least 8 in. thick with a 2
in. skirt around the circumference of the baseplate. The
baseplate should be securely anchored into the foundation
by 1/2 in. diameter “J” bolts 12 in. long. Four bolts should
be used for models 91, 291, and 491. Six bolts should
be used for model 691. The total mass of the foundation
should be approximately twice the weight of the compressor
system (compressor, baseplate, motor, etc.).
After leveling and bolting down baseplate, the volume
beneath the channel iron baseplate must be grouted
to prevent flexing of the top portion
of the baseplate and the “J” bolt that
extends beyond the foundation. The
grout also improves the dampening
capabilities of the foundation by
creating a solid interface between the
compressor and foundation.
On some of the longer baseplates, such
as with the 691–107, a 3 in. hole can be
cut in the baseplate for filling the middle
section of the baseplate with grout.
See ED410 (Compressor Foundation
Design).
2.3 Piping
Proper piping design and installation
is as important as the foundation is to
smooth operation of the compressor. Improper piping
installation will result in undesirable transmission of
compressor vibration to the piping.
DO NOT SUPPORT PIPING WITH THE COMPRESSOR.
Unsupported piping is the most frequent cause of
vibration of the pipe. The best method to minimize
transmission of vibration from the compressor to the
piping is to use flexible connectors (see figure 2.3A).
Pipe must be adequately sized to prevent excessive pressure
drop between the suction source and the compressor as
well as between the compressor and the final discharge
point. In most cases, piping should be at least the same
diameter as the suction nozzle on the compressor. Typically,
LPG/NH3liquid transfer systems should be designed to
limit pressure drops to 20 psi (1.3 bar). Appendix D shows
recommended pipe sizes for each compressor for typical
LPG/NH3installations.
Figure 2.2A: Recommended Foundation Details
for Corken Compressors 91 - 691
2” MIN.
ALL SIDES
8” MIN.
HEX NUT
WASHER
COMPRESSOR
BASEPLATE
GROUT BENEATH
BASE
CONCRETE FOUNDATION
WITH REINFORCEMENTS
SHOULD BE USED ON ALL
MODELS
1/2” “J” BOLTS
12” LONG
NOTE:
LOCATE “J” BOLTS PER
COMPRESSOR OUTLINE
DIMENSION DRAWINGS.
Ground level
Concrete
foundation
Baseplate should be
a maximum of 4″ high
Grouted
baseplate
Pipe support
Pipe support
Flexible connections Flexible connections
Figure 2.3A: On –107 mountings, the flexible
connectors should be located near the four way valve.
Chapter 2—Installing Your Corken Compressor
8

Care must be taken if a restrictive device such as a valve,
pressure regulator, or back-check valve is to be installed
in the compressor’s suction line. The suction line volume
between the restrictive device and the compressor
suction nozzle must be at least ten times the swept
cylinder volume.
107 style compressors are usually connected using a five-
valve (figure 2.3B) or three-valve manifold (figure 2.3C).
The five-valve manifold allows the storage tank to be
both loaded and unloaded. The three-valve manifold only
allows the storage tank to be loaded. Adequate sizing of
the liquid and vapor lines is essential to limit the pressure
drop in the system to a reasonable level (20 psi or less).
The line size helps determine the plant capacity almost
as much as the size of the compressor, and liquid line
sizes are a bigger factor than vapor lines. If the pressure
gauges on the head indicate more than a 15 to 20 psi
(2.07 to 2.40 bars) differential between the inlet and outlet
pressures, the line sizes are too small or there is some
fitting or excess flow valve creating too much restriction.
The less restriction in the piping, the better the flow.
Appendix D shows recommended pipe sizes for typical
LPG/NH3compressor installation.
A tank car unloading riser should have two liquid hoses
connected to the car liquid valves. If only one liquid hose
is used, the transfer rate will be slower and there is a good
possibility that the car’s excess flow valve may close.
Since the heat of compression plays an important part in
rapid liquid transfer, the vapor line from the compressor to
the tank car or other unloading container should be buried
or insulated to prevent the loss of heat and the compressor
should be located as near as possible to the tank being
emptied. In extremely cold climates, if the line from the
storage tank to the compressor is over 15 feet (4.6 meters)
long, it should be insulated to lessen the possibility of
vapors condensing as they flow to the compressor. The
vapor recovery discharge line is better not insulated.
Placing the compressor as close as possible to the tank
being unloaded will minimize heat loss from the discharge
line for the best liquid transfer rate.
Unloading stationary tanks with a compressor is quite
practical. Delivery trucks and other large containers can be
filled rapidly if the vapor system of the tank to be filled will
permit fast vapor withdrawal, and if the liquid piping system
is large enough. Many older trucks (and some new ones) are
not originally equipped with vapor excess flow valves large
SERVICE TO PERFORM VALVE POSITION
4-WAY A B C D E
1. Unload Tank Car into
Storage Tank
Position
One Open Open Close Close Close
2. Recover Vapors from Tank
Car into Storage Tank
Position
Two Close Open Open Close Close
3. Unload Transport or Truck
into Storage Tank
Position
One Open Close Close Close Open
4. Recover Vapors from
Transport or Truck into
Storage Tank
Position
Two Close Close Open Close Open
5. Load Truck or Field Tank
from Storage Tank
Position
Two Open Close Close Close Open
6. Load Truck or Field Tank
from Tank Car
Position
One Close Open Close Open Close
7. Equalize Between Tank Car
and Storage Tank without
using Vapor Pump
— Open Open Close Open Open
8. Equalize Between Truck or
Field Tank and Storage Tank
without using Vapor Pump
— Open Close Close Open Close
Figure 2.3B: Five-Valve Manifold Piping System
9

enough to do a good job and these should be replaced
by a suitable size valve. The liquid discharge should be
connected to the tank truck pump inlet line rather than the
often oversized filler valve connection in the tank head.
It is of extreme importance to prevent the entry of
liquid into the compressor. The inlet of the compressor
should be protected from liquid entry by a liquid trap
(see section 2.4). It is of equal importance to protect
the discharge of the compressor from liquid. This may
be done by installing a check valve on the discharge
and designing the piping so liquid cannot gravity-
drain back into the compressor. Make sure to install
a check valve on vapor lines discharging to the liquid
space of the tank.
All piping must be in accordance with the laws and codes
governing the service. In the United States, the following
codes apply:
For LP Gas – The National Fire Protection Association
Pamphlet No. 58, Standard for the Storage and Handling
of Liquefied Petroleum Gases.
For Ammonia – The American National Standards
Institute, Inc., K61.1-1989, Storage and Handling of
Anhydrous Ammonia.
Copies of these are available from NFPA, 60 Baterymarch
Street, Boston, Mass, 02110 and ANSI, 1430 Broadway,
New York, N.Y., 10018. Install, use and maintain this
equipment according to Corken instructions and all
applicable federal, state, and local laws and previously
mentioned codes.
2.4 Liquid Traps
Compressors are designed to pressurize gas, not to
pump liquids. The entry of even a small amount of
liquid into the compressor will result in serious damage
to the compressor.
On liquefied gas applications, a liquid trap must be used
to prevent the entry of liquid into the compressor.
Corken offers three types of liquid traps for removal of
entrained liquids. The simplest is a mechanical float trap
(see figure 2.4A). As the liquid enters the trap the gas
velocity is greatly reduced, which allows the entrained
liquid to drop out. If the liquid level rises above the
inlet, the float will plug the compressor suction. The
compressor creates a vacuum in the inlet piping and
continues to operate until the operator manually shuts it
down. The trap must be drained and the vacuum-breaker
valve opened before restarting the compressor, to allow
the float to drop back. This type of trap is only appropriate
for use where the operator keeps the compressor under
fairly close observation. This trap is provided with the
109 and 107 compressor packages (see Appendix D for
details on standard Corken compressor packages).
When the compressor will not be under more-or-less
constant observation an automatic trap is recommended
Figure 2.4A: Mechanical Trap
Figure 2.3C: Three-Valve Manifold Piping System
SERVICE TO PERFORM VALVE POSITION
4-WAY A B C
1. Unload Tank Car into
Storage Tank
Position
One Open Open Close
2. Recover Vapors from
Tank Car into Storage
Tank
Position
Two Close Open Open
10