Corken WFD551 User manual

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 qualified 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, flammable or explosive substances
using Corken products is at user’s risk and equipment should be operated only by qualified personnel according to applicable laws and safety standards.
WFD551 Compressor Shown
Installation, Operation
& Maintenance Manual
D-Style Two-Stage Gas Compressor
Model WFD551
ORIGINAL INSTRUCTIONS IE106A

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., 9201 North I-35 Service Road, Oklahoma City, OK. 73131.
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
2

Table of Contents
COMPRESSOR FEATURES .....................................................................4
CHAPTER 1—INSTALLING YOUR CORKEN COMPRESSOR ..........................................5
1.1 Location .................................................................................5
1.2 Foundation ...............................................................................5
1.3 Piping ...................................................................................5
1.4 Driver Installation/Flywheels .................................................................6
1.5 Crankcase Lubrication ......................................................................6
1.6 Purging, Padding, Venting and Draining of Distance Pieces.........................................7
1.7 Relief Valves ..............................................................................7
1.8 Shutdown/Alarm Devices....................................................................8
1.9 Compressor Cooling ......................................................................10
CHAPTER 2—STARTING UP YOUR CORKEN COMPRESSOR .......................................10
2.1 Inspection After Extended Storage ...........................................................10
2.2 Flywheel and V-belt Alignment ..............................................................10
2.3 Crankcase Oil Pressure Adjustment ..........................................................11
2.4 Startup Check List ........................................................................11
CHAPTER 3—ROUTINE MAINTENANCE CHART ..................................................12
CHAPTER 4—ROUTINE SERVICE AND REPAIR PROCEDURES......................................13
4.1 Va lves ..................................................................................13
4.1.1 Reverse Unloader Option .................................................................14
4.2 Heads..................................................................................14
4.3 Piston Rings and Piston Ring Expanders Replacement ...........................................14
4.4 Piston Replacement.......................................................................15
4.5 Piston Rod Packing Adjustment .............................................................15
4.6 Cylinder Replacement .....................................................................16
4.7 Bearing Replacement for Crankcase and Connecting Rod ........................................17
4.8 Oil Pump Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CHAPTER 5—EXTENDED STORAGE PROCEDURES...............................................19
APPENDICES
A. Model Number Identification Code ............................................................20
B. Material Specifications .....................................................................21
C. Outline Dimensions ........................................................................24
D. Troubleshooting...........................................................................26
E. Assembly Details ..........................................................................27
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Compressor Features
Figure 1.1: Model WFD551
Corken industrial gas compressors are unique among
compressors their size. Unlike ordinary lubricated gas
compressors, Corken compressors completely isolate
the pressurized gas in the compression chamber from
the crankcase. While piston rings seal the piston tightly
enough for it to do compression work, they do not provide
enough sealing to isolate the compression chamber from
the crankcase. To further seal the compression chamber,
a crosshead/piston rod design with seals around the
piston rod is required.
By utilizing specialized piston-rod sealing systems,
Corken compressors can compress pressurized,
flammable and toxic gases. It is also used to compress
harmless gases where oil-free compression or elevated
suction pressures are required. With a large selection of
design options available, Corken offers the most versatile
line of small gas compressors in the world.
Why Corken Compressors are Special
High-efficiency valves:
Corken valves offer quiet operation and high
durability in oil-free gas applications.
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.
Adjustable packing screw:
Ensures maximum sealing capacity during the life of
the packing (T791 and T891 models only).
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.
Lower packing (V-ring)
Upper packing (V-ring)
Water jacket
(for cooling packing)
Water cooling
jackets
Distance piece
Barrier
(purge, pad, or vent)
Oil deflector ring
4

1.1 Location
WARNING
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.
WARNING
Corken compressors handling toxic or
flammable gases such as LPG/NH3should be
located outdoors in a well ventilated area. A
minimum of 18 inches (45 cm) clearance between the
compressor and the nearest wall is recommended. This
will make it accessible from all sides and provide
unrestricted air flow for adequate cooling.
Noise Level: Many factors affect the noise level generated
by a compressor installation. Several of these, including
motor noise, piping vibration, foundation/skid design,
and surrounding structures are outside Corken’s control.
The use of sufficient pipe supports, flexible hoses, and
proper baseplate/skid support will all reduce noise. Thus,
Corken cannot guarantee a particular noise level from our
compressors. However, noise levels from a properly installed
Corken compressor should not exceed 85dBa at three feet.
1.2 Foundation
Proper foundations are essential for a smooth running
compression system. Corken recommends the
compressor be attached to a concrete slab at least 8
inches thick with a 2 inch skirt around the circumference
of the baseplate. The baseplate should be securely
anchored into the foundation by 1/2 inch diameter “J”
bolts that are 12 inches long. The total mass of the
foundation should be approximately twice the weight of
the compressor system (compressor, baseplate, motor,
etc.). See figure 1.2 for details.
After leveling and bolting down the baseplate, the volume
beneath the channel iron baseplate can 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 107
mountings, a 3 inch hole can be cut in the baseplate for
filling the middle section of the baseplate with grout.
For a more detailed explanation of a proper foundation
design, please refer to Important "Instructions for
Compressor Foundation Design” (item number ED410).
Main beam (C-Beam)
Cross beam (H-Beam)
3/4″ diameter “J” bolt
Hex nut
&
washer
Concrete foundation
Note: The depth of the concrete foundation will
vary based on local soil conditions.
Figure 1.2: Recommended foundation details
for Corken compressors
1.3 Piping
Proper piping design and installation is as important as a
proper foundation is to a smooth operating 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 1.3 for details).
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.
If a restrictive device such as a valve, pressure regulator,
Chapter 1—Installing Your Corken Compressor
Ground level
Concrete
foundation
Baseplate should be
a maximum of 4″ high
Grouted
baseplate
Pipe support
Pipe support
Flexible connections Flexible connections
Figure 1.3: 103 mounting shown above.
5