Gardner Denver Reavell H5000 Series Service manual

Gardner Denver Ltd. Reavell House
53-56 White House Road IPSWICH ENGLAND IP1 5PB
Telephone: [phone] Fax: [phone] Parts Fax: [phone] Service [phone]
www.reavell.com e-mail:- reav[email protected]
Gardner Denver Ltd
OPERATOR HANDBOOK
For a
5217.2.IA
Water-cooled Air Compressor
In any correspondence please quote;
REAVELL JOB NUMBER:-
CUSTOMER:-
CUSTOMER ORDER NUMBER:-
MACHINE NUMBER:-
PUBLICATION NUMBER:- 98407.1183
ISSUE DATE:- MAY 2012

TABLE OF CONTENTS
PAGE 1
OPERATOR HANDBOOK FOR A 5217.2.IA
WATER-COOLED AIR COMPRESSOR
TABLE OF CONTENTS
1SAFETY....................................................................................................................................................... 5
1.1OWNERSHIP DATA............................................................................................................................. 6
1.2FOREWORD......................................................................................................................................... 7
1.3MAINTENANCE.................................................................................................................................... 7
1.4WARRANTY.......................................................................................................................................... 7
1.5CAUTION.............................................................................................................................................. 8
1.6DISPOSAL OF CONDENSATE AND USED PARTS........................................................................... 8
1.7HEALTH AND SAFETY PRECAUTIONS............................................................................................. 8
1.7.1GENERAL...................................................................................................................................... 8
1.7.2WARNINGS, CAUTIONS & NOTES ............................................................................................. 9
1.7.3GENERAL SAFETY PRECAUTIONS ........................................................................................... 9
1.7.4INSTALLATION PRECAUTIONS.................................................................................................. 9
1.7.5OPERATIONAL PRECAUTIONS................................................................................................ 10
1.7.6MAINTENANCE & REPAIR PRECAUTIONS.............................................................................. 11
1.7.7PRECAUTIONS IN THE EVENT OF FIRE WITHIN THE COMPRESSOR................................ 12
1.8PURGING INSTRUCTIONS FOR GAS INSTALLATIONS................................................................. 12
1.8.1PURGING.................................................................................................................................... 12
1.9HAZARDOUS AREA OPERATION .................................................................................................... 13
1.9.1ELECTRICAL CONNECTIONS................................................................................................... 13
1.9.2DEFINITIONS..............................................................................................................................13
1.9.3IGNITING CLASSIFICATIONS.................................................................................................... 14
1.9.4TEMPERATURE CLASSIFICATIONS ........................................................................................ 14
1.9.5PRODUCTION METHODS ......................................................................................................... 15
2AMENDMENTS ......................................................................................................................................... 17
3COMPRESSOR LOG SHEET ................................................................................................................... 19
4GENERAL DESCRIPTION AND OPERATION ........................................................................................ 21
4.1CONFIGURATION..............................................................................................................................21
4.2LUBRICATION.................................................................................................................................... 21
4.3SYNTHETIC OILS ..............................................................................................................................21
4.4COOLING............................................................................................................................................ 21
4.5DRIVE................................................................................................................................................. 21
4.6LUBRICATION SCHEMATIC FLOW DIAGRAM................................................................................ 22
4.7RUNNING GEAR................................................................................................................................ 23
4.8VALVES.............................................................................................................................................. 23
4.9INSTRUMENTATION ......................................................................................................................... 23
4.10DELIVERY UNLOADING AND CONDENSATE............................................................................. 23
4.11AUTOMATIC STOP/START CONTROL......................................................................................... 23

TABLE OF CONTENTS
PAGE 2
5LEADING PARTICULARS ........................................................................................................................25
5.1UNIT DESIGNATION..........................................................................................................................25
5.2GENERAL...........................................................................................................................................25
5.3TEMPERATURES...............................................................................................................................25
5.4SPEEDS..............................................................................................................................................25
5.5PRESSURES......................................................................................................................................25
5.6INTERNAL DIMENSIONS...................................................................................................................25
5.7LUBRICATION....................................................................................................................................25
5.8COOLING............................................................................................................................................25
5.9CONNECTIONS..................................................................................................................................25
5.10RUNNING CLEARANCES ..............................................................................................................26
5.11TORQUE WRENCH SETTINGS.....................................................................................................26
5.11.1CLASS A – CRITICAL .................................................................................................................26
5.11.2CLASS B – NON-CRITICAL........................................................................................................26
6INSTALLATION.........................................................................................................................................27
6.1HANDLING..........................................................................................................................................27
6.2LOCATION..........................................................................................................................................27
6.3MOUNTING.........................................................................................................................................28
6.4CONNECTIONS, PIPEWORK AND FITTINGS..................................................................................28
6.5DRIVE RECOMMENDATIONS...........................................................................................................28
6.6COOLING............................................................................................................................................29
6.7ELECTRICAL CONNECTIONS ..........................................................................................................29
6.8RECOMMENDED ANCILLARIES SUMMARY...................................................................................30
7COMMISSIONING OR RECOMMISSIONING...........................................................................................31
7.1BEFORE STARTING ..........................................................................................................................31
7.2START-UP PROCEDURE..................................................................................................................32
8OPERATION AND ROUTINE MAINTENANCE........................................................................................33
8.1OPERATION AND GENERAL MAINTENANCE.................................................................................33
8.2STARTING UP....................................................................................................................................33
8.3RUNNING ON LOAD ..........................................................................................................................33
8.4STOPPING..........................................................................................................................................33
8.5STANDING IDLE.................................................................................................................................33
9MAINTENANCE SCHEDULE....................................................................................................................35
9.1GENERAL...........................................................................................................................................35
9.2DAILY..................................................................................................................................................35
9.3WEEKLY .............................................................................................................................................35
9.4AFTER THE FIRST 100 HOURS RUNNING TIME ON MINERAL OIL..............................................35
9.5CHANGING OVER FROM MINERAL TO SYNTHETIC LUBRICANT................................................35
9.6SERVICE PLAN..................................................................................................................................36

TABLE OF CONTENTS
PAGE 3
10DISMANTLING AND REASSEMBLY OF VALVES.............................................................................. 39
10.1GENERAL ....................................................................................................................................... 39
10.2CLEANING AND INSPECTION – ALL STAGES............................................................................ 39
10.3VALVE REMOVAL AND DISMANTLING........................................................................................ 39
10.4CLEANING VALVE UNITS.............................................................................................................. 39
10.5VALVE REPLACEMENT................................................................................................................. 40
10.6VALVE REASSEMBLY ................................................................................................................... 41
10.6.1FIRST STAGE CONCENTRIC VALVE ....................................................................................... 41
10.6.2SECOND STAGE CONCENTRIC VALVE .................................................................................. 41
11FAULT GUIDE........................................................................................................................................ 43
11.1WILL NOT START........................................................................................................................... 44
11.2CUTS OUT ON START-UP............................................................................................................. 44
11.3LOW OUTPUT ................................................................................................................................ 44
11.4SAFETY VALVE BLOWING............................................................................................................ 45
11.5STOPS SUDDENLY........................................................................................................................ 46
11.6HIGH OIL CONSUMPTION............................................................................................................. 46
11.7LOW OIL PRESSURE..................................................................................................................... 47
11.8OVERHEATING ..............................................................................................................................47
11.9UNUSUAL NOISE – ON LOAD...................................................................................................... 47
11.10UNUSUAL NOISE – UNLOADED.................................................................................................. 47
12PARTS LIST........................................................................................................................................... 49
12.1CRANKCASE PARTS..................................................................................................................... 51
12.2RUNNING GEAR PARTS ............................................................................................................... 53
12.31ST STAGE CYLINDER PARTS .................................................................................................... 55
12.42ND STAGE CYLINDER PARTS.................................................................................................... 57
12.51ST & 2ND STAGE COOLER PARTS............................................................................................ 59
12.6PRESSURE GAUGE PARTS.......................................................................................................... 61
12.7LUBRICATION PARTS................................................................................................................... 63
12.8DRAIN VALVE & PIPING PARTS................................................................................................... 65
12.9EXTERNAL COMPONENTS PARTS ............................................................................................. 67
12.10DRIVE PARTS................................................................................................................................. 69
12.111ST STAGE CONCENTRIC VALVE PARTS.................................................................................. 71
12.122ND STAGE CONCENTRIC VALVE PARTS................................................................................. 73
12.13DIAPHRAGM DRAIN VALVES PARTS.......................................................................................... 75
12.14JOINT KIT........................................................................................................................................ 76
12.15'O' RING KIT.................................................................................................................................... 76
12.16VALVE MAINTENANCE KIT........................................................................................................... 76
12.17DDV MAINTENANCE KIT U334K & L ............................................................................................ 77
12.18SERVICE KIT FOR DDV'S.............................................................................................................. 77
12.19SERVICE TOOLS ........................................................................................................................... 77

TABLE OF CONTENTS
PAGE 4
13ANCILLARY PARTS..............................................................................................................................79
13.1TEMPERATURE CONTROLLER – APP090 ..................................................................................79
13.2SAFETY VALVE – APP167.............................................................................................................81
13.3SOLENOID VALVE DDV – APP138................................................................................................83
13.4ANTI VIBRATION MOUNTS – APP003..........................................................................................84
13.5WATER PUMP DRIVE – APP074...................................................................................................85
13.6EXPANSION TANK COOLING WATER SYSTEM – APP076-5217...............................................86
13.7PRESSURE GAUGES – APP070...................................................................................................88
13.8FLEXIBLE HOSE – APP248 ...........................................................................................................89
14STANDARD WIRING TERMINAL NUMBERS......................................................................................91

SAFETY
PAGE 5
1 SAFETY
5000 SERIES COMPRESSORS
FOR USE ON AIR, FLAMMABLE OR NON-FLAMMABLE GASES
WARNING
The use of replacement parts or lubricating oils not supplied, recommended
or approved by Reavell Ipswich, or the failure to maintain this equipment in
accordance with the maintenance instructions, may invalidate the
WARRANTY, cause equipment failure, create unsafe or hazardous
conditions or result in damage to the equipment.
Reavell Ipswich cannot accept responsibility for damage, injury or failure
caused by these situations.
USE ONLY
GENUINE PARTS
AND
AUTHORISED SERVICE AGENTS

SAFETY
PAGE 6
1.1 OWNERSHIP DATA.1 OWNERSHIP DATA
TECHNICAL DATA
It is recommended that details taken from the compressor nameplates are recorded below.
Reavell CONTACT DETAILS
Address:
Reavell House
53-56 White House Road
Ipswich IP1 5PB
ENGLAND
Notes:
Sales – Contact Names:
Telephone:
Fax:
[phone]
[phone]
Parts – Contact Names:
Telephone:
Fax:
[phone]
[phone]
Service – Contact Names:
Telephone:
Fax:
[phone]
[phone]
For any comments or queries about the contents of this manual, please write to Reavell at the
above address, marked for the attention of Mr. Owen Dale, Technical Author.

SAFETY
PAGE 7
1.2 FOREWORD
The STANDARD build of all Reavell products are not intended for use in either Explosive or Potentially
Explosive Atmospheres as defined in Directive 94/9/EC.
An Explosive atmosphere is a mixture with air, under atmospheric conditions, of flammable gases,
vapours, hazes or dusts in which, after ignition has occurred, combination propagates to the entire
unburned mixture and may cause a hazard.
A Potential Explosive atmosphere is an atmosphere, which could become explosive due to local
conditions.
Reavell H5000 Series compressors are designed and manufactured to give optimum performance and
safety, together with long life and reliability whilst compressing the gas for which they have been
designed.
They must not be used to compress other gases without prior consultation with the Reavell factory.
This Manual will help you to obtain the best performance from your compressor. It provides the
information required for safe installation, commissioning and operation, together with a maintenance
schedule to ensure maximum service life.
Servicing facilities and the supply of genuine replacement parts are provided through a world-wide
network of Gardner Denver companies and authorised distributors, backed by the Reavell factory.
The information in this Manual was correct at the time of printing, but modifications to parts and
procedures may be made without notice which could affect the servicing requirements of the compressor.
In any communication concerning the compressor it is necessary to quote the the MODEL, SERIAL No.
and CONTRACT reference in order that the correct information is supplied.
It is important that this Manual is retained with the compressor for reference and that it should remain
with the compressor if it is sold or transferred to another user. The new user must be made fully aware of
the need to study this Safety Section and any Warnings for safe operation given throughout the manual.
1.3 MAINTENANCE
Before any servicing or maintenance work is undertaken, the user is advised to contact the local Gardner
Denver Company or authorised Distributor for revised or up-dated information.
To ensure continued trouble free operation of the compressor it is important that periodic maintenance
and servicing are carried out in accordance with the information given in the "Maintenance" section of this
Manual. If any replacement or repair is needed use genuine Reavell parts.
Any unauthorised modifications or failure to maintain this equipment in accordance with maintenance
instructions may make it unsafe. The use of replacement parts not supplied by Reavell may create
hazardous conditions over which Reavell has no control.
Such hazardous conditions may lead to accidents that can be life threatening, cause substantial bodily
injury or result in damage to the equipment. Reavell can bear no responsibility for equipment for
which unapproved replacement parts are included.
WARNING
The use of replacement parts or lubricating oils not supplied or approved by Reavell may lead to
failures in service which would not be covered by warranty.
1.4 WARRANTY
Conditions of the Reavell warranty are stated in our Standard Conditions of Sale. Details of warranty for
a particular contract may be obtained from the local Gardner Denver Company or authorised Distributor.

SAFETY
PAGE 8
1.5 CAUTION
Compressor sets designed for use with flammable gases are fitted with low inlet pressure switches.
These are an essential safety item. Their operation should be checked regularly. They must not be
tampered with or linked out of operation.
Should the gas inlet pressure fall to a low level and the switch has been linked out or made inoperable
there is a danger the compressor will draw in air. This could then form an explosive mixture within the
compressor. In extreme conditions it could also allow air to be drawn into the gas main with serious
implications for the general public.
1.6 DISPOSAL OF CONDENSATE AND USED PARTS
Whilst recyclable materials are used as far as possible, please ensure when disposing of condensate,
spent oil, used filter elements and any discarded parts or waste material of any kind make sure that there
is no pollution to any natural water-course, drain system and that no burning of waste takes place which
could cause pollution of the atmosphere.
Condensate, waste oil and used consumable items should be disposed of in line with Local Authority
regulations and Section 7.1.4 of EN 626-1:1994+A1:2008.
1.7 HEALTH AND SAFETY PRECAUTIONS
THE FOLLOWING HEALTH AND SAFETY PRECAUTIONS MUST BE READ IN CONJUNCTION
WITH ANY OTHER MANUFACTURERS EQUIPMENT SUPPLIED.
1.7.1 GENERAL
Operation, maintenance, repair or modifications to the compressor and its associated equipment
must only be carried out by competent persons under the control of a qualified supervisor.
The compressor safety relates to the document EN1012-1 Compressors and vacuum Pumps - Safety
Requirements, and the UK Pressure Systems Safety Regulations 2000.
Reavell re-fuelling stations are generally in accordance with International Gas Standards that apply
locally.i.e. UK LTD. GE/GAS/UP
GERMANY TUV
Most accidents which occur during the operation and maintenance of machinery are the result of failure
to observe basic safety rules or precautions. An accident can often be prevented by recognising a
situation that is potentially hazardous.
When handling, operating or carrying out maintenance on the station, personnel must observe safe
engineering practices and all relevant local regulations. The attention of users is drawn to the UK. Health
& Safety at Work Act 1974 and the Regulations of the Institution of Electrical Engineers.
Reavell cannot anticipate every possible circumstance which might represent a potential hazard. The
WARNINGS in this manual are therefore not all inclusive. If the user employs an operating procedure, an
item of equipment or a method of working which is not specifically recommended by Reavell, then they
must ensure that the unit will not be damaged or made unsafe and that there is no risk to persons or
property.
Failure to observe the precautions listed in the ‘HEALTH AND SAFETY PRECAUTIONS’ section may be
considered dangerous practice or misuse of the compressor.
Read and understand all WARNINGS, CAUTIONS & MANDATORY LABELS on the compressor before
operating, carrying out maintenance or servicing.

SAFETY
PAGE 9
1.7.2 WARNINGS, CAUTIONS & NOTES
The following details for this Safety Section relate to ESSENTIAL SAFETY REQUIREMENTS referred to in
Machinery Directive 2006/42/EC.
Warnings call for attention to operating procedures involving specific hazards which could cause injury
or death and are identified by the following
RISK OF DANGER
RISK OF ELECTRIC SHOCK
RISK OF HIGH PRESSURE
RISK OF HOT SURFACE
RISK OF GAS EXHAUST
CONSULT MANUAL
1.7.3 GENERAL SAFETY PRECAUTIONS
When using cleaning solvents, local Health & Safety Regulations must be complied with. Provide good
ventilation and use suitable protection such as a breathing filter face mask, safety glasses, protective
apron and gloves.
Safety shoes should be compulsory in all workshops. Safety helmets must be worn if there is a risk of
falling objects.
If using compressed air for cleaning purposes, ensure safety regulations are complied with and
appropriate clothing worn. Never use compressed air to clean loose dirt from clothing.
Never direct compressed gas onto your skin or at other people.
Before releasing compressed air or gas through a flexible hose, make sure the free end is held securely
so that it cannot whip and cause injury.
1.7.4 INSTALLATION PRECAUTIONS
Installation work must only be carried out by competent personnel under qualified supervision.
A fused isolator switch must be fitted between the main power supply and the compressor. The isolator
shall be suitably sized and be in accordance with Section 7.2 of EN 60204-1:2006 & A1:2009.
If not requested with the supplied equipment, suitably sized over-current protection must be provided to
protect the power circuit. The protection shall be in accordance with Section 7.2 of EN 60204-1:2006 &
A1:2009.
Precautions must be taken to ensure that no injury is caused to passers by through loose clothing being
drawn into cooling air intake ducting or louvers.
Ensure that the discharge gas piping from the compressor module to the users pipework, gas storage
cylinders or gas dispensing system is free to expand and that no flammable material is within the
vicinity. If any such material is close-by take steps to preclude ignition.

SAFETY
PAGE 10
A manual shut-off valve should be fitted in the discharge line to allow the compressor to be isolated.
Non return valves cannot be relied upon for isolating parts from a pressure system. A safety valve must
be installed between any compressor unit and the isolating valve.
A pressure-reliving device must be fitted to every pressure vessel, or equipment containing air or gas
above atmospheric pressure. They must be suitably sized for the pressure and flowrate of the gas
involved. For specific details, contact Reavell.
Never remove or tamper with safety devices, guards or insulation material.
In order to limit the risk of Legionnaires Disease, Reavell advise caution with the use of cooling towers
for water cooling the compressor. Potable water should be used, treated where necessary to prevent
harmful bacteria from entering the compressed air. Cooling tower manufacturers should be contacted
for suitable maintenance schedules to prevent persons coming into contact with harmful bacteria.
Closed circuit or direct mains cooling is preferred.
Cables, chains or ropes should never be applied to lifting eyes. Always use an appropriate shackle or
hook, properly positioned. Arrange lifting cables so that there are no sharp bends. Use a spreader bar
to ensure vertical lift and avoid side loads on hooks, eyes and shackles and never leave a heavy load
unattended.
When a load is on a hoist stay clear of the danger area beneath and around it. Keep lifting acceleration
and speed within safe limits.
1.7.5 OPERATIONAL PRECAUTIONS
The compressor must only be operated by competent personnel under a qualified supervisor.
Ensure that all instructions concerning operation and maintenance are strictly followed and that the
complete installation with all accessories and safety devices are kept in good order.
Do not operate the compressor module, or any other parts of the equipment with any inspection cover
removed. e.g. compressor crankcase doors, valve covers,dispenser panel etc.
Never remove or tamper with safety devices, guards or insulation material.
Pipework or other parts with a surface temperature above 70°C which may be accidentally touched in
normal operation must be guarded or insulated. Other high temperature pipework should be clearly
marked.
The compressor must only be operated at the supply voltage and frequency for which it is designed.
Always isolate power before maintenance or servicing.
When mains power is ON, lethal voltages are present in the electrical circuits and extreme caution is
needed when essential work is carried out on the electrical system.
ALWAYS CONSULT A QUALIFIED ELECTRICIAN BEFORE ANY SUCH ESSENTIAL WORK.
If the compressor is equipped with a Remote Control device, attach warning notices stating “THIS
UNIT CAN BE STARTED REMOTELY” in prominent locations around the equipment.
As a further safeguard, take adequate precautions that no one is working or checking the unit before
attempting to switch on the remotely controlled equipment. Attach a “CHECK THAT ALL PERSONNEL
ARE CLEAR OF UNIT BEFORE STARTING” or similar notice.
If there is any indication that the compressor is overheating it must be shut down. (A high air or gas
temperature switch is fitted as standard to guard against operating with excessive temperature).
Beware of burns from hot oil and water (if applicable) when working on a unit recently shut-down.

SAFETY
PAGE 11
Use only lubricating oils and greases approved by Reavell to avoid potential hazards especially
the risk of explosion or fire and the possibility of decomposition or generation of hazardous
gases.
Do not operate the unit when guards provided for protection for all rotating and reciprocating parts have
been removed for essential maintenance. Secure guards following any servicing or repair.
Do not open the starter / control panel for any reason whilst the electrical supply is live. Such work
should only be carried out by a qualified Electrician with appropriate tools and protection against an
electrical hazard.
Local noise regulations must be observed. Ear defenders are suggested by Noise at Work Regulations
1989 when the level is greater than 85 dB A at one meter. Be aware high noise levels can interfere with
communication.
1.7.6 MAINTENANCE & REPAIR PRECAUTIONS
Maintenance, repair and modifications must only be carried out by competent persons under a qualified
supervisor.
Before dismantling any part of the compressor, ensure that all heavy movable parts are secure.
On completion of any maintenance or repair ensure that no tools, loose items or rags etc., are left on or
inside the compressor or other parts of the system.
Oil lubricated compressor will have preserving oil applied to interior surfaces. Oil free models will have
desiccant bags in valve covers and distance pieces which must be removed prior to start-up.
Handling components such as seals, gaskets and diaphragms should not present a personal hazard.
Preserving oils should not present a personal hazard provided normal handling practices are employed.
Whilst the compressors are asbestos free; treat all damaged gaskets as asbestos – when the Asbestos
at Work regulations apply.
Isolate the compressor from the main electrical supply. Lock the isolator in the OFF position and
remove the fuses.
Attach the following label. “DO NOT START – MAINTENANCE WORK IN PROGRESS”.
Close, and lock if possible, the isolating valves upstream and downstream of the compressor system’s
air, gas and water supplies as appropriate. Attach a label "WORK IN PROGRESS - DO NOT OPEN" to
each valve.
Drain the cooling water from the compressor as appropriate.
Check that all pressure gauges register zero and that all air or gas pressure in the system has been
released.
Always leave compressor valve cover retaining nuts engaged by 2 or 3 threads when commencing
removal of valve covers. Use withdrawing screws to raise the valve cover and release the ‘O’ ring seal.
Remove the nuts and withdraw the cover.
Viton ‘O’ seals under normal operating conditions are safe.
However, should there be a fire within the compressor or these seals are likely to exceed a temperature
of 300°C the material will decompose.
Degraded Viton gives off Hydrogen Fluoride fumes and if in contact with skin an acid is formed
causing severe burns.

SAFETY
PAGE 12
If Viton seals appear charred or gummy do not touch with unprotected hands: wear neoprene or PVC
gloves.
When the seal has been removed, wash the area with limewater and avoid breathing any fumes. If
contamination of the skin occurs, wash with limewater and seek medical advice.
Always clean oil spills from the compressor module before and after maintenance work
NEVER USE A LIGHT SOURCE WITH AN OPEN FLAME FOR INSPECTION
Pressure gauges, temperature switches and other protection devices should be checked at least every
12 months and thoroughly examined at least every 48 months. They must be renewed or service
exchanged if acceptable tolerances are exceeded or if they are not functioning correctly.
The maximum pressure for safety valves under fault conditions is 1.10 times the set pressure, the set
pressure being a minimum of 1.05 times the maximum operating pressure to ensure seat tightness.
Do not use any flammable liquid to clean valves, filter elements, cooler passages, pipes bores or any
component carrying a flow of air or gas during normal operation. If chlorinated hydrocarbon substances
are used for cleaning, safety precautions must be taken against toxic vapours which may be released.
DO NOT USE CARBON TETRACHLORIDE.
Precautions must be taken against using acids, alkalis and chemical detergents for cleaning machined
parts. These materials cause irritation and are corrosive to the skin, eyes nose and throat.
Avoid splashes and wear suitable protective clothing and safety glasses. Do not breathe mists. Ensure
clean water and soap is readily available.
Protect components and exposed openings by covering with clean cloths or tape during repair or
maintenance work.
Protect all items as necessary against the ingress of moisture if steam cleaning is undertaken.
Precautions must be taken when carrying out any hot working. The adjacent components must be
screened with non-flammable material and if oil is present, the area must be first cleansed thoroughly
by steam cleaning.
1.7.7 PRECAUTIONS IN THE EVENT OF FIRE WITHIN THE COMPRESSOR
Use extreme caution when handling components that have been subjected to fire or very high
temperature. Some components may contain fluoroelastomer materials which decompose under these
conditions to form highly corrosive residues. Skin contact can cause painful and penetrating burns
resulting in permanent skin and tissue damage.
1.8 PURGING INSTRUCTIONS FOR GAS INSTALLATIONS
BEFORE ANY ATTEMPT IS MADE TO RUN THE COMPRESSOR ON PROCESS GAS, THE
OPERATOR MUST BE SATISFIED THAT THE COMPRESSOR AND ITS ASSOCIATED PIPEWORK
IS PURGED FREE OF AIR AND THAT THEY ARE FULLY CONVERSANT WITH THE OPERATING
PROCEDURES OF THE EQUIPMENT.
If in any doubt as to efficiency of the purging, ALWAYS REPEAT THE PROCEDURE.
1.8.1 PURGING
When the gas being compressed is flammable, or its purity is important, it must be a plant requirement
to purge the compressor to remove any air in it before letting the process gas into the system. The
compressor should be purged free of air, in accordance with purging procedures which apply to the
whole plant using the inert gas specified, after the compressor has been commissioned on air and
before the process gas is introduced into the system.

SAFETY
PAGE 13
The installation should have purging valves fitted to the inlet and outlet lines of the compressor,
permitting the inert gas used for purging to be admitted and discharged before and after the equipment
being purged.
Once this has been acheived the valves should be locked and /or plugged to avoid them being left
open whilst running on gas.
Operators should also be aware that the compressor is not guaranteed leak tight whether in normal
operation or under fault conditions and It is assumed that the compressor is situated in a well
ventilated area with suitable gas leakage detection equipment to minimise possible risks.
Due to the unknown nature of the plant processes involved, Reavell cannot be held responsible
for any heath risk arising from leakage of gas into the atmosphere.
The following comments may help to achieve successful purging of the compressor:-
The use of an Oxygen meter is recommended when purging prior to running on flammable gases.
Feeding the purge gas at pressure (maximum 0.5 bar g) will speed up procedure.
The crankcase will be purged more quickly if the oil filler cap is removed and the rod inside is
depressed to allow the air to escape.
The pipes from the separators to the unloader valves and from the first stage to unloaders (and water
valve if fitted) can be purged by disconnecting them at their far end, allowing the purge gas to pass
through and remove the air, before reconnecting them.
After any maintenance or repairs have been carried out which involves dismantling and opening up gas
containing parts, the system must always be re-purged.
1.9 HAZARDOUS AREA OPERATION
1.9.1 ELECTRICAL CONNECTIONS
There are varying regulations covering electrical equipment specifications for use with flammable
gases. It is the responsibility of the user to meet all regulations for electrical equipment and its
connections whether or not supplied by Reavell.
1.9.2 DEFINITIONS
When flammable materials are mixed with air in appropriate proportions, a potentially explosive mixture
is produced. There is therefore a danger of explosion existing whenever flammable gases are being
handled.
To protect personnel and plant, special precautions must be taken to prevent ignition. Conditions likely
to ignite a potential explosive mixture include, but are not limited to the following:-
Electrical sparks produced when a circuit is opened or closed (e.g. cut-out switches)
Conductors heated by the passage of the current or by faulty equipment.
Sparks produced by a moving object hitting a stationary one.
Sparks produced by the periodic discharge of static electricity.

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1.9.2.1 AREA CLASSIFICATIONS
Areas where the above hazards can exit are categorised into three ZONES for countries complying with
the standards produced by the IEC (International Electrotechnical Standardisation). The USA and
Canada still use standards which identify these areas as DIVISIONS.
IEC USA & CANADA
ZONE 0: Explosive gas atmosphere is
present continuously, or is present for long
periods
ZONE 1: Explosive gas atmosphere is
likely to occur in normal operation.
ZONE 2: Explosive gas atmosphere is not
likely to occur in normal operation and if it
does occur, it will exist for a short period
only.
DIVISION 1: Hazardous concentrations of
flammable gases of vapours - or
combustible dusts in suspension -
continuously, intermittently or periodically
present under normal operating conditions.
DIVISION 2: Volatile flammable liquids or
flammable gases present, but normally
confined within closed containers or
systems from which they can escape only
under abnormal operating or fault
conditions. Combustible dusts not normally
in suspension nor likely to be thrown into
suspension.
1.9.3 IGNITING CLASSIFICATIONS
The flammable gases are also given a classification according to the spark energy (or strength)
required to ignite the most easily ignitable mixture with air. Apparatus is approved as safe for a
particular group. It will also be safe for all groups that are less easily ignitable.
IEC USA & CANADA
Surface Industries
Group IIC: Acetylene
Group IIC: Hydrogen more
Group IIB: Ethylene easily
Group IIA: Propane ignited
Mining Industries
Group I: Methane (firedamp)
Surface Industries
Class I, Group A: Acetylene
Class I, Group B: Hydrogen more
Class I, Group C: Ethylene easily
Class I, Group D: Propane ignited
Class II, Group E: Metal dust
Class II, Group F: Carbon dust
Class II, Group G: Flour, starch, Grain
Mining Industries
Unclassified: Methane (firedamp)
1.9.4 TEMPERATURE CLASSIFICATIONS
Mixtures can also be ignited by hot surfaces and gases are therefore given to a TEMPERATURE
CLASSIFICATION which identifies their ignition temperature.
TEMPERATURE
CLASSIFICATION IGNITION TEMPERATURE °C
T1
T2
T3
T4
T5
T6
450
300
200
135
100
85
The maximum surface temperature of hazardous location apparatus MUST NOT exceed the gas
ignition temperature. Therefore, the best equipment has a T6 temperature classification.

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1.9.5 PRODUCTION METHODS
There are two main types of protection against explosion occurring in hazardous areas; INTRINSIC
SAFETY and FLAMEPROOF. There are various levels of the latter, brief descriptions and options
available are as follows:-
1.9.5.1 INTRINSIC SAFETY (IS)
This is based on the principle of restricting the electrical energy available in circuits in the hazardous
area such that any sparks or hot surfaces that may occur as a result of electrical faults are toop weak
to cause ignition.
The useful power is about 1 watt which is sufficient for most modern instrumentation. I.S. is therefore
inherently safe as evidenced by the fact that it is the only technique that is accepted for Zone 1 (high
risk) hazardous areas.
It is also safer for personnel since the voltages are low and it allows field equipment to be maintained
and calibrated ‘live’ without the need to obtain a gas-free certificate. I.S. equipment is light in weight
and can be inter-connected by ordinary instrument cabling.
Note: Intrinsic safety is only suitable for low power duties such as cut-out or control switches.
Although I.S. classified solenoid valves are available for some duties they are expensive.
1.9.5.2 FLAMEPROOF
Flameproof equipment must be used for electric motors and solenoid valves. There are varying
degrees of protection in this category which are described below.
Flameproof EExd
A type of protection in which the parts which can ignite an explosive atmosphere are placed in an
enclosure which can withstand the pressure developed during an internal explosion of an explosive
mixture and which prevents the transmission of the explosion to the explosive atmosphere
surrounding the enclosure.
Increased Safety Eexe
The method of protection by which additional measures are applied to electrical equipment so as to
give increased security against the possibility of excessive temperatures and of the occurrence of
sparks and arcs during the service life of the apparatus, It applies only to equipment no parts of which
produce sparks or arcs or exceeds the limiting temperature in normal service.
Non Sparking ExN
A type of protection applied to electrical apparatus such as that, in normal operation, it is not capable
of igniting a surrounding explosive atmosphere and a fault capable of causing ignition is not likely to
occur.
Pressurised Eexp
Protection is given by subjecting the equipment’s internal parts to a positive pressure relative to the
surroundings so that the potential explosive atmosphere cannot penetrate the equipment in service.
Continuous flushing or compensation for leakage must be arranged. It is also necessary to provide
shut-down switches to operate in the event of failure to maintain the positive pressure.

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AMENDMENTS
PAGE 17
2 AMENDMENTS
ISSUE No REASON DATE SECTION
1 - MAY 2003 ALL
2 SERVICE PLAN UPDATED APRIL 2009 9.6
3 SAFETY SECTION UPDATED
STANDARD WIRING TERMINAL NUMBERS ADDED MAY 2012 1 14

AMENDMENTS
PAGE 18