Quincy QRNG Owners Manual - JBL LLC

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Q R N G SeriesInstruction ManualThis manual contains important safety information and must becarefully read in its entirety and understood prior to installation byall personnel who install, operate and/or maintain this product.Manual No. 50158-101July 2003 Edition

WARRANTYQuincy CompressorIndustrial Reciprocating ProductsQRNG Natural Gas Series CompressorsGENERAL PROVISIONSQuincy Compressor (The Seller) warrants to each retail purchaser (Purchaser) products of the Seller's own manufacture againstdefects in material and workmanship. With respect to products not manufactured by the Seller, the Seller will, if practical, passalong the warranty of the original manufacturer.The Seller's sole obligation under this warranty shall be, at its option, to repair, replace, or refund the purchase price of anyproduct or part thereof which is deemed to be defective, provided the Purchaser meets all of the applicable requirements of thiswarranty and none of the limitations apply.WARRANTY PERIODSQRNG Pressure Lubricated Basic CompressorsSeller warrants for six (6) months from date of factory shipment or three (3) months from date of installation, whichever comes first,the following parts: head, cylinder, crankcase, lubricant pump, crankshaft, pistons, connecting rod assemblies and bearings.Material and workmanship only. No reimbursement for travel to be allowed.Replacement PartsSeller warrants repaired or replaced parts of its own manufacture against defects in material and workmanship under normal useand service for ninety (90) days, or for the remainder of the warranty on the product being repaired, whichever is longer.Parts purchased outside the compressor's warranty period are warranted for ninety (90) days from the date of distributor sale,or one (1) year from the date of shipment from the factory, whichever occurs first.Normal maintenance items and procedures are not warranted unless found to be defective in material or workmanship, i.e. butnot limited to filters, gaskets, rings, valves and control lines.LimitationsNotice of the alleged defect must be given to the Seller in writing with all identifying details, including serial number, model number,type of equipment and date of purchase within thirty (30) days of discovery of same during the warranty period. If requested by Seller,such product or product thereof must be promptly returned to Seller, freight prepaid for inspection.The Seller must have the warranty registration card on file at Quincy, IL. within ten (10) days of start-up or the warranty maybe declared null and void.The above warranties shall not apply and Seller shall not be responsible nor liable for:(a) Consequential, collateral or special losses or damages.(b) Equipment conditions caused by fair wear and tear, abnormal conditions, accident, neglect or misuse of equipment,improper storage or damages resulting during shipment.(c) Deviation from operating instructions, specifications or other terms of sales.(d) Labor charges, loss or damage resulting from improper operation, maintenance or repairs made by person(s) otherthan Seller or Seller's authorized service station.(e) Improper application or installation of product.(f) compression of other than sweet, dry natural gas as defined by NACE MRO 175.(g) Inadequate filtration (scrubbing) of inlet natural gas.(h) Failure to maintain adequate lubricant in the crankcase.DisclaimerIn no event shall Seller be liable for any claims, whether arising from breach of contract or warranty or claims of negligence ornegligent manufacture, in excess of the purchase price.This warranty is the sole warranty of Seller and any other warranties, express, implied in law or implied in fact,including any warranties of merchantability and fitness for particular use, are hereby specifically excluded.QRNG Series50158-101, July 2003Quincy Compressori3501 Wismann Lane, Quincy IL. - 62305-3116

ContentsSECTION 1SAFETYSafety First . 1Summary of Changes . 3SECTION 2SYSTEM DYNAMICSDescription & Application . 4Principles of Compression Cycles . 4Principles of Lubrication Systems . 4Specifications . 5SECTION 3INSTALLATIONINSTALLAALLATIONReceiving Delivery . 6Freight Damage . 6Location . 7Electrical Supply Requirements . 8Mounting . 8System Components . 9Induction System . 10Compressed Natural Gas Discharge System . 10SECTION 4START-UP & OPERATIONSTARART-UPOPERATIONPre-Starting Checklist . 11Initial Starting & Operating . 12Daily Starting Checklist . 12SECTION 5MAINTENANCE & LUBRICATIONLUBRICATIONStopping for Maintenance . 13Maintenance Schedule . 13Maintenance Schedule Checklist Sample . 14Lubrication . 14Pulley / Sheave Alignment & Belt Tension . 15Reversal of Compressor Rotation . 15Torquing Cylinder to Head Capscrews . 17SECTION 6TROUBLESHOOTINGTroubleshooting . 18QRNG Series50158-101, July 2003Quincy Compressorii3501 Wismann Lane, Quincy IL. - 62305-3116

SECTION 1SAFETYSafety FirstAt Quincy Compressor safety is not only a primary concern, but a faithfullyperformed practice. Beginning with the design stage, safety is built into “TheWorld’s Finest Compressor”. It is the intention of this manual to pass along the“safety first” concept to you by providing safety precautions throughout itspages.“DANGER !”, “WARNING !”, and “CAUTION !” are displayed in large boldcapital letters in the left hand column to call attention to areas of vital concern.They represent different degrees of hazard seriousness, as stated below. Thesafety precaution is spelled out in bold upper and lower case letters in the righthand column.DANGER !Immediate hazards which will result in severe personal injury ordeath.WARNING !Hazards or unsafe practices that could result in personal injury ordeath.CAUTION !Hazards or unsafe practices which could result in minor personalinjury, product or property damage.Each section of this instruction manual, as well as any instructions suppliedby manufacturers of supporting equipment, should be read and understoodprior to starting the compressor. If there are any questions regarding any partof the instructions, please call your local Quincy Compressor distributor, or theQuincy Compressor factory before creating a potentially hazardous situation.Life, limb, or equipment could be saved with a simple phone call.Compressors are precision high speed mechanical equipment requiringcaution in operation to minimize hazard to property and personnel. There aremany obvious safety rules that must be observed in the operation of this typeof equipment. Listed below are some additional safety precautions that must beobserved. Transfer of toxic, dangerous, flammable or explosive substances using QuincyCompressor products is at the user’s risk. Turn off and lockout/tagout (per OSHA regulation 1910.147) the main powerdisconnect switch before attempting to work or perform any maintenance. Do not attempt to service any part of the unit while it is operating. Per OSHA regulation 1910.147, relieve the system of all pressure beforeattempting to service any part of the unit. Do not operate the unit with any of its safety guards, shields, or screensremoved.QRNG Series50158-101, July 2003Quincy Compressor13501 Wismann Lane, Quincy IL. - 62305-3116

Allow ample time for the compressor to cool before performing serviceprocedures. Some surface temperatures exceed 350 F when the compressor isoperating. Do not remove or paint over any DANGER!, WARNING!, CAUTION!, orinstructional materials attached to the compressor. Lack of informationregarding hazardous conditions can cause property damage or personal injury. Periodically check all pressure relief valves for proper operation. Do not change the pressure setting of the pressure relief valve, restrict thefunction of the pressure relief valve, or replace the pressure relief valve witha plug. Do not install a shutoff valve in the compressor discharge line without firstinstalling a pressure relief valve of proper size and design between the shutoffvalve and the compressor. Do not use plastic pipe, rubber hose, or lead-tin soldered joints in any part ofthe compressed gas system. Alterations must not be made to this compressor without Quincy Compressor’sapproval. Be sure that all tools, shipping and installation debris have been removed fromthe compressor and installation site prior to starting the compressor. Do not operate the compressor in excess of the ASME pressure vessel ratingfor the receiver or the service rating of the compressor, whichever is lower. Make a general overall inspection of the unit daily and correct any unsafesituations. All fasteners and fittings must be kept tight. Reckless behaviour of any kind involving compressed gas is dangerous and cancause very serious injury to the participants. Provisions should be made to have the instruction manual readily availableto the operator and maintenance personnel. If for any reason any part of themanual becomes illegible or the manual is lost, have it replaced immediately.The instruction manual should be read periodically to refresh one’s memory.It may prevent a serious or fatal accident. Never use a flammable or toxic solvent for cleaning the inlet filter or any parts.DANGER !Air used for breathing or food processing must meet OSHA. 29 CFR1910.134 or FDA 21 CFR 178.3570 regulations. Failure to do so maycause severe injury or death.WARNING !Do not operate a Quincy natural gas compressor in excess of itspublished rating listed in the parts book.QRNG Series50158-101, July 2003Quincy Compressor23501 Wismann Lane, Quincy IL. - 62305-3116

The owner, lessor or operator of any compressor unit manufactured byQuincy Compressor is hereby warned that failure to observe the safetyprecautions and procedures outlined in this manual may result in seriouspersonal injury, damage to property, and may void your warranty. QuincyCompressor must authorize all warranty service. Before contacting yourdistributor or the factory, check the maintenance requirements and thetroubleshooting guide for your compressor. Most warranty issues can beresolved by following proper maintenance procedures.Quincy Compressor neither states as fact, nor in any way implies that theabove list of safety precautions is an all inclusive list, the observance of whichwill prevent all damage to property or injury to personnel.Quincy Compressor’s liability is limited to the basic compressor as suppliedby Quincy Compressor, and is limited in defects in material and workmanship.Any modifications of system components related to the operation of the basiccompressor such as (but not limited to) the suction and discharge connectionsand drive arrangements are the responsibility of the owner / operator.Every effort has been taken to ensure that complete and correct instructionshave been included in this manual. However, possible product updates andchanges may have occurred since this printing. Quincy Compressor reservesthe right to change specifications without incurring any obligation for equipment previously or subsequently sold.Summary of Significant Changes to This Manual(since previous printing dated August 1997):· Added Terms & Conditions statement· Edited verbiage pertaining to lubrication (compressors shipped withlubrication in the crankcase).· Removed torque specifications (torque specifications are now available inrespective parts books).QRNG Series50158-101, July 2003Quincy Compressor33501 Wismann Lane, Quincy IL. - 62305-3116

SECTION 2SYSTEM DYNAMICSDescription & ApplicationQuincy Compressor QRNG Series naturalgas compressors are heavy duty industrial,aircooled, single acting, belt driven, singleor two stage compressors. These compressors are designed to compress sweet gasonly (with a hydrogen sulfide content nogreater than 10 ppm).Principles of CompressionCyclesSingle Stage CompressorsPix 1064Fig. 2-1 Cross Section of Typical QRNG2 Stage Pressure Lubricated Cylinder & CrankcaseDuring the downstroke of a single stagenatural gas compressor, natural gas is drawnthrough an intake valve in the head of thecompressor and into the compression cylinder. At the bottom of the stroke, the intakevalve closes and natural gas is trapped inthe cylinder. The natural gas is then compressed in the cylinder during the upstrokeof the piston. Total compression, from intake pressure to the final discharge pressure, is accomplished in one stroke of thepiston.Two Stage CompressorsDuring the downstroke of a two stage natural gas compressor, natural gas isdrawn through an intake valve in the head of the compressor into the lowpressure cylinder and compressed during the upstroke of the piston.The compressed natural gas is then released through a discharge valve inthe head of the compressor to an intercooler (usually finned tubing) where theheat resulting from compression is allowed to dissipate. The cooler, compressednatural gas is then drawn into a second compression cylinder, the high pressurecylinder, for compression to final pressure.From there the compressed natural gas is released through a dischargevalve to a natural gas receiver tank or directly to a network of compressednatural gas supply lines. In one revolution of the crankshaft a compression cycleis completed.Principles of Lubrication SystemsMoving parts within the crankcase are supplied with lubrication by a positivedisplacement, gerotor type lubricant pump. Lubricant is drawn up from thebottom of the crankcase to the lubricant pump through an lubricant sumpstrainer screen. The lubricant is then forced under pressure through thelubricant filter (if so equipped). Lubricant travels under pressure throughdrilled journals in the crankshaft and connecting rods to lubricate crankshaftbearings, wrist pin bearings and the cylinder walls.QRNG Series50158-101, July 2003Quincy Compressor43501 Wismann Lane, Quincy IL. - 62305-3116

SpecificationsSingle Stage ModelsCylinder Bore Dia.Piston Skirt Dia.Piston / Cylinder (at skirt)Crankshaft Dia. (at main bearing)Housing Bore (at main bearing)Crankshaft End PlayCrankshaft Journal SizeQRNG 240QRNG 270QRNG 41254.001 / 4.0003.9985 / 3.9980.0015 / .0031.5015 / 1.50253.000 / 3.001.0015 / .0031.7500 / 1.75054.501 / 4.5004.491 / 4.490.009 / .0112.0015 / 2.00253.6718 / 3.6728.0015 / .0032.2480 / 2.24854.501 / 4.5004.491 / 4.490.009 / .0112.1265 / 2.12754.375 / 4.376.002 / .00352.2480 / 2.2485QRNG 325QRNG 340QRNG 3502.501 / 2.5004.503 / 4.5022.4985 / 2.49804.497 / 4.496.0015 / .0030.005 / .0071.5015 / 1.50253.000 / 3.001.0015 / .00301.7500 / 1.75053.001 / 3.0005.251 / 5.2504.491 / 4.4903.251 / 3.2506.001 / 6.0004.491 / 4.490.0015 / .0030.004 / .0062.0015 / 2.00253.6718 / 3.6728.0015 / .00302.2480 / 2.2485.0020 / .0035.007 / .0092.0015 / 2.00253.6718 / 3.6728.0015 / .00302.2480 / 2.2485QRNG 370QRNG 51203.251 / 3.2506.001 / 6.0003.2480 / 3.24755.993 / 5.992.002 / .0035.007 / .0092.0015 / 2.00253.6718 / 3.6728.0015 / .0032.2480 / 2.24853.251 / 3.2506.001 / 6.0003.2480 / 3.24755.993 / 5.992.0020 / .0035.007 / .0092.1265 / 2.12754.375 / 4.376.0020 / .00352.2480 / 2.2485Two Stage ModelsCylinder Bore Dia.H.P.L.P.Piston Skirt Dia.H.P.L.P.Piston / Cylinder (at skirt)H.P.L.P.Crankshaft Dia. (at main bearing)Housing Bore(at main bearing)Crankshaft End PlayCrankshaft Journal SizeCylinder Bore Dia.H.P.L.P.Piston Skirt Dia.H.P.L.P.Piston / Cylinder (at skirt)H.P.L.P.Crankshaft Dia. (at main bearing)Housing Bore(at main bearing)Crankshaft End PlayCrankshaft Journal SizeQRNG Series50158-101, July 2003Quincy Compressor53501 Wismann Lane, Quincy IL. - 62305-3116

SECTION 3INSTALLATIONINSTALLAALLATIONReceiving DeliveryImmediately upon receipt of compressor equipment and prior to completelyuncrating, the following steps should be taken:CAUTION !Step 1)Inspect compressor equipment for damage that may have occurredduring shipment. If any damage is found, demand an inspectionfrom the carrier. Ask the carrier how to file a claim for shippingdamages. (Refer to SECTION 3, Freight Damage for completedetails.) Shipping damage is not covered by Quincy Compressor warranty.Step 2)Insure that adequate lifting equipment is available for moving thecompressor equipment.Improper lifting can result in component or system damage, orpersonal injury. Follow good shop practices and safety procedureswhen moving the unit.Step 3)Read the compressor nameplate to verify the model and sizeordered.Step 4)Read the motor nameplate to be sure the motor is compatible withyour electrical conditions (volts, phase, hertz).Step 5)Read the pressure relief valve nameplate to be sure it does notexceed the working pressure shown on the compressor or any othercomponent in the system.Step 6)Read and understand the safety precautions containedwithin this manual. The successful and efficient operation ofcompressor equipment depends largely upon the amount of caretaken to install and maintain the equipment. Quincy Compressorstrongly recommends that any or all person(s) in charge of installing, maintaining, or servicing one of our compressors read andunderstand the entire contents of this manual in order to performsuch duties safely and efficiently.Freight DamageIt is extremely important that you examine every carton and crate as soon asyou receive it. If there is any obvious damage to the shipping container, havethe delivering carrier sign the freight bill, noting the apparent damage, andrequest a damage report.If concealed damage is discovered at a later date, the carrier mustbe notified within 15 days of initial receipt of freight. Concealedshipping damage is not covered by Quincy Compressor Warranty.Contact the carrier as soon as possible, giving them an opportunity to inspectthe shipment at the premises where the delivery was made. Do not move thedamaged freight from the premises where the original delivery was made.QRNG Series50158-101, July 2003Quincy Compressor63501 Wismann Lane, Quincy IL. - 62305-3116

Retain all containers and packing for inspection by the carrier.A claim form can be requested from the carrier: Standard Form forPresentation of Loss and Damage Claims (form # 3208). Your claim will needto be substantiated with the following documents:a.)form #3208b.)original bill of ladingc.)original paid freight billd.)original invoice or certified copye.)other particulars obtainable in proof of loss or damage (photos,damage inspection, etc.)The proper description and classification of our product in the NationalMotor Freight Classification 100-H, contained in item 118100, reads as follows:Compressors, air, or air ends: with or without air tanks, hose or nozzles,mounted or not mounted.”We suggest that these instructions be circulated to your shipping andreceiving personnel.LocationQuincy natural gas compressors should be installed in an area that is clean, dry,well lighted, adequately ventilated and not more than 24 inches to a wall oranother compressor. Inspection and maintenance checks are required daily,therefore, sufficient space needs to be provided around the compressor for safeand proper inspection, cleaning, and maintenance.Allows ample circulation of air must be provided across the compressorcylinders, heads and cooler (if so equipped). Do not allow hot air from additionalequipment to blow towards the compressor. If at all possible, the pulley drivesystem (i.e. motor pulley, compressor sheave, belts and guard) should belocated next to a wall to minimize any danger created by the drive system whilethe compressor is operating.The compressor should be operated in temperatures under 104 F. In coldclimates, the compressor should be installed in a heated building.CAUTION !Do not operate this compressor in ambient temperatures lowerthan -15 F. A crankcase heater is recommended for a compressorthat is to operate in temperatures under 32 F.WARNING !Under no circumstances should a compressor be used in an areathat may be exposed to toxic or corrosive atmosphere. Do notstore toxic or corrosive agents near the compressor.NoiseNoise is a potential health hazard that must be considered. There are federaland local laws governing acceptable noise levels. Check with local officials forspecifications.QRNG Series50158-101, July 2003Quincy Compressor73501 Wismann Lane, Quincy IL. - 62305-3116

Excessive noise can be effectively reduced through various methods. Totalenclosures, intake silencers, baffle walls, relocating or isolating the compressorcan reduce noise levels. Care must be taken when constructing total enclosuresor baffle walls. If not properly constructed or positioned, they could contributeto unacceptable noise levels or overheating. Consult your local Quincy gasapplication distributor if assistance is required.CAUTION !Unusual noise or vibration indicates a problem. Do not operate thecompressor until the source has been identified and corrected.Electrical Supply RequirementsThe electrical installation of this unit should be performed by a qualifiedelectrician with knowledge of the National Electrical Code (NEC), OSHA. codeand/or any local or state codes having precedence.Before installation, the electrical supply should be checked for adequate wiresize and transformer capacity. A suitable circuit breaker or fused disconnectswitch should be provided. When a 3 phase motor is used to drive a compressor,any unreasonable voltage imbalance between the legs must be eliminated andany low voltage corrected to prevent excessive current draw. Note: This unitmust be grounded.The installation, electric motor, wiring, and all electrical controls must bein accordance with NFPA National Electric Code, National Electric SafetyCode, state and local codes. Failure to abide by the national, state and localcodes may result in physical harm and/or property damage.DANGER !High voltage may cause personal injury or death. Disconnect andlockout/tagout per OSHA. regulation 1910.147 all electrical powersupplies before opening the electrical enclosure or servicing.WARNING !Never assume a compressor is safe to work on just because it is notoperating. It could restart at any time. Follow all safety precautions outlined in SECTION 5, Stopping For Maintenance.CAUTION !NEMA electrical enclosures and components must be designed tooperate in the area in which they are installed.MountingProper mounting of Quincy natural gas compressors is crucial to the safeoperation and longevity of the equipment. The installation requires a flat andlevel concrete floor or pad. Satisfactory results can usually be obtained bymounting the compressor on vibration isolating pads available from your localQuincy gas application distributor. Refer to Fig. 3-1, Isolator Installation forUnanchored or Anchored Receiver.State or local codes may mandate that the compressor be bolted to the floor.In this case the unit must be leveled and bolted making absolutely certain thefeet are not stressed in any manner. Leave the flange nut loose & lock it withQRNG Series50158-101, July 2003Quincy Compressor83501 Wismann Lane, Quincy IL. - 62305-3116

FLANGE NUTLeave loose & lockwith a back-up nutRECEIVER FOOTFLANGE NUTISOLATOR BACKINGPLATE OR SHIMS IFNECESSARYRECEIVER FOOTISOLATOR BACKINGPLATEISOLATORSystem componentsBOLTISOLATORANCHOREDFLOOR STUDUNANCHOREDa back-up nut! Uneven feet drawn tightly to the concretepad will cause severe vibrations resulting in crackedwelds or fatigue failure. The customer is responsible forproviding a suitable foundation & isolator mountingwhere necessary.ANCHOREDQRNG natural gas compressors are used for a wide rangeof applications, each with their own specific requirementsfor supportive and protective system components. Forthis reason Quincy Compressor includes minimal information regarding the vast array of available components.110365Safety and efficiency are the primary concerns whenselecting components for compressed natural gas systems. All components used on packaged QRNG compressors must be designed to operate safely (at a minimum) in a Class 1, Division2, Group D environment. Products of inferior quality can not only hinderperformance of the unit, but could cause system failures that result in bodilyharm or even death. Select only top quality components for your system. Callyour local Quincy gas application distributor for quality parts and professionaladvice.Fig. 3-1 Isolator Installation forUnanchored or Anchored ReceiverDrive Pulleys / SheavesVarious pulley and sheave combinations are available to obtain the desirednatural gas pressure and delivery rate of your compressor. Consideration mustbe given to these combinations to ensure that the motor is not overloaded byoperating above or below the designed speed range.Whatever combination is employed, the drive pulleys & compressor sheavesmust be properly aligned and drive belt tension set to specifications (refer toSECTION 5, Pulley / Sheave Alignment & Belt Tension). Improper pulley/sheave alignment and belt tension can cause motor overloading, excessivevibration, and premature belt and/or bearing failure.WARNING !Excessive compressor RPM’s (speed) could cause a pulley or sheaveto shatter. In an instant, the pulley or sheave could separate intofragments capable of penetrating the belt guard and causing bodilyharm or death. Do not operate the compressor above the recommended RPM listed in the parts book.GuardsAll mechanical action or motion is hazardous in varying degrees and needs tobe guarded. Guards should be designed to achieve the required degree ofprotection and still allow full air flow from the compressor sheave across theunit. Guards shall be in compliance with OSHA safety and health standards 29CFR 1910.219 in OSHA manual 2206 and any state or local codes.WARNING !Guards must be fastened in place before starting the compressorand never removed before cutting off and locking out the mainpower supply (refer to SECTION 5, Stopping for Maintenance).QRNG Series50158-101, July 2003Quincy Compressor93501 Wismann Lane, Quincy IL. - 62305-3116

Pressure Relief ValvesPressure relief valves aid in preventing system failures by relieving systempressure when compressed natural gas reaches a determined level. They areavailable in various pressure settings to accommodate a range of applications.Pressure relief valves are preset by the manufacturer and under no circumstances should the setting be changed by anyone other than the manufacturer.DANGER !Pressure relief valves must be provided to protect compressednatural gas systems in accordance with ASME B19 safety standards. Failure to provide properly sized pressure relief valves maycause property damage, severe personal injury or even death.Induction SystemScrubbers Dryers & FiltersOn closed systems, the inlet piping must include the necessary filters andscrubbers to eliminate liquid or solid carry-over to the compressor. Additionally, protection from overpressurization must be provided.It is the user’s responsibility to provide adequate filtration. Warranty will bevoid if a failure is determined to be caused by inadequate filtration oroverpressurization.Pulsation DampenerRemotely installed inlets can lead to vibrations in the inlet pipi

QRNG Series Quincy Compressor 50158-101, July 2003 3 3501 Wismann Lane, Quincy IL. - 62305-3116 The owner, lessor or operator of any compressor unit manufactured by Quincy Compressor is hereby warned that failure to observe the safety precautions and procedures outlined in

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