Compressor Cyllnder lnstructions

F. Push the band off the end of the cone, onto the pistan and into its groove.

NOTE

Normally the rider band contracts as it dissipates heat. lf the rider

fails to constrict, reheat it with a broad based flame to between 350°
to 400°F (177° to 204ºC).

4. Check to be certain the rider bands are tight in their respective grooves befare reinstalling
the pistan in the cylinder.

5. Previous instructions describe the installation of the pistan and rod assembly into the
cylinder.

Replacing Flanged Cylinder Liners

The replacement liner is shipped with a new liner ñanqe-to-oylinder gasket and a new 0-
ring (if used). Ensure that ali cylinder materials are available befare beginning work. lt is
imperative that the replacement gasket fumished with the liner is used during installation. The
material specification, hardness and dimensions are critica! toan effective seal.

T ake micrometer readings of the cylinder liner for proper bore size prior to installation.
Check for any liner damage that may have occurred during shipping.

Befo re working on any compressor cylinder, to avoid serious

lnjury or death, shut down the compressor and lock the main
driver in the OFF position. Engage the ftywheel locking device
and bleed all pressurized gas from the compressor cylinders.

NOTE
Procedures for replacing the liner are somewhat different between
cylinder types.

Grey /ron and Ductil• /ron Cylinders

Preparation:

1. Remove the outer head and the wom cylinder liner. The liner normally can be pressed out
or pulled out using a wheel-puller fücture. When a press or puller is not available, machine
the liner out of the cylinder barre!.

2. Replacement Jiners are fumished compietely machined exceptas noted below:

A. The O. D. of the liner is fumished 0.060 to 0.070 inch (1.5 to 1.8 mm) oversize and
must be rnachined to fit in the cylinder bore as defined in Table VII.

60
 Compressor Cyllnder lnstructions

NOTE
Because the cylinder bore has a step provided for ease of liner
installation, the outside diameter of the liner must also be machined
to match this step. See dimensions •A• and •e• for approxirnate
loca.tions for bore measurements in Rgure 19. These dimensions
rnay indica.te that a light machining cut, or honing, is necessary to
restare the bore to the desired state of roundness for pressed-in
liners. The larger diameter on the outer end of the liner must stop
short of the smaller diameter of the cylinder bore at the trame encl.
Refer to Figure 19, Dimension •L•.

Mlnimum L"
11
= 0.500 inch (12.7 mm}

B. The indicator holes and lubrica.tionhales, with the exception of liners designed with
oil grooves on the O. D. of the liner, will be rnachined after installation of the linar
in the cylinder.

. FRAME END OF CVUNDER OUTER END OF CYUNDER ·

LUBRICATOR /
HOLE

LINEA

GASKET MUST BE PLACED UNDER FLANGE BEFORE INSTALLATION

OF LINEA IN CYUNDER (GASKET SUPPLIED WITH REPLACEMENT LINEA)
TP-4513-A

Figure 19. Replacement Cylinder Uner

(Grey and Ductile lron Cyllnders)

61
Compressor Cylinder lnstructlons

Table VII. Liner Outside Diameter-to-Cylinder Bore Fit

< 6 inches (152 mm) Metal-to-Metal to 0.002 inch

6 to 16 inches (152 to 406 mm)
> 16 inches (406 mm)
(0.05 mm) lnterference
0.002 inch (0.05 mm) Slip Frt
to 0.002 inch (0.05 mm)
lnterference
0.003 inch (O.OS mm) Slip Fit
to 0.003 inch (0.08 mm)
1 nterference

C. Below 1000 PSIG (6.8 Mpa) Max:imum Allowable Working Pressure (MAWP), the
liner flange is finished to size on the O.O. when received. Above 1000 PSIG (6.8
Mpa) MAWP, the liner flange is fumished 0.060 to 0.070 inch ( 1.5 to 1.8 mm)
oversize on the outside diameter. This flange O. D. must be machined to match the
cylinder flange counterbore at the same time the O. D. of the liner is finish·
machined to size. For clearance, see Table VIII and Figure 19, dimension "C".

Table VIII. Liner Flange Outside Dlameter-

to-CyllnderCounterboreClearance

< 1000 PSIG (6.8 Mpa) MAWP 0.010-0.030 inch (0.25-0.77 mm)
On Diameter

> 1000 PSIG (6.8 Mpa) MAWP 0.002-0.004 inch (0.05-0.10 mm)
On Diameter

3. lf the cylinder liner uses an 0-ring seal on the outer circumference, the following
procedures should be followed:

A. lf the original liner was designed with 0-ring seals on the outside diameter of the
liner, duplicate the groove depth and width machining dimensions in the replace-
ment liner and place a new 0-ring in the groove before installing the liner in the
cylinder.

B. Slide the flange gasket on the liner, then position the sealing 0-ring(s) into the
grooves on the liner circumference. Lubricate the 0-ring(s) liberally using a silicone
lubricant or other lubricant compatible with the 0-ring(s) and the process gas.
Press the liner into place within the cylinder taking care to avoid damaging or
displacing the 0-ring(s).

62
 Compressor Cylinder lnstructions

lnstallation:

1. Make sure the new liner flange gasket, supplied with the liner, is in its proper position
befare insertion of the liner into the cylinder bore.

2. Ensure that the valve port holes are accurately aligned with the matching cylinder valve
hole machining while inserting the liner into the cylinder bore.

3. Scribe a line through the valve port on the outside diameter ot the liner and a matching
mark on the cylinder to act as guides in properly positioning the liner.

4. lnstall the liner into the cylinder barrel with the liner-to-cylinder bore fit as shown in Table
VII. The cylinder barrel can be thermally expanded using steam in the water jacket, or
electrical heaters [not to exceed 300ºF {149°C)], to assist in the insertion of the liner.

5. A flanged cylinder liner utilizes the clamping action of the outer head and flange to hold the
cylinder liner in place, and to prevent liner rotation during operation.

6. Allow the cylinder (with liner in place) to reach room temperature naturally and check the
liner bore for roundness.

7. Drill the lubricating oíl holes in the lineras needed after installation ot the liner into the
cylinder barrel. Radius the hole at the intersection with the liner inside diameter to 0.12
inch (3 mm).

8. Drill the indicator holes in the liner as needed after installation of the liner into the cylinder
barre!. Radius the hole at the intersection with the liner inside diameter, again to 0.12 inch
(3 mm).

9. Blow out and clean ali chips and debris from the lubricator and indicator holes. Reinstall
all lubricator lines and pipe plugs previously removed during drilling and cleaning.

Fabrícated Carbon Steel, Stainless Steel and Cast Steel Cylinders

Preparation:

1. Remove the outer head and the wom cylinder liner. The liner norrnally can be pressed out
or pulled out using a wheel-puller fixture. When a press or puller is not available, machine
the liner out ot the cylinder barrel.

2. Replacement liners are furnished completely machined exceptas noted below:

A. The O. D. of the liner is furnished 0.060 to 0.070 inch (1.5 to 1.8 mm) oversize and
must be machined to suit the cylinder bore as defined in Table VII.

NOTE

lt may be necessary to take a light machining cut or hone in the

cylinder bore afterwardsto restorethe desired state of roundness for
installation of the liner.

63
Compressor Cyllnder lnstructlons

B. The iooicator holes and lubrication holes, with the exception of liners designad with
oil grooves on the O. D. of the liner, will be machined after installation of the liner
in the cylinder.

C. Below 1000 PSIG (6.8 MPa) Maximum Allowable Working Pressure (MAWP), the
liner flange is finished to size on the O.O. when received. Above 1000 PSIG (6.B
MPa) MAWP, the liner flange is fumished 0.060 to 0.070 inch (1.5 to 1.8 mm}
oversize on the outside diameter. This flange O. O. must be machined to match the
cylinder flange counterbore at the same time the O. D. of the liner is finish-
machined to size. For clearance, see Table VIII and Figure 20, dimension ·e•.
3. lf the cylinder liner uses an 0-ring seal on the outer circumference, the following
procedures should be followed:

A. lf the original liner was designad with 0-ring seals on the outside diameter of the
liner, duplicate the groove depth and width machining dimensions in the replace-
ment liner and place a new 0-ring in the groove before installing the liner in the
cylinder.

B. Slide the flange gasket on the liner, then position the sealing 0-ring(s) into the
grooves on the liner circumference. Lubricate the 0-ring(s) liberally using a silicone
lubricant or other lubricant compatible with the 0-ring(s) and the process gas.
Press the liner into place within the cylinder taking care to avoid damaging or
displacing the 0-ring(s).
FRAME END OF CYUNDER OUTER END OF CYUNDER

GASKET MUST BE PLACED UNDER FLANGE BEFORE INSTALLATION

OF LINEA IN CYUNDER (GASKET SUPPUED WITH REPLACEMENT LINEA)

TP-4512

Figure 20. Replacament Cyllnder Linar

(Fabricated, Stalnless and Cast Steel Cylinders)

64
 Compressor Cylinder lnstructions

lnsta/lation:

1. Make sure the new liner flange gasket, supplied with the liner, is in its proper position
before insertion of the liner into the cylinder bore.

2. Ensure that the valve port holes are accurately aligned with the matching cylinder valve
hole machining while inserting the liner into the cylinder bore.

3. Scribe a line through the valve port on the outside diameter of the liner and a matching
mark on the cylinder to actas guides in properly positioning the liner.

4. lnstall the liner into the cylinder barrel with the liner~to~cylinderbore fit as shown in Table
VII. The cylinder barrel can be thermally expanded using steam in the water jacket, or
electrical heaters [not to exceed 300ºF (149°C)], to assist in the insertion of the liner.

5. A flanged cylinder liner utilizes the clamping action of the outer head and flange to hold the
cylinder liner in place, and to prevent liner rotation during operation.

6. Allow the cylinder (with liner in place) to reach room temperature naturally and check the
liner bore for roundness.

7. Drill the lubricating oil holes in the liner as needed after installation of the liner into the
cylinder barrel. Radius the hole at the intersection with the liner inside diameter to 0.12
inch (3 mm).

8. Drillthe indicator holes in the liner as needed after installatíon of the liner into the cylinder
barrel. Radius the hole at the intersection with the liner inside diameter, again to 0.12 inch
(3 mm).

9. Blow out and clean all chips and debris from the lubricator and indicator hales. Reinstall
all lubricator lines and pipe plugs previously removed during drilling and cleaning.

XIV. TIGHTENINGREQUIREMENTS

The fasteners used in compressors must be correctly tightened

to the deslgn pr•stress to ensure safe operation of the equip-
ment. Prior to the lnitial start-up of the equipment, or before
starting an overhauled machine, fasteners must be checked for
proper tightness to ensure the full mechanical integrity of the
unit. After start-up, fasteners that were properly tightened can
loosen due to operating temperaturas and pressures, gaskat
crush, fastener and joint relaxation, and other factors.
THEREFORE, IT IS IMPORTANTTHAT ALL FASTENERSSUB-
JECTED TO THE ABOVE CONDITIONS BE PERIODICALLY
RECHECKEDFOR TIGHTNESS. Particular attantion should be
given to all bolts and nuts on the compressor cylinders, frame
extensions and distance plecas and to the bolting which atta-
ches these parts to the frame.

65
 PARTS LIST

COMPRESS ORCYLINDER

2 021-871
 PARTS LIST
COMPRESSOR CYLINDE ML021-871Gl
ILLUS. K
NO. PART NUMBER PARTNAME 1
T
1 .555-564-201 SSEMBLV
2 .348-820-001 LUG
3 .R78164MX12025 TUD/4.50 PROJ
4 .46A4Kl4 UT HVY HEX
5 .Wl52797A TUD/10.00 PROJ
6 .46A4Kl9 .,..,.-- UT HVY HEX L¡
7 .F39507,,; YLINDER 11.00 LNR1
8 .G710220953V./ ASKET
9 .555-592-001 ,/ ASKET 4
10 .R78164MX14028 TUD/5.00 PROJ
11 .46A4Kl6 UT HVY HEX
12 .348-011-001 IPPLE
13 .002-271-329 RING
14 .R78164MX18049 TUD/9.75 PROJ
15 .46A4Kl9 UT HVY HEX
16 .12493433 UBRICATOR
.• R80746AP1 ODY LUBRICATOR
.• 001-366-003 ASKET
.• 143A7KK2 LBOW 90 DEG ST
.. 33037425 ALVE CHECK
.34A7A8 IPE PLUG/HE WTR PASS

+SE ACCESSORYLfTEAATURESECTION

FOAM:3309 ISSUE:03/07188 REV:001

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