Installation Notes for Ingersoll Rand KVG-123 Compressor Package (Up to 255 Gallon Sump Capacity) Ingersoll Rand KVG-123 Compressor Package

Transcription

1 Installation Notes for Ingersoll Rand KVG-23 Compressor Package Part # MTS-DL9 Kit # MTS-DL9 Puradyn Part # MTS- DL9 Ingersoll Rand KVG-23 Compressor Package Description UNIT MTS-DL 240 Main Assy. w/supply Line Conn. SNG Oil & Gas Services. -3 US, Top Return, Non-FPS Manual, Installation Notes for Ingersoll Rand KVG-23 Compressor (255 Gal. Sump) Manual, MTS Std. Installation Qty M T HOSES Kit, Hose Return 5/8 Off-Road W/ -2 ORFS fittings (Includes 72 Return Hose, Off-Road) Assembly, Hose 3/6" ID MTS-DL 240 Press. Manifold To Filter Inlet 2 & 3-Unit Systems- Pre-installed Assembly, Hose 3/6 ID MTS-DL 240 Pressure Manifold to filter inlet 2& 3-Unit Systems (For side units) PARTS, ADDITIONAL KIT HARDWARE Assembly, Press. Manifold W/FPS Port & ORFS Connections For Tube Inlet Line Connection w/ Sample Valve, 3-Unit System Kit, Assembly Flow Meter 2 ORFS Connections 2-20 GPH Kit, Return Track Plumbing -2 ORFS W/ Parflanged Tube Assemblies Kit, Bag Return fitting NPT X -2 ORFS MTU 4000 Frac Truck/ Cummins QSK 50 Gen-set/ IR KVG-23 Compressor MOUNTING KIT HARDWARE Kit, Bolt Bag CAT B Mounting Plate, TF 240 Plumbing Manifold Mounting Plate, CAT356 Engine Washer, Flat 3/8 (pre-assembled) Bolt, 3/8-6 X Long Hex (pre-assembled) Nut, Nylon Insert, 3/8-6 (pre-assembled) MTS-DL9_ MTS-DL9_Inst_Notes_ING-Rand_KVG-23_Rev0 Page of 6

2 Installation Notes for Ingersoll Rand KVG-23 Compressor Package Part # MTS-DL9 Kit # MTS-DL9 Customer Care Alert: The owner/operator of this equipment is responsible for proper installation, care, maintenance, product registration and usage as outlined in the puradyn Bypass Oil Filtration System Installation Manual. The following document is used in conjunction with the puradyn Bypass Oil Filtration System Installation Manual (part number ) that is included in the unit box, and as such, should be considered a supplemental source of information. Furthermore, this document covers the installation of a 3-unit MTS-DL 240 Bypass Oil Filtration System on an Ingersoll Rand KVG-23 Compressor. Mounting the Units: The (3) Bypass Filter Units should be mounted side-by-side located at a suitable area along the equipment platform where the units can be secured in place. As shown in Picture, arrange the (3) filter units side-by-side, identifying the unit that has the Pressure Manifold Assembly to be placed in the middle for future supply line connections. Prepare the mounting plates (part number ) to be secured to ground or a structural frame before-hand that can support these (3) MTS-DL 240 units (Picture 2). Picture Picture 2 (Side-by-Side arrangement) (Base plate mounting arrangement) Do not secure the (3) filter units to the base-plates yet. Push-Button Sample Valve Pressure Manifold Assembly 90-4 ORFS fitting For Pressure Manifold Assembly connections, note that () end of assembly features a Push-Button Sample Valve, while the other end features a compression fitting for connection to supply line Compression fitting Supply connection fittings on (2) adjacent bypass filter units to be connected to 90 ORFS fitting in Supply fittings pressure manifold assembly Picture 3 Picture MTS-DL9_ MTS-DL9_Inst_Notes_ING-Rand_KVG-23_Rev0 Page 2 of 6

3 Installation Notes for Ingersoll Rand KVG-23 Compressor Package Part # MTS-DL9 Kit # MTS-DL9 Installing the Pressure Fittings: Install the Shut-off Valve to engine, referring to example in Picture 5. Use supply tubing (3/8 stainless steel) to connect shut-off valve to the Pressure Manifold Assembly, by fastening tube end to 3/8 compression (Alock/Swage-lock) fitting on manifold end (see Picture 6). *Note: Shut-off valve, 3/8 tubing and fittings not part of kit - to be supplied and installed by customer; Connect (2) additional supply hose assemblies - P/N each built with 3/6 hose, () straight and () 90 crimp hose fitting, to the (2) unused -4 male 90 ORFS fittings on top face of Pressure Manifold Assembly (see Picture 6 & 7). Connect other ends of supply hose assemblies with 90 crimp fitting, to supply fittings on adjacent bypass filter units (see Picture 6 & 7) ORFS Connection Compression fitting Supply fittings Picture 5 Picture 6 Picture 7 (Install Shut-off Valve & supply line to engine- (Supply Port Connections) (Supply line connections to MTS-DL units) Actual hardware not shown) Installing the Return Line: Locate and remove the NPT (port) plug fitting on engine. Replace plug fitting with adapter fitting (P/N ) from kit bag (P/N ) provided in this application kit (See Pictures 8, 9). Now install elbow fitting (P/N ) from kit bag (P/N ), fastening to adapter fitting with elbow fitting properly oriented in the direction of bypass filter before firmly tightening adjustment nut. *Note: Applying Stay-bond hydraulic sealant or Teflon tape to NPT thread is recommended. Assemble Return plumbing materials P/N (Parflanged tube assemblies (2), tee-fitting (2) & 90 fitting) supplied with kit as shown in the Picture 0. Also connect the Flow Meter Assembly P/N provided with the application kit to the return end of plumbing connection (tee-fitting) as shown in the Picture 0. Assemble () 5/8 ID return hose assembly using supplies provided in the part number M Hose Kit. Connect () end of return hose assembly to elbow fitting end of return fitting assembly (P/N ) and route the other end of hose to return fitting of flow meter in MTS-DL 240 Bypass Filter Units return setup, and connect (see Picture 0). The oil return hoses must be routed, ensuring they do not come in contact with any sharp edges or moving parts; make sure hoses are routed in downward slope, with no kinks or traps, to oil pan. Oil is returned by gravity (SEE INSTALLATION MANUAL). Secure in place with clamps if necessary. Drain the engine oil and clean all surfaces. Note: Properly orient the fitting in order to avoid damage from debris. Note: If necessary, cover the oil return hose with a secondary hose (or equivalent) to better protect it from potential damage. NPT Return port cover NPT Adapter Fitting P/N Elbow fitting P/N Picture 8 Picture 9 (Remove plug & replace with Return fitting assembly) (Close-up view of Return fitting assembly) MTS-DL9_ MTS-DL9_Inst_Notes_ING-Rand_KVG-23_Rev0 Page 3 of 6

4 Installation Notes for Ingersoll Rand KVG-23 Compressor Package Part # MTS-DL9 Kit # MTS-DL9 Picture 0 (Return Plumbing, Flow Meter and Return Hose Installation) Testing the By-pass System: Clean all surfaces and wipe off oil. Check all fittings tightness. Check operation of shut-off and sampling valve. Tie off all lines with tie wraps. Fill engine with oil. Start engine and check all connections for oil leaks. Open sample valve and verify that oil flow is present. Shut engine off and check oil level. Place puradyn Installation Manual in the documentation holder mounted to the equipment MTS-DL9_ MTS-DL9_Inst_Notes_ING-Rand_KVG-23_Rev0 Page 4 of 6

5 Installation Notes for Ingersoll Rand KVG-23 Compressor Package Part # MTS-DL9 Kit # MTS-DL9 TROUBLESHOOTING SECTION The puradyn system has been engineered in a quality system certified to ISO 900. It is manufactured from the highest quality materials available with superior workmanship. If, however, your puradyn unit is not functioning properly, check the following conditions as indicated: ) Restricted oil Flow: Pressure line may be clogged... blow line out with high air pressure (do this first) Shutoff valve maybe closed... open valve Filter may be dirty and clogged... replace with new filter Metering jet screen maybe clogged.. clean screen thoroughly If metering jet is clogged... clean metering jet thoroughly Cleaning the Metering Jet Assembly (2 & 3-Unit MTS-DL Models) ) Loosen hose fitting, for disconnection of Inlet Plumbing Hose Assembly 2) Loosen (adjustment) locknut on 90 Degree fitting- allowing rotation of fitting 3) Slightly rotate fitting CCW, while gently pulling hose assembly rearward/downward- to fully disconnect; continue rotating fitting to remove- metering jet screen will drop down 4) Clean port internals & metering jet screen with solvent/fine wire brush; use high-pressure air to blow-out port & screen, clearing any debris Locknut Metering Jet Screen Back-up washer 5) Back-off locknut/back-up washer on 90 degree fitting and lubricate external o-ring w/system fluid, also applying a dab on face of fitting- for screen adherence 6) Place screen on face of fitting, centered, against dabbed oil; screw this end of fitting into port- by hand, until back-up washer contacts face of port. 7) Slightly unscrew fitting- as required to align with hose assembly, then use (2) wrenches to hold fitting in place while tightening locknut; reconnect hose assembly 8) Check all fittings for tightness MTS-DL9_ MTS-DL9_Inst_Notes_ING-Rand_KVG-23_Rev0 Page 5 of 6

6 Installation Notes for Ingersoll Rand KVG-23 Compressor Package Part # MTS-DL9 Kit # MTS-DL9 Oil Analysis Procedures The Puradyn Filter Technologies Oil Management Program includes an oil analysis schedule that assists our customers in achieving the benefits of extended oil drain intervals and longer service life for their engines and equipment. Oil analysis is the key to achieving the benefits that result from optimized oil life (with reasonable safety precautions) and extended drain intervals. In addition, oil analysis is the only economical way to measure wear or contamination in the engine or equipment. Of primary importance is the interpretation of the test data, which is easy to read and self-explanatory. The Puradyn oil analysis is conducted by an independent laboratory and is reported in an easy to understand format, which includes the following data of the oil: Spectrophotometric Analysis Wear Metals TBN & TAN Oil condition Contaminant levels This analysis should be conducted in order to monitor and evaluate the lubrication system. The oil analysis can present warnings of any existing or potential problems, along with measuring the performance of the puradyn system MTS-DL9_ MTS-DL9_Inst_Notes_ING-Rand_KVG-23_Rev0 Page 6 of 6