Read COMPRESSOR PARTS ­ TECHNICAL SPECIFICATIONS text version

COMPRESSOR PARTS ­ TECHNICAL SPECIFICATIONS

In order to vindicate our slogan of "Unsurpassable Quality of Compressor Spare Parts", we request you to visit our product wise details. Apart from Dimensional Accuracy, we are maintaining high standards for Material of Construction (M.O.C.) and processing in order to achieve required properties. For us, fitment of a component is always important. But at the same time, we supply components which provide longer life. Therefore, we request you to click on Dialogue Box of "More Detailed Information" to search Complete Product Wise Technical Details, which we maintain. These details are generalised for all types of Air-Conditioning Compressors as well as Air Compressors. After scrutinising, if you feel that we know our job, then kindly search for the Make, Model and parts of your interest and send us your valued Purchase Enquiry.

(01) COMPRESSOR VALVES & PERIPHERALS

(A) AIR-CONDITIONING & REFRIGERATION COMPRESSORS: PRODUCT

Valve Assembly

M.O.C.

PROCESS

PROPERTIES

SIZE

Valve Seat, Valve Guard, Valve Valve Lift is maintained @ Present 300 mm Rings/Reeds, Wavy Springs or 1.5 mm. Leakage Testing Max. 550 mm Valve Springs are assembled with is done on ElectroBolts & Nuts. Pneumatic Testing Rig. Valve Seat SGI Gr 600/2 Castings are Shell Moulded, Shot Hardness 200-220 BHN. Present 300 mm (IS 1865) or Blasted & Annealed. Then, Seats Flatness of Seats checked Max. 550 mm En-9 are Machined, Ground & Lapped. for Light Bands. Seats are phosphated. Valve Guard/ Stroke SGI Gr 600/2 Castings are Shell Moulded, Shot Hardness 200-220 BHN Present 300 mm Limitor (IS 1865) Blasted, Annealed & then Max. 550 mm Machined. Guards are Phosphated. Valve Rings/Reeds Sandvik Gr 17 Laser/Water Jet Cut, Heat Hardness @ 50 HRc; Present 225 mm SS420 Treated, Ground, Deburred & Flatness within 10 microns Max. 500 mm Lapped Checked for Light Bands. Lentoid/Wavy Sandvik Gr. 17 Laser/Water Jet Cut, Formed, Hardness @ 42-45 HRc Present 200 mm Springs Heat Treated & Deburred Max. 500 mm Valve Springs. IS 4454 Gr 2 In Wire/Flat Plate Form; Formed, Hardness @ 40-45 HRc Heat Treated & Ground on both faces. Valve Bolts/Nuts En 19 Toughened, Machined & Die Hardness @ 260-280 BHNPresent M60 Threaded

(B) AIR COMPRESSORS: PRODUCT

Valve Assembly

M.O.C.

PROCESS

Leakage Testing on ElectroPneumatic Testing Rig.

PROPERTIES

SIZE

Valve Seat/Body

Valve Guard/Stop Plate

Valve Plate/Ring, Cushion/Damper Plate, Channel, Plate Seat Spring Plates Lift Washers Valve Springs

Valve Lift is maintained @ Present 450 mm 1.5 mm. Leakage Testing Max. 550 mm is done on ElectroPneumatic Testing Rig. SS 410 If in Investment Castings, Seats areHardness 200-220 BHN. Present 450 mm Solution Annealed to achieve Flatness of Seats checked Max. 550 mm higher wear resistance. Seats are for Light Bands. manufactured from Bar Stock, as well, by milling the grooves. Seats are, then, machined, ground, lapped & deburred. CI Grade 25 Castings are shell moulded, shot Hardness 200-220 BHN. Present 300 mm (IS 210-1962) blasted & annealed. Then Flatness of Seats checked Max 550 mm machined, ground, lapped & for Light Bands. deburred. Hard Chrome/Electroless Hardness of Hard Chrome/ Nickel Plated if necessary. EN Plating @ 710 VHN. SS 410 If in Investment Castings, Seats areHardness 200-220 BHN. Present 450 mm Solution Annealed to achieve Max. 550 mm higher wear resistance. Seats are manufactured from Bar Stock, as well, by milling the grooves. Guards are, then, machined & deburred. CI Grade 25 Castings are shell moulded, shot Hardness 200-220 BHN. Present 300 mm blasted & annealed. Then Hardness of Hard Chrome/ Max 550 mm machined & deburred. Hard EN Plating @ 710 VHN. Chrome/Electroless Nickel Plated if necessary. SS 410 Laser/Water Jet Cut, Heat Treated, Hardness 43-45 HRc; Present 394 mm Ground, Lapped & Deburred. Flatness within 10 microns Max. 500 mm. Checked for Light Bands. En 47 SS 420 AISI-631 Laser/Water Jet Cut, formed, heat Hardnes 42-45 HRc. Max. 500 mm. treated & deburred. Laser/Water Jet Cut, Heat Treated, Hardness 42-45 HRc; Ground, Lapped & Deburred. Flatness within 10 microns Checked for Light Bands. It is a Precipitation Hardenable Hardnes 42-45 HRc. Austenitic Stainless Steel. Springs are formed, Heat Treated & ground on both faces. Machined, Toughened & DieHardness @ 280 BHN Threaded Machined, Toughened & DieHardness @ 280 BHN Threaded.

Valve Bolts & Nuts

SS 410 En-19 En 24

1. PISTON & PARTS OF ASSEMBLY

(A)

AIR-CONDITIONING & REFRIGERATION COMPRESSORS: M.O.C. PROCESS PROPERTIES SIZE

PRODUCT

Pistons Piston Rings Gudgeon Pin/ Piston Pin

Lock Bolts/Plates/ Cirlips

Alu. Alloy Gr Pressure Die/Gravity Cast, "T5" Hardness @ 100-150 BHNPresent 180 mm LM-13WP Heat Treatment; OD Ground & Higher size (IS 617) ID Bored possible Grey CI Gr 25 ­ Annealed, Ground, Deburred & Hardness @ 200-220 BHNPresent 180 mm Pearlitic Structure Lapped; Top Ring Chrome Higher size Plated possible En-353 (815M17) Case Carburised & Hardened; Hardness 60±2; Crack Present 150 mm (BS970 Part Case Depth: OD 1.20-1.70 mm Detection on OD by Higher size after Grinding & ID 0.6-0.9 mm; Ultrasonic/Magnaflux & on possible 3-1977)/ ID by Dye Penetration En32B (BS 970)/ Ground & Lapped 15Cr3 DIN 17210 As per design of different manufacturers

(B) AIR COMPRESSORS: PRODUCT

L.P. Piston (BOP)

M.O.C.

PROCESS

PROPERTIES

SIZE

Aluminium Alloy Casting (Chilled Cast) Gr. 4685 (IS617-1975) H.P. Piston (BOP) CI Grade FG-260 (IS210-1978) or Fe-410S (IS226-1975)

"T5" Heat Treatment, Hardness 100-150 BHN Present 600 mm Machined & Ground. Tensile Strength 29 Kg/sq. Finished Piston subjects to mm. min Dye Penetration Test. Castings are shot blasted & Hardness ­ 220-260 BHN Present 450 mm annealed. After Machining & Grinding, finished Piston undergoes Dye Penetration Test. Piston Ring Grey Cast Iron Gr. 25 Annealed castings are Hardness 200-220 BHN Present 600 mm -Lubricated Model (Pearlitic Structure) Machined, Ground & Higher Size Lapped. possible. Piston/Compression 25% Carbon filled Rings are moulded & Finished Rings have Present 600 mm Ring & Guide/Wear/ PTFE. sintered in bush form. Hardness of 63 on Shore's Higher Size Rider Rings ­ Non Rings are manufactured "D" Scale & Tensile possible. Lubricated Model from the bushes as per Strength of 18.6 MPa. dimensions & tolerances of Compressor Manufacturers. Gudgeon Pin/ En-353 (815M17) Semi-finished Pins are Hardness 60 ± 2 HRc. Present 150 mm Piston Pin (BS970 Part 3-1977) or Case Hardened, Ground & Case Depth O.D. 1.2-1.7 Higher Size En-32B (BS970) or Lapped. mm after grinding & I.D. possible. 15Cr3 (DIN 17210) 0.6-0.9 mm. No lobe is permitted. Crack detection of O.D. by Ultrosonic/Magnaflux & I.D. by Dye Penetration. Piston Rod AISI 420 Small Dia. Machined, Heat Treated to Hardness @ 710 VHN of Specifications 210-260 BHN, Hard Hard Chrome. Tensile are till Dia. 30 Chrome Plated & Ground. Strength 64 Kg/sq.mm. mm min. Crack detection is by Ultrasonic/ Magnaflux Testing. Checked for concentricity & Face Squareness by "V" block. 826M40 (Y) High Dia. Machined, Heat Treated to Hardness @ 710 VHN of Specifications {En-26(Y)} (BS970 365-430 BHN, Hard Hard Chrome. Tensile are for above Part2-1970) Chrome Plated & Ground. Strength 128-145 Dia. 30 mm Kg/sq.mm. Crack detection is by Ultrasonic/ Magnaflux Testing. Checked for concentricity & Face Squareness by "V" block.

Crosshead

Grey Cast Iron Gr. 25 FG260 (IS210-1978)

Gland Packing ­ Lubricated Model Gland Packing ­ Non Lubricated Model

Oil Wiper Ring Non Lubricated Model Piston Head Nut / Piston Washer

Castings are shot blasted & Crack detection by Dye Present 300 mm annealed, then machined & Penetration test. Higher size ground on O.D. & bored on possible. I.D. Bearing Alloy Grade 90 Machined, Slit & Bored End Gap Clearance as per Present 60 mm standard to prevent Air Higher size scavenging. possible. 25% Carbon filled Packings are moulded & Finished Rings have Present 60 mm PTFE. sintered in bush form & Hardness of 63 on Shore's Higher size then machined as per "D" Scale & Tensile possible. dimensions & tolerances of Strength of 18.6 MPa. End Compressor Gap Clearance as per Manufacturers. standard to prevent Air scavenging. Bearing Alloy Grade 6 Machined, Slit & Bored End Gap Clearance as per Present 60 mm standard to wipe out oil Higher size from Crosshead back to possible. Crankcase. En-9 / SS 410 Heat Treated & machined Hardness 200-255 BHN within tolerances Tensile Strength 70 Kg/sq. mm. min.

(03) CONNECTING ROD & PARTS FOR ASSEMBLY

BOTH ACR & AIR COMPRESSORS: PRODUCT

Connecting Rod

M.O.C.

PROCESS

PROPERTIES

SIZE

SGI Grade 600/7 Shot Blasted, Annealed & Axis of Small & Big End Bores Present 150 mm (IS1865-1974) then Machined & Bored are parallel, Side Faces of the Big End SGI Grade 600/3 to required dimensions. both are perpendicular to the (IS1865-1974) bores & Bores are perpendicular (for Both Types) to Centre Line of Connecting Rod. Tolerance for Centre Distance of bores is kept within 0.1 mm. Parallelism and Squareness with central axis is checked. Crack detection by Dye Penetration. Hardness 190-270 BHN LM 13WP Forged, Stress Relieved, Axis of Small & Big End Bores Present 60 mm BS1490 ­ 1970 Machined & Bored to are parallel, Side Faces of the Big End (ACR required dimensions. both are perpendicular to the Compressors) bores & Bores are perpendicular to Centre Line of Connecting Rod. Tolerance for Centre Distance of bores is kept within 0.1 mm. Parallelism and Squareness with central axis is checked. Crack detection by Ultrasonic/Magnaflux method. Bolts & Nuts En-24 Heat Treated, Machined, Hardness 260-280 BHN Die Threaded & Ground. Big End Bearing/ White Metal Lined Bearing material is cast Crack detection by Dye Present 150 mm. Conn. Rod Bearing (90% Sn, 3.5% or roll-bonded on Back- Penetration Test. Higher size (ACR Compressors) Cu & 6.5% Sb) up Strip possible. Big End Bearing/ M.O.C. is Copper Principal bearing material Crack detection by Dye Present 150 mm.

Conn. Rod Bearing Lined Thin/Thick is cast or roll-bonded on Penetration Test. (AIR Compressors) Wall White Metal Strips, in case of Thin (80% Sn, 18-19% Wall Bearings. Pb & 1-2% Sn) Principal bearing material Bearings. Back-upis cast or roll-bonded on strips are in low machined castings, in Carbon Steel. In case of Thick Wall case of Thick Wall Bearings. Bearings, back-up is in casting of low Carbon Steel/Bronze. Small End Bush/ Phosphor Bronze Machined and OD & ID Hardness 90-130 BHN Piston Pin Bush/ Gr PB1 Ground Gudgeon Pin Bush (IS28-1975)

Higher size possible.

Present 150 mm Higher size possible

(04) CRANKSHAFT & PARTS:

PRODUCT

Crankshaft

M.O.C.

SGI Gr 600/3 (IS 1865)

PROCESS

Crankshafts are Machined & Ground to required sizes & then Dynamically Balanced @ double the speed of Compressor, by using Bob Weights. Normalised forgings are heat treated after proof machining. Then ground

PROPERTIES

Inspected on Shadowgraph for junction radii, which is followed by Dye Penetration Test.

SIZE

Present Crankpin Dia. 150 mm & Length 2500 mm. Higher sizes possible. Present Crankpin Dia. 150 mm & Length 2500 mm.

En-8 or En-9 (BS 970-1955)

Crack detection by Ultrasonic/ Magnaflux Method & then demagnetised.

& Dynamically balanced Hardness 220-270 BHN @ double the speed of U.T.S. @ 75 Kg/sq. mm. Compressor, by using Bob Weights. Main Bearings White Metal Lined Bearing material is cast Crack detection by Dye (ACR Compressors) (90% Sn, 3.5% or roll-bonded on Back- Penetration Test. Cu & 6.5% Sb) up Strip Main Bearings M.O.C. is Copper Principal bearing material Crack detection by Dye (AIR Compressors) Lined Thin/Thick is cast or roll-bonded on Penetration Test. Wall White Metal Strips, in case of Thin (80% Sn, 18-19% Wall Bearings. Pb & 1-2% Sn) Principal bearing material Bearings. Back-upis cast or roll-bonded on strips are in low machined castings, in Carbon Steel. In case of Thick Wall case of Thick Wall Bearings. Bearings, back-up is in casting of low Carbon Steel/Bronze. Bearing Washers/ Phosphor Bronze Face Ground & Lapped Hardness 90-130 BHN Thrust Washers Gr PB1 (IS28-1975) (Bronze) Heat Treated, ground & Hardness @ 45 HRc En-31 (Steel) lapped.

Higher sizes possible. Present 150 mm. Higher size possible. Present 150 mm. Higher size possible.

Present 150 mm Higher size possible

(05) CYLINDER LINERS & ASSEMBLY PARTS:

AIR-CONDITIONING & REFRIGERATION COMPRESSORS: PRODUCT

Cylinder Liner

M.O.C.

Graded CI with Mn 04.-1.2%

PROCESS

Shot Blasted, Annaled, OD is ground & ID is bored & honed Shot Blasted & Annealed

PROPERTIES

Hardness 230-240 BHN Pearlitic Matrix with Uniform Distribution of Phosphides Hardness 200-220 BHN

SIZE

Present 180 mm Max. 350 mm

Lever Assembly for SGI Gr 500/7 Liner (IS 1865)

(06A) OIL PUMP & PARTS:

PRODUCT

Housing & Cover Gears & Shafts Bush Testing

M.O.C.

S.G. Iron Grade 500/7 (IS 1865)

PROCESS

PROPERTIES

SIZE

Castings are Shot Hardness 220-260 BHN Blasted, Annealed & then Dye Penetration Testing is done. machined as per design. IS 1570 Grade Gears are Machined, Hardness @ 280 BHN C-40 Milled, Ground on surfaceDriving shaft is tempered at the & O.D. and Deburred end. Aluminium/ Machined, OD ground & Phosphor Bronze ID bored All the parts are Tested on Fixture to check assembled in the desired oil pressure. housing.

(06B) SHAFT SEAL/ MECHANICAL SEALS:

Shaft Seals are either Multi Spring Type or Single Spring Type or Bellow (Metallic or Neoprene) Type. MOC is of various types, for different models. Sealing Surfaces are lapped with Diamond Paste & inspected for Light Bands. PRODUCT

Rotary Ring Stationary Sealing Ring En-9

M.O.C.

PROCESS

PROPERTIES

SIZE

Present ID 150 mm Higher size possible Present 150 mm Higher size possible. Present 150 mm Higher size possible.

Bellow O Ring

Heat Treated, Ground & Inspected for Light Bands Lapped by Diamond Paste. Phosphor Bronze Heat Treated, Machined, Hardness 90-130 BHN (PB-2) Ground & Lapped by Diamond Paste. Metallic Carbon Moulded, Heat Treated, Shore's D Scale 68 Machined, Ground & Lapped by Diamond Paste Metallic or As per design Neoprene Viton/HNBR/ Moulded at 45 degrees so Shore's A Scale 70 Neoprene flash will not cause any leakage.

(07A) O RINGS, SEALING RINGS/WASHERS & RUBBER GASKETS:

We supply "O" Rings in Viton, Silicon, HNBR, NBR, Neoprene & Nitrile material. O Rings are Die Moulded & Heat Treated wherever necessary. Hardness ­ Shore's A Scale 67 - 70 Maximum size: 900 mm x 900 mm (07B) GASKETS, ALUMINIUM PACKINGS & CONNECTOR PARTS:

We supply Asbestos Gaskets as well as Asbestos Free Gaskets. Gaskets are, normally, cut by Die/Punch as per design.

Information

COMPRESSOR PARTS ­ TECHNICAL SPECIFICATIONS

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