lube system installation 4-15-04

Universal Guidelines for the

Divider Block

Lubrication Systems

Installation of

BY CURTIS ROYS

Atmospheric Rupture Assemblyon Back of Anchor Cross

S.S. Tubing

S.S. Liquid FilledPressure Gauge

Purge Port Connection

Lubricator Gear Box

Pressure IndicatorsWith Memory

LubricatorPump Non By-Pass

Low Pressure Filter

MasterDivider Valve Assembly

proflo

Divider Block Monitor& Shutdown Protection

Oil Supply

IndicatorPort Plug

PistonEnclosure

Plugs

Discharge Sideof Lube Pump

High PressureIn-Line Filter

InjectionCheck Valves

Cylinder orPacking GlandInjection points

Cylinder orPacking GlandInjection points

InjectionCheck Valves

SecondaryDivider Valve Assembly(All lubrication systems do not

require secondary divider valves)Base Section

Discharge Check Valves

Set

Mode

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C

C"PROTECTING COMPRESSORS WORLD WIDE"

Midland, Texas 1-800-664-4033

C. C. Technology Inc.

prOflOCLASS I, DIV II

Groups A,B,C,D

NRTL/C

IrDA PORT

AVG 20

R

M o d e l - P F 1US Copyright Registered 2001

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CCYCLE

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DESIGNSCHEMATIC

PRE-TESTING

COMPONENTS

PRE-TESTING

COMPONENTS

FINAL INSPECTION

DIVIDER BLOCK

INSTALLATIONDIVIDER BLOCK

INSTALLATIONTUBIN

G

INSTALLATIO

N

TUBING

INSTALLATIO

N

CHECK VALVE

INSTALLATIONCHECK VALVE

INSTALLATION

NO-FLOW SHUTDOWN

3201 West Wall St. Midland, Texas 79701Office: (432) 520-6700 Fax: (432) 520-6707

Toll free: 1-800-664-4033

Visit Us on the Web: www.cct.nuemail: [email protected]

INTRODUCTION:

There are many procedures that should be observed when installing “Positive Displacement, Single

Line Progressive Lubrication Systems”. This manual is intended for the person responsible for the

installation of the divider block system. It contains procedures to maintain the system integrity and

furnish the end user with a reliable divider block system.

This Installation Guide addresses the complete divider block system installation from tubing

installation to purging the system. The recommendations are specific to Single-Line Progressive

Systems for compressor applications.

Should the end user or person responsible for design of the divider block system have any questions

concerning this manual or the operation and maintenance of the divider block system please feel free

to contact CC Technology at (432) 520-6700 , fax: (432) 520-6707 or email [email protected].

CC Technology Divider Block Installation Guide:

Copyright (C) 2004 C C Technology Inc.

All rights reserved. Printed in the United States of America. No part of this publication may bereproduced in any part without written permission from the author. For information on lubricationproducts or to obtain copies of this publication contact C C Technology.

Address: 3201 West Wall St. Midland, TX 79701Phone: (432) 520-6700 fax:(432) 520-6700E-mail: [email protected] Site: www.cct.nu

General Guidelines for Divider Block System Installation:

Testing Components for Reliable OperationDesign SchematicDivider Block Cycle Indicator and Cycle TimeFilters, Lube No-Flow and Shutdown ProtectionFinal Inspection .....................................................................................page 2

Schematic Design Example:

Position of Components:

Component Installation:

Mounting Divider Blocks:

Critical Components:

Check Valve Installation:

Tubing Preparation:.............................................................................Tubing Installation:Purging Air From the System:C C Technology Products.................

................................................................ page 3

...................................................................... page 4

.......................................................................page 4Divider Block Installation:Master Divider Block Installation:Secondary Divider Block Installation:

..................................................................... page 4 & 5

........................................................................... page 6

..................................................................... page 7

page 8..............................................................................page 9-11

..............................................................page 12....... ............................................Back Cover

Purge and Pre-Lube Connection:Pressure Gauges:Atmospheric RuptureAssembly:In-line Filters:Lube No-Flow Shutdown:Check Valves:Base Plate Check Valves:Injection Check Valves:

T CABLE OF ONTENTS

Visit Us On the Internet www.cct.nu

1

GENERAL GUIDELINES FOR DIVIDER BLOCK SYSTEMS

A. TESTING COMPONENTS FOR RELIABLE OPERATION:

Every component of the divider block system must be assembled and tested before shipping to the

installation site.

Every divider block system is designed for installation on a specific compressor.

This ensures each component functions correctly and conforms to manufacturers

specifications. Testing the assembled components before shipping eliminates possible on-site problems

with the system after installation or during start-up. All components that are shipped unassembled should

be accompanied with literature for specific assembly, testing and operating instructions.

The lube system installer must always have a certified schematic of the divider block system designed by a

qualified person.

Each lube system design is based on various gas stream components, pressures and temperatures. When

designing the divider block system the design engineer must consider not only gas stream components,

but variables for lubrication rates due to materials used for the compressor rod, packing gland, cylinder and

ring components. The schematic diagram should illustrate all tubing runs from each divider block to the

injection point it is intended to serve. It should also include specific lube rates to individual injection points

and all components needed to complete the installation of the system. (see figure "A" )

B. DESIGN SCHEMATIC:


C. CYCLE INDICATOR AND CYCLE TIME:

D. FILTERS and LUBE NO-FLOW SHUTDOWN PROTECTION:

E. FINAL INSPECTION:

The lubrication system must include a device to indicate each cycle of the divider block system to

set and monitor lube rates.

To eliminate excessive wear the lube rates

should be doubled for a minimum of 200 hours for new or rebuilt compressors.

The lube system design must always include specifications for low and high pressure in-line

filters

A no-flow shutdown device must be installed on every

divider block system, connected to the control panel and tested for operation, to ensure

shutdown protection for the compressor in the event of lube system failure

always re-check each

component of the system

There should never be any changes made to the

divider block design system without approval of the engineer responsible for the system design.

(see proflo monitor figure”A” The lube system design must include a

suggested cycle time of the master divider block. The suggested cycle time allows the operator to set lube

rates of the system for normal operation of the compressor. Lube rates should be doubled for break-in of

the compressor components when starting up a new or freshly over hauled compressor. The compressor

operator must adjust the lubricator pump until the divider block is cycling at the suggested cycle time to

prevent premature failure of the compressor components.

to avoid problems caused by contaminated lubricants, debris left in components during assembly

or trash from open containers or reservoirs.

. (see figure "A”)

After installation of the divider block system is completed, the installer should

including divider block sizes and tubing runs to ensure all lubrication points

are being serviced by the correct divider block.

3201 West Wall St. Midland, TX 79701 (432) 520-6700 1-800-664-4033 fax: (432) 520-6707

2

Pressurized Filtered Oil

Atmospheric Rupture Assembly(Purple Disc) Torque to 36 Inch Pounds

“DO NOT PLUG”

0-391040RAriel Pressure Cross Assembly

W/ S.S. Liquid Filled Pressure GaugePurge Port & Atmospheric Rupture Assy.

0-391040LAriel Pressure Cross Assembly

W/ S.S. Liquid Filled Pressure GaugePurge Port & Atmospheric Rupture Assy.

Purge Port Connection

Lubricator Gear BoxReplace Oil & Check For Wear

Every 12 Months

(2) CCT 0-923773/8” Lubricator Pump

Roller Rocker

ALEMITE-LPressure Test

Every 12 Months

15.98 PPD

20.80 PPD

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C0-391042A

CCT-0-509052High Pressure

10 Micron In-line FilterReplace Element #EK9052

Every 12 Months

15.98AVG 11.2

6

Pints Per DayLCD Should Display Sec. For Recommended Lube Rates

@ Rated RPM

Overhaul Break-in Cycle Time Seconds for 200 Hours

RPM1500 11.21400 12.01300 12.91200 14.0

1500 18.01400 19.21300 20.71200 22.5

RPM vs. Cycle TimeCompressor Divider Block

Cycle Time Sec. RPMDivider Block

Cycle Time Sec.

CCT-0-750014-1/4”Ultra Check Valve

at Each Injection Point0-T302500

Pressure Indicators

13.50” PKG- 2.40 PPD

13.50” CYL- 4.00 PPD

13.50” CYL- 4.00 PPD

18 T

30 T

13.50” PKG- 2.40 PPD

13.50” CYL- 4.00 PPD

13.50” CYL- 4.00 PPD

30 T

1-800-337-3412

ODESSA, TEXAS

Set

Mode

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C





Groups A,B,C,D

NRTL/C

IrDA PORT

PRO FLO

R


1-800-337-3412

ODESSA, TEXAS

Set

Mode

T

C





Groups A,B,C,D

NRTL/C

IrDA PORT

PRO FLO

R


CCT-0-750014-1/4”Ultra Check Valve

at Each Injection Point

0-T302500Pressure Indicators

9.750” CYL- 6.38 PPD

6.375” PKG- 2.40 PPD

9 T9.750” PKG- 2.40 PPD

6.375” CYL- 4.80 PPD

12 S

9 S

20.80AVG 18.0

9

Pints Per DayLCD Should Display Sec. For Recommended Lube Rates

@ Rated RPM

Overhaul Break-in Cycle Time Seconds for 200 Hours

SCHEMATIC DESIGN EXAMPLE Figure "A"

RPM vs. Cycle Time


Proflo Pf1Divider Block Monitor

and Lube No-FlowShutdown Device

CC Technology Divider Block Installation Guide:3

Compressor



A. POSITION OF COMPONENTS:

B. COMPONENT INSTALLATION:

1. Gearbox and Pump Installation:

C. DIVIDER BLOCK INSTALLATION:

Master Divider Block Installation:

1.

Secondary Divider Block Installation:

2.

D. MOUNTING DIVIDER BLOCKS:

1.

Positioning of components on the compressor is essential

Never install unnecessary conduit, piping, electrical connections or objects that will prevent the

operator from having access to the lubricator pump and gearbox.

to ensure the trouble free operation of any

centralized lubrication system. If the correct components have been designed and selected, improper

installation will make it difficult to access the system for purging air from the system or to replace components

when preventive maintenance is performed.

If the compressor does not have a specific mounting bracket for the lubricator reservoir, install the pump

gearbox in an area on the compressor that is easy to access and not subjected to heavy traffic or debris. Easy

access is necessary to enable the operator to adjust lubrication rates and to check the gearbox for correct oil

levels.

Install the master divider block (the first divider block downstream of the pump) as

close to the pump as possible. This will allow the operator to adjust the lubricator pump while

monitoring cycle time of the system to achieve correct lubrication rates.

Install secondary divider blocks as close as possible to the injection points on the compressor

cylinders and rod packing. This procedure eliminates long tubing runs from the divider block to the

injection points and enables the operator to easily inspect the system for tubing leaks.

Mount all divider blocks parallel to the floor. This allows complete purging of air from the system and

makes it easier to install straight and plumb tubing runs. (See Figure "B" Below)

6 S

6 S

6 T

6 S

6 S

6 T

INCORRECT MOUNTING CORRECT MOUNTING

Divider Block Mounted Parallel to FloorDivider Block Not Mounted Parallel to Floor

Figure "B”

4



D. Mounting Divider Blocks Continued:

2.

3.

4.

5

6.

7.

CAUTION:

8.

9.

10.

Avoid installing the divider blocks in locations that prevent easy access for preventative

maintenance or replacement.

The indicator port plugs on the front of the divider blocks should be easily accessed for trouble

shooting the system for blockage and for ease of replacement.

The divider blocks may be mounted directly to the compressor frame, if the surface can be drilled

and tapped. When mounting the divider blocks directly to the cylinder, “

Mount all divider blocks on a flat surface wherever possible. Mounting to an uneven surface may

cause distortion in the piston bores and create premature wear or failure.

Use properly sized bolts for mounting the divider blocks to the compressor frame.

Use divider block mounting brackets in areas that require the divider block to be raised from the

mounting surface to enable reliable tubing installation. CC Tech has several styles of mounting

brackets to ensure correct mounting of the divider blocks

When using a mounting plate that must be welded in place, “

Heat or sparking generated during welding will

permanently damage the divider blocks.

Install all divider block assemblies in an area on the compressor to avoid damage from debris or

dropped objects.

Install the tubing on the compressor frame away from common areas that must be accessed for

maintenance and out of areas commonly used for stepping or where there is the possibility of

damage from debris or dropped objects.

Keep all multiple tubing runs from secondary divider blocks as short as possible to reduce total

lubricant volume held in the lines to the injection points.

DO NOT” use long drill bits

that can penetrate through the inside wall of the compressor cylinder.

NEVER” weld on a

mounting plate with the divider block installed.

5

E. CRITICAL COMPONENTS:

1. Purge and Pre-Lube Connection:

2. Pressure Gauges:

Atmospheric RuptureAssembly:

4. In-line Filters:

Always install a purge port connection on the discharge side of the pump

The purge port connection must incorporate a check valve

Proper purging of air from the divider block system before compressor start-

up is critical for reliable and trouble free operation of the system.

It is absolutely necessary to install pressure gauges on all divider block systems

Atmospheric rupture assemblies must be installed on every divider block system

Every system must have in-line filters with a minimum of 25 micron filtration to prevent

contamination and failure of the lube pump and divider blocks.

to allow purging air

from the tubing lines before compressor startup or after any maintenance is performed on the divider

block system.(see figure “ ”) to keep

oil from blowing out of the system and allowing air to enter the system when removing the purge gun. If

no check valve is in place air will enter the system when removing the purge gun. Trapped air can

cause phantom shutdowns of the compressor and has the same indications as divider block failure or

trash in the system.

(See page 12)

to enable

the operator to monitor system pressure and operation of the divider block system. (see figure “ ”).

to release

pressure if blockage occurs in the system. The relieving of oil flow to atmosphere enables the lube no-

flow to shutdown the compressor. The compressor will never shutdown if an atmospheric assembly is

not installed or if the atmospheric rupture assembly has been plugged. (see figure " ”)

It is recommended to install both a

low pressure pre-filter before the pump and high pressure in-line filter downstream of the lube pump.

Install all in-line filters in an area that can easily be accessed for filter changes or cleaning at

recommended maintenance intervals. (see figure " ”)

3.

C-1

C-2

C-3

C-4



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C0-391042A

( )CCT-0-509052High Pressure

In-line Filter10 Micron

C-4

( )Purge PortConnection

C-1( )

AtmosphericRupture

Assembly

C-3

( )Pressure

Gauge

C-2

High Speed Separable CompressorModel 55 Type Lubricator

Figure "B"

1725 RPM -1HP

Model # 3546-230-460

TEFC ELECTRIC MOTOR

B-118( )

1211-B-118Low pressureIn-Line Filter

C-4

( )0-2Z763-9

Filter Primer

C-4

lincoln modular lube

8 : 1

C C Technology21.5:1

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( )Atmospheric

Rupture Assemblyon Back of PCA

C-3

Slow or High Speed Compressor withElectric Driven HVLP Lube Pump and Gear Box

To MasterDivider Block

From Oil Supply

( )Purge PortConnection

C-1

( )Pressure

Gauge

C-2

6

E. CRITICAL COMPONENTS CONTINUED:

5. Lube No-Flow Shutdown:

F. Check Valves:

1. Base Plate Check Valves:

The lube no-flow device is the only shutdown protection for the compressor if the pump fails or

blockage occurs in the system.

Operating pressure of the check valve must be appropriate for working pressure of the system.

to increase the dependability and fluid movement of the divider block piston. Base plate check

valves prevent introduction of gas or air into the hydraulic circuit of the divider block if the injection

check valve should fail.

“DO NOT” operate any divider block system without a lube no-flow shutdown device.

All divider block systems must have a check valve installed at each injection point.

Install base plate check valves (termed Reverse Checks) on each working outlet of the base

plate

2. Injection Check Valves:

Check valves must be installed on all lubrication points

For reliable operation “DO NOT” install the injection check valves in a vertical position.

as close as possible to the injection

point.

C

Vertical installation can allow the

introduction of hot, contaminated gas into the check valve every time the valve opens to inject oil into

the lubrication point. The gas migrating into the check valve as it opens and closes can also cause

possible coking of oil on the ball and seat of the check valve causing premature failure. (See figure "D”)

heck

valves should be installed in a manner as to permit a minimum of 1” of oil head above the check valve.

The 1" of oil head will allow a liquid seal in the check valve and keep the heated gas and debris

separated from the check valve seat for increased reliability.


Cylinder

1”MINIMUM

LIQUID SEALRECOMMENDED

Check Valve

1”

Cylinder

Check Valve

NOT RECOMMENDED RECOMMENDED

Cylinder

Check Valve

Cylinder

1”MINIMUM

LIQUID SEALRECOMMENDED

Check Valve

1”

Check Valve InstallationUsing the CC TechOil Head Adapter

1”

Cylinder

Check Valve

Oil Headto ProtectCheck ValveSealing Surface

Oil

Figure "D”


7

A. TUBING PREPARATION

1. Cleaning Tubing and Piping:

2. Tubing Flushing Procedure:

3. Cutting the Tubing:

When installing the divider block system,

. The initial startup of the divider block system is

the most critical time. Any debris or contamination that is present in the hydraulic system will

cause immediate or premature failure of the divider block components. If debris is present in the

system during initial startup it will be carried through the hydraulic circuit and deposited in the

divider block pistons, check valves and rod packing or directly into the compressor cylinder. If

debris in the hydraulic system does not cause immediate damage to the system components,

the existing particles can cause premature failure of the system due to degradation of the

components caused by wear.

1. If the ends of the tubing have been left open to the environment all tubing should

be flushed with high-pressure water to remove any debris that could be present

from transportation to the job site or during storage .

2.After loosening the debris with high pressure water washing, insert an air gun in the end of the

tubing and blow out the loose debris.Always use clean filtered air. (see figure "E")

If the tubing is to be stored for any length of time, the ends should be capped to prevent

contamination.

1. All tubing should be cut with industry standard tubing cutters such as the one in figure “F”

designed to be used with stainless steel tubing. The cutting wheel must be sharp to obtain a

smooth square cut.

2. After cutting the inside and outside of the tube end must be de-burred and cleaned to prevent

metal particles from entering the lubrication system damaging the lube pump, divider blocks, or

compressor components. It is recommended to use a de-burring tool such the one in figure "G”.

all tubing and piping must be thoroughly cleaned

to assure reliability of the lubrication system

For reliable operation of the divider block system it is extremely important to avoid any

introduction of foreign debris in the hydraulic circuit or tubing lines.


Figure "G”Figure "E”


Figure "F”

B. TUBING INSTALLATION:

1. Routing of Tubing Bends:

2.Avoid Excessive Strain on Joints:

The divider block system schematic designates the points on the compressor to be lubricated and the

exact divider block that should be connected to each injection point. The schematic must be followed as

per the drawing but it does not identify the paths to follow due to differences in compressor frames and

installations. The basic rule to remember when installing tubing is to keep all lines as short as possible

with a minimum number of bends. By reducing the number of bends you reduce the pressure drop in

the hydraulic system. The installer should remember the operator must maintain the compressor and

the tubing installation should not interfere with everyday tasks of preventative maintenance performed

on the compressor.

The most logical path and related guidelines are demonstrated in the illustrations

on the following pages.

A. Short tubing runs

should incorporate a bend to allow removal of the tubing to compensate for expansion and contraction

caused movement generated in a pressurized system. (see figure "H")

B. - Use a “U" bend in long lines to allow for expansion.

Strained joints in tubing bends will eventually leak. (see figure "H")

Routing of tubing is the most difficult but most significant of the installation

considerations. Proper routing involves installing tubing from one point to another through the

most logical path.

Avoid straight short tubing runs. A strained joint will eventually leak.

Allow for expansion and contraction

INCORRECT ROUTING

INCORRECT ROUTING

CORRECT ROUTING

CORRECT ROUTING

Figure "H”

INCORRECT ROUTINGCORRECT ROUTING



B. TUBING INSTALLATION CONTINUED:

3. Install tubing around obstructions without excessive 90 bends:

4. Do not install tubing on walkways or in areas where it could present a safety hazard.

5. Keep tubing lines away from any components that require maintenance:

6. Follow the shape of the object or surface with tubing bends:

o

Pressure drop due to one 90 bend is greater than two 5o

bends. (see figure "I")

1.Do not install tubing where it could be damaged by operators performing everyday preventative

maintenance. Tubing lines that are installed over the top of, or next to components that must be accessed for

maintenance will be moved or bent to enable the operator to access the component. Bending the tubing by

force to access components could cause leaks or failure of the tubing connections.(see figure "J")

1.Install tubing to conform to surfaces or objects as close as possible. Installation of tubing lines that

stand out away from objects are easily damaged and create possible safety hazards.(see figure "K")

Figure "I”

Figure "J”



Figure "K”




B. TUBING INSTALLATION CONTINUED:

7. TubingAppearance:

8. Securing and Supporting Tubing:

Tubing lines should have a clean and orderly appearance to allow the operator to easily troubleshoot the

system for leaks and perform repairs. (see figure "L")

Multiple tubing lines should not be left suspended in mid-air

without securing them together using tubing clips with back plates for support. Tubing clips are used to secure

multiple tubing lines together eliminating vibration against each other. Tubing left unsupported could eventually

leak due to vibration. Vibration could cause the fitting to loosen or create fatigue in the tubing which will lead to

the tubing splitting and leaking. Tubing can be clamped individually or in sets from 2 to 12 lines.

o ensure reliable trouble free service of the divider

block system and protect the compressor from possible premature wear due to insufficient lubrication. (see

figure "M")

To ensure orderly appearance of the tubing and reliability of the divider block system all tubing lines

must supported and secured after installation.

Use sufficient

tubing clips to properly support and secure the tubing t

Figure "L”

INCORRECT ROUTINGNo Tubing Clips

CORRECT ROUTINGwith Proper Tubing Clips

Figure "M”

VERTICAL TUBING SUPPORTWith Tubing Clips and Back Plates

HORIZONTAL CLAMPINGDirectly to the Compressor Frame



C. Purging Air from the System and pre-lubing the

components:

Divider block systems operate correctly only when all tubing lines and

components are completely filled with oil to eliminate air in the system.

The operator should always pre-lube the divider block system and

components before the compressor is started.

1. After the lubrication system is installed, it is necessary to

purge air from all components, (tubing, divider blocks, check

valves) and fill the entire system with oil that will be used to

lubricate the compressor components during normal operation.

Model # 382510-3

Lubrication System Purge Gun

The divider block system should always be purged of air and pre-lubed if any components are

removed or loosened after the initial installation and start-up of the compressor. Although divider block

systems can eventually self purge, this severely delays purging air from the divider blocks, tubing and filters

and can result in erratic operation of the system and cause phantom shutdowns and premature wear or failure

of compressor components.

Purge GunPump in

Vertical Position

(5) Purge Portwith Check Vakve

1/4”S.S. Tubing

(6) Discharge Sideof Lube Pump

TubingConnection(4)

SecondaryDivider Valve

Inlet

(2 & 3)Tubing

ConnectionsCylinder

orPacking GlandInjection Points

(1) Tubing ConnectionMaster Divider Valve Inlet

Follow this procedure after installation of the divider block system is completed or when any components arereplaced, removed or any maintenance is performed on the system.

Step 1:

Step 2:

Step 3:

Step 4:

Step 5:

Step 6:

Step 7:

Step 8:

The lubrication system is now ready to operate.

After installation of the lube system and before compressorstart-up loosen all tubing connections at the inlet of the masterdivider valve (1),

. If there are secondary divider valves (4) loosentubing connections at the inlet of the secondary divider valves .

If a purge port (5) is available at the pump head connect thepurge gun. If no purge port is available remove the tubing from thedischarge side of the pump (6) and connect the purge gun to thetubing.

Pump clean oil common to the system into the tubing lineuntil there are no air bubbles observed flowing from the tubingconnection at the inlet of the master divider valve. Always holdpurge gun in a vertical position to eliminate pumping air into thesystem.

Tighten the tubing connection at the inlet of the masterdivider valve while oil is still flowing.

Continue to operate the purge gun until no air bubbles areobserved flowing from the tubing connection at the inlet of thesecondary divider valve.

Tighten the tubing connection at the inlet of the secondarydivider valve while oil is still flowing.

Continue to operate the purge gun until there are no airbubbles observed flowing from the tubing connections at thecylinder or packing gland injection points.

Tighten the tubing connections at the cylinder and packinggland injection points while oil is still flowing.

cylinder injection points (2) and packing glandinjection points (3)

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(2 & 3)Tubing

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orPacking GlandInjection Points


lube system installation 4-15-04

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