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S ?AL D
EVALUATION OF BAUER K220
I HIGH PRESSURE BREATHING AIR COMPRESSOR
GEORGE D. SULLIVAN
MARCH 1990
IBUTION STATEMENT A: Approved for public release;
distribution is unlimited.
NAVY EXPERIMENTAL DIVING -UNIT
'a * ~ ELECTE
*f ;ul 2e 0
4w -v:"
DMTB-NTON MUMTMTA
I D~wi~-mt0-O06 18 129-
DEPARTMENT OF THE NAVYNAVY EXPERIMENTAL DIVING UNIT
PANAMA CIM FLORIDA 32407-5001 IN REPLY REFER TO:
NAVSEA Task 89-11
NAVY EXPERIMENTAL DIVING UNIT
REPORT NO. 6-90
EVALUATION OF BAUER K220HIGH PRESSURE BREATHING AIR COMPRESSOR
GEORGE D. SULLIVAN
MARCH 1990
DISTRIBUTION STATEMENT A: Approved for public release;distribution is unlimited.
Submitted by: C eviewed by: A roved by:
G.D. SULLIVAN J . MCCARTHY ,J. HALWACHSGS-9 ( GqM-14 I, J C, U.S. NavyTest Director .- ,[perbaric Engineer Commanding Officer
C.'. SCHWARTZ
CAPT, MC, USN D T ICSenior Medical Officer
E-ECTE
J U 2 .9 DLCDR, CFFleet Projects Officer
K.A. HODINALT, USNActing Senior Projects Officer
.B. MCDONELL,' CDR, USN\'--xecutive Offr r
UNCLASSIFIEDSECURITY CLASSIFICATION OF THIS PAGE
REPORT DOCUMENTATION PAGEla. REPORT SECURITY CLASSIFICATION lb. RESTRICTIVE MARKINGS
UNCLASSIFIED
2a. SECURITY CLASSIFICATION AUTHORITY 3. DISTRIBUTION/AVAILABILITY OF REPORTDISTRUBUTION STATEMENT A: Approved for publicrelease; distribution is unlimited
2b. DECLASSIFICATION/DOWNGRADING SCHEDULE
4. PERFORMING ORGANIZATION REPORT NUMBER(S) 5. MONITORING ORGANIZATION REPORT NUMBER(S)NEOU Report #6-90
6a. NAME OF PERFORMING ORGANIZ. 6b. OFFICE SYMBOL 7a. NAME OF MONITORING ORGANIZATIONNavy Experimental Diving Unit (If applicable)
6c. ADDRESS (City, State, and ZIP Code) 7b. ADDRESS (City, State, and ZIP Code)Panama City, Florida 32407-5001
8a. NAME OF FUNDING/SPONSORING 6b. OFFICE SYMBOL 9. PROCUREMENT INSTRUMENT IDENTIFICATION NUMBERORGANIZATION (If applicable)
Naval Sea Systems Command DOC
8c. ADDRESS (City, State, and ZIP Code) 10. SOURCE OF FUNDING NUMBERSWashington D.C. 20362-5101 PROGRAM PROJECT TASK WORK UNIT
ELEMENT NO. NO. NO. ACCESSION NO.89_11
11. TITLE (Include Security Classification)BAUER K220 HIGH PRESSURE BREATHING AIR COMPRESSOR
12. PERSONAL AUTHOR(SO
SULLIVAN, David
13a. TYPE OF REPORT 13b. TIME COVERED 14. DATE OF REPORT (YearMonth'Day) 15. PAGE COUNT
FINAL March 1990 15
16. SUPPLEMENTARY NOTATION
17. COSATI CODES 18. SUBJECT TERMS (Continue on reverse if necessary and identifyFIELD GROUP SUB-GROUP by block number)
ABSTRACT (Continue on reverse if necessary and identify by block number)
n response to reference (1) and as outlined in reference (2) Navy Experimental Diving Unit(NEDU) tested the BAUER K220 high pressure, breathing air compressor from November 14 thru 21, 1989.The purpose of this test was to determine if the equipment was suitable for use by the United StatesNavy (USN) diving community and if so, added to the Approved for Navy Use (ANU) Procurement List.
The BAUER K220 met manufacture's specifications for quantity of air produced with a quality whichmet or exceeded purity standards in reference (3). The design and engineering was determined to beadequate. With the inclusion of the recommendations in section V the BAUER K220 compressor isconsidered suitable for USN requirements for compressors of this size and type.
20. DISTRIBUTION/AVAILABILITY OF ABSTRACT 21. ABSTRACT SECURITY CLASSIFICATION
Ij UNCLASSIFIED/UNLIMITED SAME AS RPT. OTIC USERS
22a. NAME OF RESPONSIBLE INDIVIDUAL 22b. TELEPHONE (Include Area Code) 22c. OFFICESYMBOL
DD FORM 1473, 84 MAR 83 APR edition may be used SECURITY CLASSIFICATION OF THIS PAGEuntil exhausted.All other editions are obsolete. UNCLASSIFIED
CONTENTS
Pae No
I. INTRODUCTION .............................................. I
II. EQUIPMENT DESCRIPTION ................................... 1-2
III. TEST PROCEDURE ............................................. 8
A. ENDURANCE TEST ......................................... 8
B. CHARGE RATES ................. ....................... 8
C. OIL CONSUMPTION ........................................ 8
D. AIR SAMPLING ........................................... 8
E. MAINTENANCE ............................................ 9
IV. RESULTS ................................................ 9-10
V. RECOMMENDATIONS ........................................ 10-11
VI. CONCLUSIONS ............................................... 11
REFERENCES .................................................... 12
APPENDIX A - Manufacture's Technical Specifications .......... A-I
APPENDIX B - Test Plan ......................................... B-I thru B-7
APPENDIX C - Test Log .......................................... C-I thru C-6
APPENDIX D - Air Sample Results ............................... D-1 thru D-3
Accession ForNTIS IA&IDTIC TAP 0
Unaranunced 0
Just riction,
Ant1'lb11ty Codes
r vsi/ land/or
ott S caKYI
ILLUSTRATIONS
Figure No. Page No.
1 Front View (Flyaway side) 3
2 Rear View (Fan-wheel side) 4
3 Right hand side, viewed from flywheel 5
4 Left hand side, viewed from flywheel 6
5 Air flow diagram 7
iii
I. INTRODUCTION
In response to reference (1) and as detailed in reference (2), the BauerK220 compressor was tested by NEDU. The test was to determine if the
compressor discharged suitable breathing air and had a service life whichsatisfied the requirements for divers air supply compressors throughout theNavy. Other material variations were also evaluated and are listed as
considerations in Section V.
Highly portable divers air compressors are designed to have high pressurewith relatively how volume outputs. Divers require low pressure with highvolume. The average divers high pressure air compressor is connected to largevolume high pressure air storage flasks to meet this need. In normaloperations the high pressure air is reduced to a lower pressure to act as a
breathing media for divers. As this is accomplished, the pressure gradually
reduces in the storage flasks. The compressors tend to run on a continousbasis as the diving day continues because the demand is usually greater thanthe supply. At the end of the diving day or when air requirements are reduced,the compressors will exceed the demand and fill the air flasks.
There are various methods of testing compressor capacities. For the purposesof this compressor test, NEDU chose compressor testing consisted of chargingfrom 0 to 2500 psig daily then opening the vent and maintaining 2000 to 2500psig for continuous run. This method more closely simulated the use acompressor would experience in the field. Additionally during the continuousrun, random charge rates were taken from 2000 to 2500 psig. The compressor wasoperated a total of 50 test hours. The testing included subjective evaluationof the system operation but did not include detailed mechanical review of theindividual components of the system.
II. EQUIPMENT DESCRIPTION
The BAUER K220 high pressure, breathing air, compressor (Figures I thru 4)is a four stage, three cylinder design. The 1st and 2nd stage are housed inone common stepped cylinder. The three cylinders are arranged in a "W"configuration. The lst/2nd stage cylinder is positioned vertically, the 3rdstage cylinder to the right, viewing from the flywheel. The 4th stage cylinderat the left side forms the second leg of the W arrangement.
The lst/2nd stage and 4th stage cylinders are lubricated by means of theforced-fed lubrication system, the 3rd stage cylinder is splash-lubricated.The compressor requires approximately 8 quarts (US) of lubricating oil. Themanufacturer recommends that only specific lubricants be used. These oils arenot stocked in the Federal Supply System.
The K220 compressor block is used as a standard in the breathing air aswell as in the industrial high pressure compressor units. It is particularlysuitable for continuous operation because of its rugged design and thecorrosion resistant intermediate filter and cooler assemblies.
I
The prime mover is a TOSHIBA 25 horse power, three phase 460 volt, 1765RPM electric, motor, ser #9306796C, (see recommendation a). Rotational torqueis transferred to the compressor by triple "vee" belts.
Filtration was accomplished by an intake filter cartridge,interfilters/moisture separators downstream of the 2nd and 3rd stages, a 4thstage water separator and a Pall Trinity filter immediately upstream of thecharging whip. The automatic condensate drain unit drains the intermediatefilters after the 2nd and 3rd stage, and the oil and water separator after the4th stage every 15 minutes.
A pressure maintaining valve/non-return valve is provided down stream fromthe filter system to ensure that pressure build up occurs in the filters duringstart up and initial compressor air delivery. This achieves constant, optimumfiltering, moisture separation and prevents compressed air from returning fromthe charged air storage tanks to the compressor during unit shut down.
All four stages of the compressor block are protected by safety reliefvalves.
Figure 5 provides an air flow disgram of the compressor and filter system.For these tests the BAUER final filter package was replaced with a Paul Trinityfilter which is also available from BAUER upon request.
2
1015
Fig. 1 Front View (Flywheel side)
I Interfilter 3rd/4th stage 6 Flywheel
2 Oil and water separator 7 Intake filter
3 Safety valve, 1st stage 8 Oil filler neck
4 Safety valve, 3rd stage 9 Cylinder 3rd stage
5 Final pressure safety valve 10 Cylinder 4th stage
3
Fig. 2 Rear View (Fan-wheel side)
1 Inter-cooler lst/Znd stage 4 Fan-wheel
2 Inter-cooler 2ndl3rd stage 5 Safety valve, Znd/3rd stage
3 Inter-cooler 3rd/4th stage 6 Inter-filter 2nd/3rd stage
and after-cooler 7 Oil filter
00 00
6
5
Fig. 3 Right hand side, viewed from flywheel
1 Cylinder 3rd stage 5 Safety valve, 3rd stage
2 Inter-filter 2nd/3rd stage 6 Cylinder Ist/2nd stage
3 Safety valve, 2nd stage 7 Intake filter
4 Inter-filter 3rd/4th stage 8 Fan-wheel
\ , 3
2 q2
4
12
13 5
10
11 9 14 8
Fig. 4 Left hand side, viewed from flywheel
1 Fan-wheel 9 Condensate drain valve, 3rd stage2 Intake filter 10 Condensate drain valve, 2nd stage3 Flywheel 11 Manual condensate drain valve4 Cylinder 4th stage 12 Condensate manifold
5 Oil and water separato, 13 Condensate outlet6 Final pressure safety valve 14 Oil drain plug
7 3/ 2 -way solenoid valve 15 Air outlet
8 Condensate drain valve, 4th stage
17 92 o
2.. , 28
C C,I ) 7
Fig. AR LOW mAGRA
1f m i
I yide1n 'ae2 irot; conctrfrueue
L n o- --gr sa
7 _nercolr2n/r stg 25Pesr wtcitreit
10Itrfle n/r tg prssr r/t tg
v 29 2 9
14 Safty vave 2n stag 3 odnaedan av n tg
Fig. 5 AIR FLWDIAGRAM
1 Intake filter 21 Pressure maintaining valve2 Cylinder 1st stage 22 Non-return valve3 Cylinder 2nd stage 23 Air outlet; connector for tube outer4 Cylinder 3rd stage dia. 10 mm5 Cylinder 4th stage 24 Pressure switch, intermediate6 Inter-cooler lstf2nd stage pressure lst/2nd stage7 Inter-cooler 2nd/3rd stage 25 Pressure switch, intermediate8 Inter-cooler 3rd/4th stage pressure 2nd/3rd stage9 After-cooler 26 Pressure switch, intermediate10 Inter-filter 2nd/3rd stage pressure 3rd/4th stage11 Inter-filter 3rd/4th stage 27 Temperature switch 4th stage12 Oil and water separator 28 Final pressure switch.13 Safety valve 1st stage 29 3/2-way solenoid valve14 Safety valve 2nd stage 30 Condensate drain valve 2nd stage15 Safety valve 3rd stage 31 Condensate drain valve 3rd stage16 Safety valve 4th stage 32 Condensate drain valve 4th stage17 Pressure gauge, intermediate 33 Manual condensate drain valve
pressure lst/2nd stage 34 Condensate manifold18 Pressure gauge, intermediate 35 Oil pump
pressure 2nd/3rd stage 36 Oil filter29 Pressure gauge, intermediate 37 deleted
pressure 3rd/4th stage 38 Oil pressure gauge20 Pressure gauge, final 39 Oil pressure switch
pressure 4th stage
7
III. TEST PROCEDURE
The compressor was set up in accordance with the manufacturer's
instructions. A Cole Palmer model 8502-14 temperature monitor and Yellow
Springs Instruments 700 series thermistor probes were attached to measure
compressor discharge and ambient temperatures. A safety line was installed on
the charging whip. The unit was placed in an exterior work area, open to
ambient temperature but protected by an awning from direct weather. APPENDIX B
contains the complete test plan and the pass/fail criteria used during the
evaluation. APPENDIX C is the test log and contains the recorded data.
A. ENDURANCE TEST
The compressor was operated daily to charge four 2250 cubic inch
(floodable volume) cylinders. The four cylinders were interconnected to
simulate one large 9000 cubic inches air flask. After a charge of 2500 psig on
the flasks the vent was opened to allow the compressor to run continuously at
2000 to 2500 psig discharge. A total of 50 hours of operation were logged on
the compressor. The following parameters were recorded:
1. Date
2. Time
3. Total meter hours
4. Total test hours
5. Oil level6. Oil pressure
7. All four stage pressures
8. Discharge air temperature
9. Ambient air temperature10. Flask size
11. Flask pressure
B. CHARGE RATES
The volume of air delivered and the time to achieve that volume was logged
on the average of three times per day and is recorded in Appendix C.
C. OIL CONSUMPTION
At the beginning of the test the oil sump level was measured as full. Oil
level was monitored during operations and consumption logged. An oil change
was accomplished at 25 hours of compressor operation. The oil used for the
change was Anderol 750 (as per manufacturer's recommendations).
D. AIR SAMPLING
Air samples were taken from the compressor discharge at hours 1, 25 and 50
and sent to the NCSC Laboratory, Code 5130, for purity analysis.
8
E. MAINTENANCE
Scheduled maintenance was performed in accordance with the manufacturer's
instructions and consisted of a lubricating oil and filter change at 25 total
hours of operation. The oil sump level was checked prior to start-up each day.
IV. RESULTS
A. ENDURANCE TEST
The compressor was successfully operated a total of 50 hours to insure
proper functioning and to draw air samples.
B. CHARGE RATES
The data collected provided a complete operational and maintenance log for
this test and was the basis for computing and evaluating all the test results.
Compressor charge rates for the air cylinders used during the test were as
follows:
TIME TOTAL VOLUME CHARGE RATE
MINIMUM: 4 MINUTES 53 SECONDS 177 CUBIC FEET 36.2 SCFM
MAXIMUM: 4 MINUTES 28 SECONDS 177 CUBIC FEET 39.6 SCFM
AVERAGE: 4 MINUTES 42 SECONDS 177 CUBIC FEET 37.65 SCFM
NOTE: Differences in maximum and minimum charge rates were the result of gauge
fluctuation that caused difficulty in reading the minute pressure indicationson the gauge used for this particular test.
The majority of the temperature differentials between ambient and compressor
discharge temperatures were 12 to 17 degrees Fahrenheit. The maximum recordeddifferential temperature was 22 degrees Fahrenheit. This minor carry over of
the heat of compression is not great enough to have significant effect on the
resulting air cylinder temperature.
C. OIL CONSUMPTION
During the test the compressor consumed one quart of oil. Average
consumption was 0.04 pints per hour and is considered acceptable.
D. AIR SAMPLING
The results of the air samples is shown in APPENDIX D. All samples were
vithin limits established by reference (3).
9
E. MAINTENANCE
The Bauer K220 compressor unit was easily maintained and only minorproblems were encountered. The maintenance manual for the compressor isconsidered adequate.
NOTE: During start up on day 2 (test hr 7) with an ambient airtemperature of 51 degrees Fahrenheit, a problem was encountered with the lowoil pressure switch. The switch had to be re-adjusted to a lower cut offpressure. This allowed continuous running until the oil sufficiently warmed upand the 40 second timed relay delay could shift to automatic. (Seerecommendation B.)
NOTE: At 28 hours into the test the air pressure switch failed tofunction at the preset pressure and had to be re-adjusted. This is considered
to be a minor problem. Whereas the operating procedures would take intoconsideration the fine tuning of the pressure switch prior to operation.
V. RECOMMENDATIONS
The following are recommended considerations that the user should be aware of
when purchasing this compressor.
Depending on the specific use and environment it may be prudent to have the
manufacturer make the recommended changes prior to purchasing the compressor.
A good example of this would be if the compressor was going to be used inside aprotected area the recommendations would not apply as much if it was going to
be used out in the weather.
These are only considerations and not requirements.
RECOMMENDATION
A. Primary power source be changed to meet specifications standards ofMIL-M-17060-E Amendment 1.
JUSTIFICATION
In accordance with reference 5 to meet Navy specifications the primemover, if electric, should be a Sealed insulation system (service A use) in
accordance with MIL-M-17060 E, Amendment 1.
10
RECOMMENDATION
B. The oil sump heating device be installed in all US Navy purchased BAUER
K220 compressors.
JUSTIFICATION
Since 51 degrees is a moderate temperature, it is recommend that the oil
heating devices available from BAUER, be installed in BAUER K220 compressorspurchased by the US Navy.
RECOMMENDATION
C. The cadmium coated fittings be replaced with a suitable substitute.
D. JUSTIFICATION
Reference (4) states that cadmium coated fittings cannot be used insystems that exceed 400 degrees Fahrenheit or if the cadmium could come incontact with petroleum products. At this time the only authorized HP
compressor lubricant by the Navy is 2190-TEP.
VI. CONCLUSIONS
Evaluation of the BAUER K220 compressor revealed the following
1. The BAUER K220 compressor delivers acceptable breathing air at acharge rate and volume which meet's or exceeds the manufacture's
specifications.
2. The unit is sturdy, reliable and readily maintainable.
3. The operating and maintenance manuals for the compressor are
adequate.
4. The BAUER K220 compressor is suitable for use by the US Navy.
11
REFERENCES
1. NAVSEA Task 89-11; Testing of commercially available air compressorsfor divers use for ANU list.
2. Test Plan Number 89-48; Operational Evaluation of Divers High PressureAir Compressor.
3. NAVSEA 0994-LP001-9010, U S Navy Diving Manual Vol 2, Para 5.3.2 Airpurity standards.
4. Navy Publication No. S9AA-AA-SPN-010/GENSPEC of Jan 19, 1987. GeneralSpecifications for Ships of the Navy, Cadmium Fittings
5. MIL-M-17060 E, Amendment 1, Sealed insulated systems, (service A use).Navy specifications for compressor power source.
12
MANUFACTURE'S TECHNICAL
SPECIFICATIONS
Model K224J (mod. 3)
Operating pressure max. bar (psi) 350 (5,000)
Delivery /min (c.f.m.) 650...930 (23...33)
Speed min-1 980...1320
Power requirement kW 14.5...20.5
Req'd motor kW 15...22
No. of stages 4
No. of cylinders 3
Cylinder diameters mm (in.)
1st stage 130 (5.11)
2nd stage 130/110 (5.1/4.3)
3rd stage 36 (1.4)
4th stage 16 (.63)
Piston stroke mm (in.) 80 (3.15)
V-belt pulley diameter mm (in.) 450 (17.7)
V-belt profile 3 x SPA
Sense of rotation, viewing at flywheel ccw
Cooling system air
Lubricating system pinion gear driven
oil pump
Lube oil pressure bar (psi) 2...3 (28...43)
Lube oil capacity, approx. I (US qts.)(Imp.gal.) 8.0 (8.5) (2.1)
Intermediate pressures (approx. values at max. op. press.)
1st stage bar (psi) 3 (43)
2nd stage bar (psi) 13 (188)
3rd stage bar (psi) 68 (965)
Max. allowable inclination 100 to all sides
Condensate drain Automatically every
15 minutes
Weight kg (lbs.) 300 (660)
Air outlet tube dia. mm 10
DEPARTMENT OF THE NAVYNAVY EXPERIMENTAL DIVING UNIT
PANAMA CITY, FLORIDA 32407-5001 IN REPLY REFER TO:
NAVSEA Task 89-11
NAVY EXPERIMENTAL DIVING UNIT
STANDARD TEST PLAN
OPERATIONAL EVALUATION OFDIVERS HIGH PRESSURE AIR COMPRESSORS
TEST PLAN NUMBER 89-48
NOVEMBER 1989
Submitted: Reviewed: Approved:
SLLIVAN - J. McCARTHY J E. HALWACHS)G.~ M 1 CDR USN
e T or ,-rr Engineer -- mmanding Officer
H.L. PRUITTLCDR, USNSenior Projects Officer
J.B. McDONELL/ jCDR, USN
"Executive Officer
DISTRIBUTION: Codes 00, 01, 03, 05Original to Technical Library
RECORD OF CHANGES
Except as provided for herein, changes will be made only on the authority ofthe Commanding Officer, NEDU. A dark vertical line in the left-hand marginindicates the coverage of change.
CHANGE NO. AUTHORITY INSERTION SECTION INITIAL
B-2
TABLE OF CONTENTS
Pane
Record of Changes .............................................. 2
Table of Contents ............................................. 3
SECTION:
1. Introduction .......................................... 4
2. Test Parameters ....................................... 4
3. Preliminary Arrangements .............................. 5
4. Test Procedure ........................................ 5
5. Safety Rules and Emergency Procedures ................. 6
6. Termination Criteria .................................. 6
7. Personnel Requirements ................................ 7
8. Logistic Support................... ................... 7
9. Control and Safety of Systems ......................... 7
10. Post Test Arrangements ................................ 7
11. Report Production ..................................... 7
ANNEXES:
A Operational Test Log .................................. A-I
B-3
References:
(a) NAVSEA Task 89-11(b) NEDU Test Plan Number 80-37, Bauer Portable High Pressure Air
Compressor(c) NCSC Field Test Procedure SP80-13-0S6 for Testing Diving Air
Compressors(d) Bauer Compressors Instruction Manual OPM-4(e) Bauer Compressor Instruction Manual for the K220(f) NEDU Report 11-83, Evaluation of Bauer Mariner "D" High Pressure
Breathing Air Compressor
1. Introduction. This test plan provides a series of procedures forstandardized evaluation of commercially available divers high pressure aircompressors. The compressors will be evaluated and data compiled during thesetests to determine their suitability and reliability and eventual Approval forNavy Use (ANU).
Reference (a) directed NEDU to survey the commercial domestic market todetermine if currently available high and low pressure compressors areapplicable for fleet use. If applicable, procure compressor systems asrequired for evaluation. Make recommendations for inclusion on ANU listing.
2. Test Parameters. Evaluation of the compressor will be conducted asfollows:
a. Conduct inspection of compressor using manufacturers instructionmanuals treferences (d) and (e)] to ensure all parts and material are receivedand on hand.
b. Using the manufacturers technical manual for the specific aircompressor and its components, inspect for and determine if the followingitems exist and/or comply, and record results and comments in ANNEX A.
(1) All instruments and controls are clearly and permanently markedaccording to their functions.
(2) All controls, gauges and indicators necessary for operation ofthe compressor are visible and convenient to the operator.
(3) Safety devices are provided and audible and/or visual warningfunctions as specified.
(4) Liquid level indicators accurately display liquid level.
(5) All removable components can be removed and properly reinstalledin working conditions using the manufacturers operating manual, i.e. filters.
(6) All drain, traps and safety valves discharge ports will functionwithout splashing, are conveniently located, and are away from operatingpersonnel.
B-4
c. Have all instrumentation provided by manufacturer compared for
accuracy.
d. Operate the compressor for one hour under a no load condition.
e. Take and analyze air samples following no load test run.
f. Conduct testing in accordance with the procedures set forth in
Section 4. Total compressor running time will be 50 hours.
3. Preliminary Arrangements
a. Arrange for photographic support.
b. Arrange for air analysis as required.
c. Arrange for all instrumentation to be compared by calibration facility.
d. Prior to the actual test procedure the air compressor system shall be
operated then shut down when the system is at maximum pressure and the
following steps accomplished.
(1) Hold pressure.
(2) Allow the system to cool to ambient temperature, and conduct a 90minute drop test as follows:
(a) After temperature has stabilized, record the storage flask
pressure.
(b) After 90 minutes, record pressure again.
(3) Leak rate shall be zero.
4. Test Procedure. The following test procedures will be conducted as
specified, and the results entered in the log sheets, ANNEX A.
a. Take air samples at hours 1, 25, 50 and anytime air quality is
questioned.
b. Log the following measurements on the log sheet, ANNEX A.
(1) Date
(2) Time
(3) Compressor meter hour (if applicable)
(4) Total hours running time on compressor (this test)
(5) Compressor oil level
(6) Compressor oil pressure
(7) First stage pressure
(8) Second stage pressure
(9) Third stage pressure
(10) Fourth stage pressure
(11) Discharge air temperature
(12) Ambient air temperature
(13) Flask size and pressure
(14) Remarks
c. The compressed air system shall be set to cycle 10 times per hour by
adjusting controls and bleed off rate.
d. Compute volume output of the compressor by charging a known volumestorage flask to 3000 psig. Log total charging time and calculate chargingrate.
e. Oil consumption shall be measured and recorded during testing, withmeasurements and additions entered in the log.
f. Perform maintenance as required by the manufacturers instructionmanuals.
5. Safety Rules and Emergency Procedures. Safety rules and precautions asoutlined in the specific manufacturers instruction manuals.
6. Termination Criteria. The following is failure criteria for thesuitability for the specific compressor system for ANU.
a. Failure of any component which cannot be corrected in accordance withthe recommended schedule of maintenance.
b. Failure of the diving air system to operate as specified by the
manufacturers instruction manuals.
c. Failure of the valves to operate as specified.
d. Failure of the pressure relief valves to operate as specified.
e. A decrease in capacity of the compressor during this performance
evaluation.
f. A discharge air temperature from any cylinder in excess of
manufacturers specifications or recommendations.
g. Failure of the air samples to pass breathing air specifications.
7. Personnel Requirements. NEDU Hyperbaric Department and/or Test and
Evaluation Division personnel (one each).
8. Logistic Support
a. Photographic support.
b. Gauge calibration.
c. Air analysis.
9. Control and Safety of Systems. The NEDU Task Leader and Test director are
responsible for the control and safety of systems. All control systems,safety systems and valves shall be activated by making the necessary temporary
alterations to the compressor controls and operations whenever such
alterations will not result in a risk of damage to the compressor unit. Where
a risk is present, the test may be conducted with control systems completely
removed from the compressor unit by subjecting control system sensors to other
sources of temperature and pressure; for example, the oil safety switches and
sensors, automatic condensate blow down valves overpressure switches and
sensor, high temperature switches and sensors, and other devices designed tooperate or protect the system and attending personnel.
10. Post Test Arrangements. Make all necessary arrangements as previously
determined to return compressors system and test fixtures to proper locations.
11. Report Production. Test report and camera ready copy to be written andprepared by the Test Director and submitted for approval to the Commanding
Officer via the Task Leader. Estimate publication date is six weeks following
completion of testing. Test Directors will be the point of contact for NEDU
concerning this test and will be appointed by the Task Leader.
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Memorandum 15 Nov 1989
To: Dave Sullivan, EDU
From: Glen Deason, Code 5130
Subject: Results of air sample from Bauer compressor. This was
the one hour test. Test number 89-48.
1. In accordance with your request, on 15 Nov 1989 the air
sample delivered to the gas analysis lab was analyzed and found
to contain:
Component Air Sample
Oxygen 21.0%
Nitrogen 78.1%
Argon 0.9%
Carbon Dioxide 362 PPM
Carbon Monoxide <0.5 PPM
Total Hydrocarbons* 3.4 PPM
Total HalogensN* <0.5 PPM
Methane 3.4 PPM
Acetylene <0.1 PPM
Acetone <0.1 PPM
Freon 113 <0.1 PPM
Methyl Ethyl Ketone <0.1 PPM
Ethylene <0.1 PPM
Toluene <0.1 PPM
Benzene (0.1 PPM
C4+ <0.1 PPM
*Expressed as methane equivalents.wExpressed as methyl chloride equivalents.
2. The above sample showed no appreciable contamination; all
components were within the acceptable range.
Glen DeasonChemist
I)-'.
4.
Memorandum 20 Nov 1989
To: Dave Sullivan, EDUFrom: Glen Deason. Code 5130
Subject: Results of air sample from Bauer compressor. This wasthe twenty-five hour test.
1. In accordance with your request, on 20 Nov 1989 the airsample delivered to the gas analysis lab was analyzed and foundto contain:
Component Air Sample
Oxygen 21.0%Nitrogen 78.1%Argon 0.9%Carbon Dioxide 392 PPMCarbon Monoxide <0.5 PPMTotal Hydrocarbons* 3.6 PPMTotal Halogens** <0.5 PPMMethane 3.6 PPMAcetylene <0.1 PPMAcetone <0.1 PPMFreon 113 <0.1 PPMMethyl Ethyl Ketone <0.1 PPMEthylene <0.1 PPMToluene <0.1 PPMBenzene <0.1 PPM
C4+ <0.3 PPM
*Expressed as methane equivalents.**Expressed as methyl chloride equivalents.
2. The above sample showed no appreciable contamination; allcomponents were within the acceptable range.
Glen DeasonChemist
1)-:
Memorandum 27 November 1989
To: Dave Sullivan. NEDUFrom: Glen Deason, Code 5130
Subject: Tent results of air sample from Bauer compressor after50 hours.
1. In accordance with your request on 27 Nov 1989, the airsample delivered to the gas analysis lab was analyzed and foundto contain:
Component Air Sample
Oxygen 21.0%Nitrogen 78.1%Argon 0.9%Carbon Dioxide 348 PPMCarbon Monoxide (0.5 PPMTotal Hydrocarbons* 2.1 PPMTotal Halogens** (0.5 PPMMethane 2.1 PPMAcetylene (0.1 PPMAcetone (0.1 PPMFreon 113 <0.1 PPMMethyl Ethyl Ketone (0.1 PPM
Ethylene (0.1 PPMToluene (0.1 PPMBenzene (0.1 PPM
C4+ (0.1 PPM
*Expressed as methane equivalents.**Expressed as methyl chloride equivalents.
2. The above sample showed'no appreciable contamination; all
components were within the acceptable range.
Glen DeagonChemist
D- 3
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Memorandum 15 Nov 1989
To: Dave Sullivan, EDUFrom: Glen Deason, Code 5130
SubJect: Results of air sample from Bauer compressor. This wasthe one hour test. Test number 89-48.
1. In accordance with your request, on 15 Nov 1989 the airsample delivered to the gas analysis lab was analyzed and foundto contain:
Component Air Sample
Oxygen 21.0%"Nitrogen 78.1%Argon 0.9%Carbon Dioxide 362 PPMCarbon Monoxide <0.5 PPMTotal Hydrocarbons* 3.4 PPMTotal Halogens** <0.5 PPMMethane 3.4 PPMAcetylene <0.1 PPMAcetone <0.1 PPMFreon 113 <0.1 PPMMethyl Ethyl Ketone <0.1 PPMEthylene <0.1 PPMToluene <0.1 PPMBenzene (0.1 PPM
C4+ (0.1 PPM
*Expressed as methane equivalents.WExpressed as methyl chloride equivalents.
2. The above sample showed no appreciable contamination; allcomponents were within the acceptable range.
Glen DeasonChemist
Memorandum 20 Nov 1989
To: Dave Sullivan. EDUFrom: Glen Deason. Code 5130
Subject: Results of air sample from Bauer compressor. This was
the twenty-five hour test.
1. In accordance with your request, on 20 Nov 1989 the air
sample delivered to the gas analysis lab was analyzed and found
to contain:
Component Air Sample
Oxygen 21.0%
Nitrogen 78.1%
Argon 0.9%
Carbon Dioxide 392 PPM
Carbon Monoxide <0.5 PPM
Total Hydrocarbons* 3.6 PPM
Total Halogens** <0.5 PPM
Methane 3.6 PPM
Acetylene <0.1 PPM
Acetone <0.1 PPM
Freon 113 <0.1 PPM
Methyl Ethyl Ketone <0.1 PPM
Ethylene <0.1 PPM
Toluene <0.1 PPM
Benzene <0.1 PPM
C4+ <0.3 PPM
*Expressed as methane equivalents.**Expressed as methyl chloride equivalents.
2. The above sample showed no appreciable contamination; all
components were within the acceptable range.
Glen DeasonChemist
Memorandum 27 November 1989
To: Dave Sullivan. NEDUFrom: Glen Deason, Code 5130
Subject: Teat results of air sample from Bauer compressor after50 hours.
1. In accordance with your request on 27 Nov 1989, the air
sample delivered to the gas analysis lab was analyzed and foundto contain:
-"Component Air Sample
Oxygen 21.0%Nitrogen 78.1%Argon 0.9%Carbon Dioxide 348 PPMCarbon Monoxide <0.5 PPMTotal Hydrocarbons* 2.1 PPMTotal Halogens** (0.5 PPMMethane 2.1 PPMAcetylene (0.1 PPMAcetone (0.1 PPMFreon 113 <0.1 PPMMethyl Ethyl Ketone <0.1 PPMEthylene (0.1 PPMToluene (0.1 PPMBenzene <0.1 PPM
C4+ (0.1 PPM
*Expressed as methane equivalents.**Expressed as methyl chloride equivalents.
2. The above sample showed no appreciable contamination; all
components were within the acceptable range.
Glen Deason
Chemist
I)- '