Technologies of the aircraft systems refilling by the special gases.html
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The unit consists of:
- compressor КП-75М;
- systems of the compressor lubrication;
- compressor drive;
- compressor rotary speed control gear;
- systems of pre-start warming up of compressor lubricant;
- systems of the oxygen cooling;
- oxygen dehydration systems;
- control panel with the oxygen pipework and accessories;
- fire-prevention systems;
- electrical equipment systems of unit.
3. Design and operation of component parts of unit
3.1 Compressor КП-75М.
Compressor is intended for transferring and compression the oxygen inside the refilled gas cylinders. Basic units of compressor (fig. 1.3.5., 1.3.6.): casing, crank shaft, cylinders jackets, rod, plungers, insert, cylinders heads, intake and outlet valves, fly-wheel.
Compressor gear is swinging arm link. In case of rod motion to the left in the right cylinder underpressure is created and oxygen is sucked in through the inlet valve. Meanwhile in the left cylinder there is a squeezing of oxygen, and when the pressure in cylinder achieves a greater value, than pressure behind the outlet valve, it is opened and oxygen is pumped inside the pressure pipework. When the rod moves backward - a reverse process takes place. The complete cycle of suction, squeezing and pumping the oxygen in both cylinders takes place per one revolution of crank shaft. For the smoother run on the compressor shaft a fly-wheel is installed.
Technical specifications of oxygen compressor.
Compressor type...............................................................double cylinder, single-stage
Working pressure, MPa (kg/sm2)...............................15,0(150)
Compression ratio....................................................................3
Rotary speed, rps (rpm).........................................4,6-5,0 (820-300)
Cylinder diameter, mm............................................................30
Piston stroke, mm...............................................60
Lubrication of the gear...................................................glycerin
Fig. 1.3.5. КП-75М compressor (longitudinal sectioning): 1 - fly-wheel; 2 - crank shaft; 3, 4 - plugs; 5 - upper window (lid); 6 - rear window; 7 - casing; 8 - rod; 9 - drain cork
Fig. 1.3.6. КП-75М compressor (sectioning along the valves): 1 - intake pipeline; 2 - inlet valve; 3 - insert; 4,9 - cylinders jackets; 5 - casing; 6 - manifold; 7 - rod; 8 – lubricant heat exchanger; 10 - outlet valve; 11 - pressure pipeline; 12 - cylinder head
3.5 System of the oxygen cooling
A cooling system assembly is intended for oxygen cooling (fig. 1.3.7.), which is delivered from compressor. It is a three line worm-pipe, which is blown around by air fan. It is made of the copper pipes with diameter of 9×5 mm. The air blowing fan is fastened on the compressor fly-wheel. The air, blowing pipes, goes out through opening in fan sump.
Fig. 1.3.7. Oxygen air-cooling system: 1 - assembly of worm-pipes; 2 - fan; 3 - fly-wheel; 4 – sump
3.6 Oxygen dehydration system
Dehydration (fig. 1.3.8. and 1.3.9.) unit is intended for the removal of the moisture from oxygen, which is imbibed in oxygen as a result of contact with the water-glycerin mixture during compressor work. A unit consists of moisture separator and dehydrator.
Moisture separator (fig. 1.3.9.) is intended for the separation the moisture drops from oxygen. Working principle of moisture separator is the following. Oxygen is delivered from cooler through the connecting pipe in moisture separator in the bent pipe. When passing through the moisture separator stream of oxygen is spun, and moisture parts under the action of centrifugal
Fig. 1.3.8. Dehydration unit: 1 – moisture separator; 2 – dehydrator
Fig. 1.3.9. Moisture separator: 1 – connector; 2 – bent pipe; 3 – axial pipe; 4 – casing
force and speed change are settled on the casing walls and then flow down in the lower part of vessel. Moisture which was accumulated in the casing bottom is to be periodically removed through the drain cock. The oxygen through the axial pipe of moisture separator is delivered in dehydrator.
Two dehydrators of identical design are installed on the unit (fig. 1.3.10.), and connected in parallel (shunt) circuit. Dehydrator is intended for absorption of water vapors, which had been remained in oxygen after passing through moisture separator. It is a steel vessel of 5 liters capacity, filled by zeolite (СаА or Na grades according to МРТУ 6-01-906-66). A connector is screwed in the dehydrator oxygen inlet with the gauze filter, on the oxygen outlet from the dehydrator a ceramic filter is mounted with filtration fineness of 100±20 micrometers.
Fig. 1.3.10. Dehydrator: 1 – steel vessel; 2 - flange; 3 - gauze filter; 4 - ceramic filter; 5 – nut.
Dehydrator functioning is based on the high adsorption ability, that is the zeolite property of well absorption of the water vapors, which are in gases. Expiring the servicing time a zeolite is gradually moistened and its adsorption properties are worsened. However the wet zeolite after roasting can recover its adsorption properties and can well absorb the moisture again.
Restoration of a wet zeolite is to be done in the oven of the Ш-0,05 type at temperature +300-350 °C in 4,5-5,5 hours.
3.7 Control panel with the oxygen pipework and equipment
A control panel is mounted in the compressor compartment in the carbody rear part and is closed by the special cover. Valves and pressure gauges of oxygen pipework, switches and warning lamp are mounted on the right side of panel. The oxygen pipework panel and wiring are mounted on the back side.
The pipework mounted on the control panel depending on its intention are subdivided on the following pipelines (fig. 1.3.11.):
a) intake pipeline is from the inlet valves of compressor to the intake valves on the control panel.(Intake of oxygen is done by this pipeline, valves of this pipeline are marked by the numbers 6, 14, 21);
b) supply pipeline is from the outlet valves of compressor to the delivery valves on the control panel. (Pumping of oxygen is performed by this pipeline. Within the supply line cooler, moisture separator, two dehydrators and safety-valve are installed. Valves of delivery pipeline are marked by the numbers 5, 13, 20);
c) refilling pipeline is to the outlet valves on the control panel (5,13,20) to the refilling coupler through the valve 22;
d) loading pipeline is from the refilling coupler to the intake valves on the control panel (6,14,21) through the valve 24.
Pressure in the delivery pipeline is read by the pressure gauge with table "refilling pressure", in the intake pipeline – by pressure gauge with table "intake pressure". Indications of these pressure gauges are additionally duplicated by indications of pressure gauge of gas cylinders banks.
The unit circuit allows transferring the oxygen from one bank of gas cylinders into another. So, for example, with the open valves 14 and 20 the compressor will suck the oxygen by the intake pipeline from gas cylinders of the second bank, and deliver it through the supply pipeline in gas cylinders of the third bank.
The intake and supply pipelines are connected between themselves by the bypass valve of the idling cycle 16. This valve is used, when we need temporally to cease the oxygen transferring, without the stopping of the compressor. In this case a valve 18 is open and some valves of supplying bank, for example 21. The oxygen will be then sucked by the compressor from gas cylinders of the third bank by the intake pipeline and through the supply pipeline and valve 18 will return back, that is why there will be the idling cycle without the pressure rise in pipeline.
The valve 22 of refilling pipeline is intended for the delivery of oxygen to the refilling coupler.
An intake pipeline is connected with the delivery pipeline using the valve 24.
Fig.1.3.11. Principle diagram of unit oxygen pipework.
On the intake and supply pipelines near the filling coupler check valves 29 and 30 are installed, they enable the oxygen flow in one direction only.
From the supply pipeline the branch goes through valve 23 to the reduction valve, which reduces the pressure to 3,0 MPa. Using this reduction valve refilling of low pressure gas cylinders to 3,0 MPa can be done. Reduced pressure is monitored by pressure gauge 27 on the control panel.
For oxygen discharge from pipework in the atmosphere the valves 17 and 25 are used. The drain cock 17 is also intended for the periodic removal of moisture, which is flowing in bottom of moisture separator.
Moisture is scavenged through the pipeline that is laid under the unit carbody. Reloading of the unit and refilling the consumers by oxygen is done through the same coupler 28.
A control panel (fig. 1.3.12.) panel is made from the steel sheet. All measuring devices and regulation valves are located on the panel. Valves are located in the first line 3 and 5 of oxygen reduction valve. Between this valves, the clock 4 is located
Three pressure gauges are located in the second line 2, showing pressure in three banks of gas cylinders and two pressure gauges, which show pressure in delivery 6 and in intake 7 pipelines. On the right of them there is a pressure gauge of reduction valve 8, on the left - indicator of remote thermometer 1, showing a glycerin temperature in compressor casing.
Fig. 1.3.12. Control panel:
1 - indicator of remote thermometer; 2,6,7 - pressure gauges; 3,5 - valves of refilling in 3,0 MPa; 4 - clock; 8 - pressure gauge of reduction valve; 9,11 – stop valve; 10 - refilling valve of 15,0 MPa; 12 - first bank valves; 13 - second bank valve; 14 - third bank valves; 15 - idling cycle valve; 16 - refilling valve of 15,0 MPa; 17 - hose scavenging valve; 18 - safety-valve; 19 - tables; 20 - indicator lamp of the fire prevention system; 21 - compressor starting up button; 22 -clock warming up switch; 23 - engine emergency shut down button; 24 - compressor illumination switch; 25 - compressor shut down button; 26 - panel illumination switch; 27 - compressor rotary speed indicator.
In the third line under pressure gauges of gas cylinders bank three valves are located: 12, 13, 14 supply pipeline. On the right of them - stop valve 9, enabling work on the idling cycle to close the gas flow to the dehydrators; valve 10 of 15 MPa refilling pressure and drain cock 11 of moisture separator.
In the fourth line under valves of the supply pipeline 12, 13 and 14 valves of intake pipeline are located. To the right from them there is a valve 15 of idling cycle, reloading valve 16 of unit gas cylinders in 15 MPa and valve 17 of hose scavenging.
Under fourth line the buttons are alongside located 21 and 25 warning about the start up and shutdown of compressor and button of 23 engine emergency shutdown, to the right from them the device 27 is located, that indicates a compressor rotary speed.
At the bottom of the panel the clock warming up switch is located 22, compressor illumination switches 24 and panel 26, control lamp 20 of fire prevention system.
Under every device a table, which specifies the name of this device is placed.
On the control panel also four more tables are placed:
- first and second - with instructions about the observance of unit precautionary issues;
- third - with circuit of oxygen communication;
- fourth – with table of oxygen pressure diagram in gas cylinders from the ambient temperature.
Labour precaution rules during application of
oxygen truck
On-board oxygen systems regardless of their intention are to be refilled only by the medical oxygen.
To avoid the refilling hoses explosion application of the depreservated and not degreased oxygen hoses is forbidden.
Oxygen gas cylinders where the pressure will turn out equal to atmospheric are admitted to the further application only after the twin-thrice-repeated washing by oxygen with the following refilling them to the nominal pressure.
Oxygen and other equipment, which contains pressurized gases, is allowed to application, if it completely in good state and is tested by institutions of State Inspectorate.
Repair of equipment which contains pressurized gases is allowed only after the gas discharge with the observance of precautionary issues, foreseen by instruction.
With purpose of prevention of inflammation and explosion in the oxygen compressors, vessels and accesories you should:
- apply for lubrication of oxygen compressors only those lubricating substances, which are recommended by factories-manufacturers (glycerin, water-glycerin mixture etc.).
- take the actions for prevention of oxygen devices polution by oil and greasings, do not approach to such equipment with the fatty wiping rags and in the dirty overall robes;
- check impermeability of oxygen equipment using the soapy water, not using smouldering items;
- servicing procedures of the oxygen equipment is to be done in the clean, without the oily stains, overall, by degreased tools;
- when leaving the area, enreached by oxygen, ventilate an overall and hairs for the oxygen removal; at that do not approach to the fire and smoke, for prevention of self-ignition of clothes and hairs;
Application of mineral oils for lubrication of oxygen compressors and usage of oxygen truck without earth bonding cables connected are forbidden.
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