A0DAI05 608 NAVY EXPERIMENTAL DIVING UNIT PANAMA CITY FL F/6 6/11TEST AND EVALUATION OF BAUER PORTABLE HIGH-PRESSURE BREATHING A--ETC(U)NOV So R L BOWDISH

UNCLASSIFIED NEDU-15-80 NL-,, mmmEEmm..mmmmEmmEmmmEEEEEEmmmmmmEEmmmEmmmmmEEEmmmmmmm

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NAVY EXPERIMENTAL DIVING UNS OCT0 118

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LEVEL1DEPARTMENT OF THE NAVY

NAVY EXPERIMENTAL DIVING UNITPanama City, Florida 32407

'WAVY EXPERIMENTAL DIVING UNITREPORT NO. 15-80

TEST AND JVALUATION OF4AUERJORTABLE. HIGH-&RESSURFJREATHING_4IR

tOMPRESSOR, MOEL VARIUS G-3.

R L./BOWDISH

Novin=W80

E

Approved for public release; distribution unlimited

Submitted: Reviewed: Appro

R. L. BOWDISHJ HARRISON R. A. BORNHOLDTBMC(DV) LCDR, USN CDR, USNT&E Department T&E Department Head Commanding Officer

CDR, USExecutive Officer

3 ii:

UNCLASSIFIED

qECUiITY CLASSIFICATION OF THIS PAGE (When Data Entered)

REPORT DOCUMENTATION PAGE RED CMSTRUCTIONS_________________________________ EFORE COMPLETIN FORM

I. REPORT NUMBER 12. GOVT ACCESSION NO. 3. RECIPIENT'S CATALOG NUMBER

NEDU REPORT NO. 15-80 41O5 s '4. TITLE (and Subtitle) S. TYPE OF REPORT & PERIOD COVEflE-:

TEST AND EVALUATION OF BAUER PORTABLE HIGH- Test Repot

PRESSURE BREATHING AIR COMPRESSOR, MODELVARIUS G-3 6. PERFORMING ORG. REPORT NUMC!.k

7. AUTHOR(e) S. CONTRACT OR GRANT NUMUER(e)

R. L. BOWDISH, BMC(DV), U.S. Navy

9. PERFORMING ORGANIZATION NAME AND ADDRESS 10. PROGRAM ELEMENT. PROJECT, TASK

AREA & WORK UNIT NUMBERS

NAVY EXPERIMENTAL DIVING UNITPANAMA CITY, FL 32407

I 1. CONTROLLING OFFICE NAME AND ADDRESS IZ. REPORT DATE

NOVEMBER 1980IS. NUMBER OF PAGES57

14. MONITORING AGENCY NA..E & ADDRESS(II different from Controlling Office) IS. SECURITY CLASS. (of this report)

UNCLASSIFIED

IS. OECL ASSI FI C ATION/ DOWN R ACIN GSCHEDULE

16. DISTRIBUTION STATEMENT (of this Report)

Approved for public release; distribution unlimited.

17. DISTRIBUTION STATEMENT (of the abstreet entered in Block 20, If different from Report)

IS. SUPPLEMENTARY NOTES

19. KEY WORDS (Continue on revere side if necessary and Identify by block number)

Portable Air Compressor Flow Tate

High-pressure Breathing Air Air Analysis

Three-stage Compression%;adoline Engine Driven

20. ANATRACT (Continue on reveres side if necoeaoay d identilf by blo k ma i a)A gasoline engine driven highr-pressure Dreatning air compressor, BAUER

Varius G-3, was evaluated by the Navy Experimental Diving Unit to determine

its suitability for Navy use. Restus of the 50-hour test showed that the

portable compressor delivers breatdng air at an average charge rate of2.07 CFM, charging twin 72 cu.ft., twin 50 cu.ft., and single 80 cu.ft. scubatanks in 71, 44, and 39 minutes respectively. The unit is easily manitained,sturdily constructed, and econmical in gasoline fuel consumption. The BAUERhigh-pressure breathing air compressor (Varius G-3) is recommende

DD I AN 7' 1473 EDITION OF I NOV S IS 0so,.91'd UNCLASSIFIEDS/N 01 02-LF-0 1-6601 .

.'ICURITY CLASSIFICATION OF THIS PAd (fte., Doto &Irend

UNCLASSLYLEDI

SILCURITY.CLASSIFICATION OF TIS PACE (UWmo. D8t6 31te0 -----

0. (Continued).

placement on the list of equipment Approved for Navy Use (A2NU).

oor

UNCLASSIFIEDSECURITY CLASSIFICAT'ION OF THIS PAOI(US" DO#* 8000POO

TABLE OF CONTENTS

Section Page

1. INTRODUCTION

1.1 Objectives .. ......... ..... ........ 1

1.2 Scope.............. . . ... . . .. .. .. .. ..........

1.3 Background............. . . .. .. .. .. .. ........

2. DESCRIPTION

2.1 General DescrIption. ............... ...... 2

2.2 Functional Description .. ............... .... 5

2.3 Physical Dimensions. ................... 5

3. TEST PROCEDURE

3.1 Preliminary Arrangements .. ............... .

3.2 Test Plan ..............

4. RESULTS AND DISCUSSION

4.1 Endurance Test .. .. .. .. . . .. . . .

4.2 Data Computation .. .............. ... 8

4.3 Maintenance.............. . . .... . .. .. .. . .......

5. CONCLUSIONS AND RECOMMENDATIONS..... .. .. . . . ....

LIST OF REFERENCES ... ............ . .. .. .. . .16

APPENDIX A. NAVSEA Task No. 80-5 .. ................ .. 17

APPENDIX B. Test Plan and Test Equipment .. ............... 19

APPENDIX C. Operational Test Log .. .............. ..... 5

APPENDIX D. Manufacturer's Manual. ........... ... ... 54

ABSTRACT

A gasoline engine driven high-pressure breathing air compressoriBAUER Varius G-3, was evaluated by the Navy Experimental Diving Unit todetermine its suitability for Navy use. Results of the 50-hour test shovedthat the portable compressor delivers breathing air at an average charge rateof 2.07 CFM, charging twin 72 cu.ft., twin 50 cu.ft., and single 80 cu.ft. scubatanks in 71, 44, and 39 minutes respectively. The unit is easily maintained,sturdily constructed, and economical in gasoline fuel consumption. The BAUERhigh-pressure breathing air compressor (Varius G-3) is recommended for placementon the list of equipment Approved for Navy Use (AMU).

- i

1. INTRODUCTION

1.1 OBJECTIVES

By direction of the Commander, Naval Sea Systems Command (reference I),the BAUER high-pressure breathing air compressor, model Varius G-3, was testedby the Navy Experimental Diving Unit to determine if'the compressor dischargessuitable breathing air and has a service life which satisfies the requirementsfor portable scuba diving compressors throughout the Navy.

1.2 SCOPE

1.2.1 Compressor Operation

Compressor testing simulated the field opey in of intermittently

filling scuba cylinders to 2250 psig and 3000 psig. A total of 50 hours ofcompressor operation have been compiled. The testing included subjectiveoperational evaluations but not detailed mechanical considerations of singlecomponents of the compressor.

1.2.2 Air Quality Analysis

Testing for analysis of discharged air was conducted as specified inAppendix B.

1.3 BACKGROUND

The Experimental Diving Unit has previously evaluated several portablehigh-pressure air compressors (references 2 through 5). Mechanical failuresin the compressor or prime mover, low capacity, or poor quality of breathiAgair were cited as reasons for nonacceptance of all but one unit. At the timeof this report there are four portable high-pressure air compressors whichhave been Approved for Navy Use; three are gasoline engine driven and one isdiesel driven.

t1

i i

2. DESCRIPTION

2.1 dEN9RAL DESCRIPTION

The BAUER Varius G-3 high-pressure breathing air compressor (figures Iand 2) is one of a line of high-pressure air compressors manufactured byBAUER Breathing Air, Incorporated, 1328 Azalea Garden Road, Norfolk, Virginia,23502.

2.1.1 Air Compressor

The Varius G is a highly portable three stage, three cylinder, highpressure compressor designed to deliver 2.3 actual cubic feet per minute(ACFM) at 3200 psig.

2.1.2 Prime Mover

The prime mover for the air compressor tested by NEDU is a four-stroke,single cylinder, L-head, air cooled gasoline engine rated at 3 hp at 3600 rpm.The engine is mounted on the compressor unit with a torsion spring axle, andis coupled to the compressor by a V-belt and detensioning mechanical clutchfor ease of engine starting. In addition, an option of three different elec-tric motors (each producing different volume outputs) is available with all

prime movers readily interchangeable.

2.1.3 Purification System

The purification block is constructed of machined, anodized aluminum,and consists of three chambers: an oil and water demister; a dehumidifier;and a filter. Replaceable cartridges are used in chambers 2 and 3, with thecartridge service life dependent on ambient temperature and humidity, as

indicated in the following table:

COMPRESSOR OPERATING AIRRUNNING TEMPERATURE PROCESSED

HOURS AMBIENT IN°C OF C.F.

25 15 60 350020 27 80 275015 38 100 210012 50 120 1700

A back pressure regulator set at 2750 psig is provided to ensure thata constaTit back pressure is maintained on the final stage of the compressor.The purification block also contains an adjustable relief valve which protectsthe compressor and the receptacle being filled. It can be set to any pressurefrom 2800 to 3200 psig.

2

i Mover IMP • W

Air Compressor

3rd Stage Relief Valve

Air Intake

Charging Whip

Figure 1. BAUER High-Pressure Breathing Air Compressor, Varius G-3

(modified according to NEDU recommendations)3

kwwDisassembled AirInlet Pipe

Torsion spring Axle

'Prime Mover & Compressor - pr u e o r

Var lus G with prime mover detached

'Figure 2. BAIJER Varius G-3

4

2.2 FUNCTIONAL DESCRIPTION

2.2.1 Compressor Air Flow (Figure 3)

Air is taken into the compressor through the micronic intake filter (2)and is compressed in the first stage cylinder (3) to 80 psig. The air isthen cooled in an intermediate cooler (6) and passes into the second stagecylinder (4) for further compression to 800 psig. The air is again cooledin an intermediate cooler (7) and compressed in the third stage cylinder (5)to the charging pressure. In the after cooler (8) the air is cooled toapproximately ambient temperature. The stages are protected by safety valves(9) and (10), preset to 116 psig and 1160 psig respectively, and the finalsafety valve (11) which is adjustable from 2755 psig to 3200 psig. Operating(back) pressure is read from the gauge (12), which is installed in the filterassembly block and indicates the third stage discharge pressure. From theafter cooler the compressed air passes through the oil and water separator inthe purification assembly (13), and thence through purification cartridges (15).Here vapor and remaining moisture is removed and CO is converted to C02.Condensaticn in the purification assembly is removed by drain valve (14).Downstream of the purification assembly is the back pressure maintaining valve(16) which insures a minimum operating pressure of 2750 psig at both the thirdstage discharge and purification chambers. The air then flows through thecharging hose to the filling valve (18) and the pressure gauge (19), whichregisters the pressure to the tanks being filled.

2.2.2 Compressor Lubrication

The second stage cylinder, third stage cylinder, and driving gears aresplash lubricated from the crankcase by an oil thrower pin. Due to thedirection of crankshaft rotation adequate lubrication of the first stage isnot provided by the oil thrower pin. Additional lubrication for the firststage cylinder is provided by venting oil mist from the crankcase into thefirst stage intake down stream of the micronic filter.

2.3 PHYSICAL DIMENSIONS

Weight 65 lb.

Length 26 in.Width 12 in.Height 14 in.

- S

Model 3200 psig/PN 200 bar VG 35000 psig/PN 300 bar vG 3-H

Number of cylinders 3

Working process 3stage

Cylindei bore -m 60/28/12

Piston Stroke m 15

Compressor speed rpm 2600

Inter- 3200 psig/PI 200 bar 80/800 psi(',.5/55 bar)mediate t 10%pressure 5000 psig/PN 300 bar 94/942 psi(6.5/65 bar)

Adjustment 3200 psig/PN 200 bar 2755 psig (190 bar)of minimumpress. maintaining 5000 psig/PN 300 bar 4060 psig (280 bar)valIve

Actual tank filling capacity1 ) cfm(l/min) 2.3 (64)

Standard engine/motor 4-stroke

Briggs & Stratton

Nominal power of engine/motor 3 HP (2.2kW)

Oil filling capacity (fl. ot) cm3 14-1/2 (430)of compressor

Summer above +50*F (+10* SAE 30Oil winter +50*F (+10*C) to +50.1' (-15%) -SAE 20

Approved oil brands BAUER Compressor Oil Mobil Deivac 1200 SeriesBAUER Synthetic Compr. Oil Tenneco-Anderol 750

1) measured bottle filling 0 to 3200 psig 5

1 ~ ~ 1 1eecoi ai1nae 7Itreit ooe 3Prfcto sel

2 3- 8nak 2av n/r tg 4Cnest ri a

1Tlscopic tae 12ak Gaugewdat ooe 19 Bottle tio pr ss emgaug

3 ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ (EI Cyidrltsns fecolr1 itr tallide

Figure 3. Compressor Schematic

6

3. TEST PROCEDURE

3.1 PRELIMINARY ARRANGEMENTS

A BAUER Varius G-3 air compressor, serial number 80/122/0, was receivedfrom the manufacturer and prepared for operation in accordance with instruc-tions in the manufacturer-furnished technical manual.

3.2 TEST PLAN

3.2.1 Test Setup

The compressor was set up as shown in figures 1 and 2, and test equip-ment was attached. A YSI thermistor was placed in line to check the manu-facturer installed thermometer, and an additional 0-3500 psig gauge was addeddownstream of the shutoff valve at the end of the charging whip. Appendix Bdescribes the actual test plan and test equipment used.

3.2.2 Test Parameters

3.2.2.1 Endurance Test. The compressor was operated daily to chargesingle 72 cu. ft., single 80 cu.ft., twin 72 cu.ft., and twin 50 cu.ft. scubatanks until 50 hours of operation were logged. The following measurements

were recorded:

(1) Start up time(2) Filter back pressure(3) Tank size and pressure(4) Total hours running time(5) Ambient air temperature(6) Delivery air temperature

3.2.2.2 Flow Test. Flow rate was measured approximately every threehours of operation.

3.2.2.3 Air Sample Analysis. The compressor was operated to charge asingle 72 cu. ft. tank, which was sampled for air purity analysis. Initialsampling and analysis was conducted under a no-load condition, and thensamples were repeated at 12.5, 25, 26, 37.5, and 50 hours of compressorop(:ration.

3.2.2.4 Fuel Consumption. Gasoline fuel consumption of one measuredamount of fuel, two quarts, was calculated twice during compressor testingoperations.

3.2.2.5 Oil Consumption. Lubrication oil consumption was monitoredduring operation with oil levels noted in the test logs.

- 7

4. RESULTS AND DISCUSSION

4.1 ENDURANCE TEST

4.1.1 Location

The unit was placed in an exterior open work area with the air intakefacing the prevailing wind. The test site was not changed, but the-airintake was repositioned as dictated by shifts in wind direction.

4.1.2 Initial Operation

Initially the compressor was set up and run to insure proper operation

and draw a preliminary air sample.

4.1.3 Charge Cycle

During the 50 hour operating period, the compressor accumulated 63charging cycles. Due to the nonavailability of twin 90 cubic foot cylindersas called for in the test plan, single 72 and 80 cubic foot and twin 50 and 72

cubic foot cylinders were used during the charging cycles. All data wasrecorded on log sheets, which are provided as.Appendix C. A randomly selectedcharging cycle is graphically presented as figure 4 to aid in the presentationof the relationship of running time to heat and pressure. It should also benoted that the linear progression of the pressure/time line is due to theback pressure maintaining valve insuring a constant efficiency of the thirdstage for the entire charging cycle.

4.2 DATA COMPUTATION

4.2.1 Test Data

The test data, Appendix C, for this evaluation provides a completeoperational and maintenance log for this test and is the basis for computingand evaluating test results.

4.2.2 Average Charge Rate

Average compressor charge rates for the scuba air cylinders used during

the test were:

Cylinder CFH

Twin 50 cu.ft. - 2.17Single 80 cu.ft. - 2.33Twin 72 cu.ft. - 2.02

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4.2.3 Flow Rate

The 'calculated flow rates at given points throughout the test arepresented below. It should be noted that proscribed maintenance was conductedat hour 25. The reduced flow rates starting at hour 30 are felt to be abyproduct of the engine carburetor adjustment, conducted during maintenance.

Hour Flow Rate (CFM) Hour Flow Rate

0 2.0 30 2.010 2.2 35 2.015 2.3 40 2.020 2.3 45 2.025 2.4 50 2.2

4.2.4 Filling Time

The average time required to fill standard Navy scuba cylinders isas follows:

Cylinder Filling Time (mins.)

Twin 50 cu.ft. - 44Single 80 cu.ft. - 39Twin 72 cu.ft. - 71

4.2.5 Highest Temperature Differential

The highest ambient and compressor discharge temperature differentialswere computed for ambient temperatures of 80, 90, and 100*F. The followingdata illustrates that the heat of compression retained in the gas after thethird stage intercooler is not great enough to become a major factor in theresultant bottle pressure.

Highest

Running Ambient Discharge Temp.Time Temp.°F Temp.°F Differential OF

18:28 80 124 444:21 90 120 5011:29 100 139 39

4.2.6 Fuel Consumption

Fuel consumption was calculated twice, at running times of 4 hours17 minutes and 5 hours 54 minutes. Consumption of two quarts of unleadedgasoline for each test resulted in fuel use of 3 hours and 30 minutes pergallon, and 3 hours and 19 minutes per gallon, respectively.

10

4.2.7 Air Sampling

Air samples were taken at the start and the end of the test period,every 12.5 hours, and after performance of scheduled maintenance. Thesesamples were analyzed in accordance with Appendix B. The samples indicatedno appreciable contamination, and all gas components met the acceptablecriteria for U.S. Navy standards for compressed breathing air. Table 4-1lists the results of the air sample analysis in a form that facilitates easeof comparison for the entire test. Figure 5 is a graphic display of theana ysis; the effects of the 25 hour servicing and filter change should be

notted.

4.3 MAINTENANCE

4.3.1 General

The BAUER Varius G-3 compressor is easily maintained. Proscribedmaintenance as set forth by the manufacturer's recommended procedure iscomprehensive, but specific wording of the manual is awkward.

4.3.2 Scheduled Maintenance

Sciieduled maintenance was performed in accordance with the manufacturer's

instructions and consisted of the following:

Condensate. Condensate was drained on a regular basis, approximatelyevery 10 minutes.

Fuel and Lubrication Oil. Fuel and lubrication oil levels were checkedon a regular basis and replenished as required. Use was not consideredexcessive.

25 Hour Check. After 25 hours of operation, the V-belt was checked forwear, all fittings were checked for tightness, engine and compressor oil waschanged, and the oil/water and carbon monoxide filters were replaced.

4.3.3 Corrective Maintenance

Corrective maintenance was limited to adjustment of the back pressure

valve and adjustment of the jet screw on the engine carburetor.

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14

5. CONCLUSIONS AND RECOMMIENDATIONS

5.1 CONCLUSIONS

5.1.1 The BAUER Varius G-3 compressor is suitable for use by the Navy.

5.1.2 The BAUER compressor delivers acceptable breathing air at a chargerate and volume, which meets the manufacturer's specifications.

5.1.3 The charging cycle time is considered to be satisfactory.

5.1.4 Fuel consumption of the compressor engine is satisfactory and is

very economical.

5.1.5 The unit is sturdy, reliable, readily maintained, and one man portable.

5.2 RECOMMENDATIONS

5.2.1 General

It is recommended that the BAUER Varius G-3 compressor be placed on thelist of equipment Approved for Navy Use, enclosure 2 to the NAVSEAINST 9597.1series.

15

LIST OF REFERENCES

1. Task No. 80-5 from NAVSEA OOC-3 to Commander, NEDU, Subject: Test andEvaluate BAUER Scuba Jamming Compressor (4700 psig/2.3 CFM/WT 65 lbs),25 February 1980 (Appendix A).

2. Navy Experimental Diving Unit Report 6-57, Cornelius Company Gasoline-Driven 2-CFM H.P. Air Compressor, by A. C. van Behren, p. 3, 9 February 1956.

3. Navy Experimental Diving Unit Report 5-60, Cornelius Company Scuba AirCompressor Gasoline-Driven, 3.5 CFM, by W. L. Marshall and G. M. Janney,p. 11, 10 September 1959.

4. Navy Experimental Diving Unit Report 4-65, High Pressure Engineering Co.,Inc. H. P. Air Compressor 6-CFM Hurricane Model HPE 3000-7-L55, byJ. V. Harter, p. 6, 21 July 1965.

5. Navy Experimental Diving Unit Report 21-78, MAKO High-Pressure BreathingAir Compressor KA-51-DF, by D. E. Dodds, p. 17, December 1978.

1

~16

APPENDIX A

NAVSEA TASK NO. 80-5

17

INTER-OFFICE M "NOTO CO, NEDU DATE 2/25/80

FROM NAVSEA OOC-3 SUBJECT TA 80-5

MESSAGE Request you test and evaluate the Bower Scuba Jamming Compressor (4700 psig/

2.3 CFM/WT 65 ibs). Test will be conducted in accordance with standard compressor

test specification developed by NCSC; modification of test specification, where re-

quired, is authorized. Bower compressor will be provided by SEPCOV. NAVSEA point

of contact is OOC-31, Mr. Harry Rueter. Final report should include recommendation

for inclusion in NAVSEA 9597.1 INST if appropriate.

I

• 1l

REPLY DATE 15 May 1980

The Bauer Scuba-Cft Jamming Compressor is under procurement, with receipt

I anticipated prior to 30 June 1980. A full test plan will be forwarded to

NAVSEA, detailing the specific compressor test procedures. NEDU point

of contact is MMCS(DV) Dan Dodds.

. .N I

18 _________ __ _ _ _ _ _ _ _ _ _ _

APPENDIX B

TEST PLAN tVND TEST EQUIPMENT

19

DEPARTMENT OF THE NAVY... I , NAVY EXPERIMENTAL DIVING UNIT

,! . J IPANAMA CITY. FLORIDA 32407 IN REPLY REFER TO

NAVY EXPERIMENTAL DIVING UNIT

TEST PLAN - LONG FORM

Test Title: "Bauer" Iligh Pressure BreathingAir Compressor Model-Varius-G3

Test Plan Number: 80-37

Date: 21 July 1980

Prepared by: Review by: Approved by:

/'o<.,, 1j ,, 'ISOD.E. DODD S /7 I-l..A.SOdTRN1OI.I)r

I-(CS (1)V), USN LCDR, USN CI)R, USNOperationsOfficer C Gommanding, Off ic r

1R CAR1Y

Engineer Officer

.2 .D.M. ,IL ITONCDR, USNSenior Projects Officer

W.H. SPAURCAPT, MC, USN

Senior Medical Officer

I.CDR, USN

Executive Officer

20

Appendix B. Test Plan (Continued)

1. Introduction. The Bauer Varius-", High Pressure Breathing AirCompressor is a gasoline-driven 3 stage air compressor with a rated capacityof 2.3 cubic feet per minute (CFM) at a pressure of 3200 pounds per squareinch (PSI). The compressor is coupled to the engine by a V-belt anddatensionIng mechanical clutch for ease of starting the engine. The unitis assembled by Bauer Breathing Air located at 1328 Azalea Garden Road,Norfolk, Virginia.

Reference (a) directed NEDU to conduct test and evaluatidn of theVarius compressor to determine the suitability of the unit for a recommendationas authorized for Navy use (ANU). Therefore, the testing of this compressorwill evaluate whether it produces satisfactory breathing air and maintainsadequate service life to meet the requirements of fleet diving activities.In the event the compressor meets the specified requirements, it will berecommended as an addition to enclosure (2) to reference (b), EquipmentAuthorized for Navy Use (ANU).

2. References.

A. NAVSEA OOC-3 Memo 80-05 dtd 25 Feb 1980, Bauer Scuba JammingCompressor (3200 PSI/2.3 CFM/wt 65 lbs)

B. NAVSEAINST 9597.1

C. Varius Technical Manual

' 3. Test Number. 80-37

4. Program. Test and evaluation of the Bauer Varius-G wili be conductedas follows:

A. Phase 1:

(1) Receive Varius-G at NEDIT, Panama City.

(2) Conduct inspection of compressor to ensure all parts andmaterial are received and on'hand. Reference C refers.

(3) Using the technical manual for the air compressor and itscomponents, inspect for and determine if the following items

exist and/or comply:

a. All instruments ;,Ld controls are clearly and permanentlymarked according to their functions.

b. All controls, gauges and indicators necessary for operationof the compressor are visible and convenient to the operator.

c. Safety devices are provided and audible and/or visual warningfunctions Os specified.

| m .. ......... .21-

Appendix B. Test Plan (Continued)

d. Liquid level indicators accurately display liquid level.

e. All removable components can be removed and properly re-installed in working condition using the manufacturer'sOperating Manual.

f. All drains, traps, and safety valves discharge ports willfunction without splashing, are conveniently located, and aredirected away from operating personnel.

(4) Operate compressor for one (1) hour under a no-load condition.

(5) Take air sample following no-load test run, and have the airanalysis conducted by NCSC Gas Analysis Laboratory.

(6) Instrumentation provided by manufacturer shall be comparedby NEDU using a King Nutronics Gage Calibrator Model 3194.-F.These instruments shall ba compared at 0 psig, 500 psig,

1000 psig, 1500 psig, 2000 psig, 2250 psig, 2500 psig, 3000 psig.and 3200 psig with a data sheet kept as a permanent record.

(7) Conduct testing in accordance with the procedures set forthin section 6. Total compressor running time will be 50 hours.

5. Preliminary Arrangements.

A. Arrange for air analysis to be conducted by NCSC as required,

J.0. 5-712-00701.

6. Test Procedure.

The following test procedures will be conducted as specified, and theresults entered in the log sheets, (enclosure (I)):

A. Take air samples at hours 1, 25, 50, and anytime air quality is questioned.

B. Log the following measurements on-the log sheet (enclosure (1)):

(1) Start up time(2) Filter back pressure(3) Flask size and pressure(4) Total hours running time on compressor. Total testing time will

be 50 hours running time.(5) Ambient air temperature(6) Delivery air temperature.

C. Compute volume output of the compressor by charging a set of twinaluminum 90 cu. ft. scuba cylinders, timing the charge from 0 to 3000 psi,.For a single aluminum 80 cu. ft. charge to 3000 psig. For a set of71.2 cu. ft. scuba tanks, charge to a pressure of 2250 psig. Log totalcharging time for each set of tanks in order to calculate charging rate.Calculations to be made and logged at 3 hr intervals in the commentssection of the log sheet.

22

Appendix B Test Plan (Continued)

D. Measure fuel consumption of oiiw measured gallon of fuel per hoursof operation at least twice during the testing. Results will beentered in the log.

E. Oil consumption shall be measured and recorded during testing, withmeasurements and additions entered in the log.

F. Perform maintenance as required (reference C).

7. Post Test Arrangements. N/A

8. Personnel.

NEDU Test and Evaluation Department personnel (G ea).

9. Safety Rules and Precautions.

Safety rules and precautions as outlined in Technical Manual forVarlus-G Air Compressor, (Reference C).

10. Logistic Support Required.

A. Approximately $2,500.00 for preparation of camera ready copy of report.

B. $56.00 per hour for air analysis by NCSC: 4 hours per sample, 4 s~ampl.sper test = $896.00 Total.

11. Funding Source.

NAVSEA OOC TASK NO. 80-6SUPDIVE Support Funds

12. Report Production.

Under supervision of NEDU Test and Evaluation Department, test report avdcamera ready copy to be written and prepared by local firm and submitted forapproval to Commanding Officer, NEDU. Estimated publication date is six "eck,;following completion of testing. MNCS(DV) D. E. DODDS/BHCODV) R. BOWDISH arepoints of contact for NEDU concerning this test.

13. Comments/Additional Information.

The NEDU Test and Evaluation Department is responsible for thefollowing:

A. Control and Safety o( Systems. All control systems, safety systems,and valves shall be activated by making the necessary temporary alterationsto compressor controls and operations whenever such alterations will notresult 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 thecompressor unit by subjecting control system sensors to other sources oftemperature and pressure; for example, the oil safety switches and sensors,automatic condensate blow down valves, overpressure switches and sensors,high temperature switches and sensors, and any other device designed to operateor protect the system and attending personnel.

23

Appendix B. T,. t Plan (Continued)

B. In~ngrity of Air System. The air compressor system shall be shutdown when the system is at maximum pressure.

(1) Hold pressure.(2) Allow the system to cool to ambient temperature.

(3) After temperature has stabilized, record the receiver pressure.(4) After an eight-hour period, record pressure again.(5) Leak rate shall be zero.

C. The following id Failure Criteria for the suitability of the

Bauer Varius-G compressor for ANU:

(1) Failure of any component which cannot be corrected in accordancewith the recommended schedule of maintenance.

(2) Failure of the diving air system to operate as specified.

(3) Failure of the valves to operate as specified.

(4) Failure of the pressure relief valves to operate as specified.

(5) A decrease in capacity of the compressor during the performance c~t

(6) A discharge air temperati're from any cylinder in excess ofmanufacturer's specification~s or recommendations.

(7) Failure of the air samples to pass breathiog air specifications.

24

-- - - ....... ...

APPENDIX C

OPERATIONAL TEST LOG

25

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.0e 53

APPENDIX D

APPLICABLE PORTIONS OFMANUFACTURER' S MANUAL

54

1. COMPRESSOR function, maintenance

1.1. Operatlng charactedsticeThe compressor unit consists of three cylinders and three stages.Assembly of the unit see Figure I and 2.

Piping SchemeThe air flow through the compressor unit is shown on figure 8. Air is drawn in through the telescopicintake - I and intake filter - 2. compressed to final pressure in cylinder - 3 - 4 - 5 and recooled byintercoolers -6 -7 and afltercooler -8. The safety valves -9 -10 -11 protect the pressures of thesingle stages. The operating pressure is readable from gauge - 12. By purification assembly - 13, thecompressed air is purified.

The purification assembly -13, is drained by condensate drain valve -14. Pressure maintainingvalve - 16, keeps the pressure constant within purification assembly - 13. Through tilling hose - 17and filling valve - 18. the compressed and purified air is introduced into the cylinders to be filled

1.2. Valve heads and valvesThe air enters and leaves the cylinder through the valves.Piston downward = suction stroke = intake valve open, pressure valve closedPiston upward = compression stroke = intake valve closed, pressure valve open

The valves are subtected to normal wear. Maintenance schedule (item 4) has to be observed. Forchanging the valves the valve heads have to be disassembled.

First unscrew pressure valve screw from 2 or 3 turns.

Disassembly of intake valve 2nd and 3rd stage with valve too PN N4555

Disassembly of pressure valve 2nd and 3rd stage by removing it from the valve head

Attention. Reassemble pressure valve for 2nd and 3rd stage in the following sequence- secure valve cover on valve head equally

tighten torque to approx 16 fh. lbs (22 Nm) valve screw of pressure valve with 8 mm allenwrench

1.3. Lubrication

Pistons and driving gear are lubricated by oil thrower pin. Check oil level daily with dipstick.

Oil change should be accomplished while hot through oil drain plug located at the bottom of the com-pressor

Replace plug and refill with BAUER Compressor Oil. 14'/2 ft oz (430 cm). PN 059140

Check oil level with oil dipstick. Oil level has to be at the upper markirg. See item 5 for recommendedoils.

1.4 Intake filterThe intake filter is a micronc filter. Maintenance includes periodic inspection and blowing out.opposite to the direction of the air intake Before reassembling, check cover 0 ring and replace ifdetective.

1.5. Safety valvesA safety valve is installed in each stage to prevent the stage from over-loading with undue highpressure

Safety valve Ist stage set to 116 psig (8 bar)Safety valve 2nd stage sot to 1160 psig (80 bar)Safety valve 3rd stage set to ooerating pressure required

Should safety valve of Ist or 2nd stage relieve during operation. the.respective intermediate pressureis too high. Source of defect is the intake - or pressure valve of the fullowing compression stage.

Disassemble defeclive valve, clean or exchange, see 1 2

55

Appendix D. Manufacturer's Manual (Continued)

4. Maintenance4.1. Maintenance ecl'dule Interval Interval

I Filter cartridgE ; in filter chambers 14. Torsion spring axle to be checkedto be exchange% sti :ording to item for function F3 2 of this manua, H 15. V-belts to be checked for wear

2 Check oil level D and tension F

3 Oilchange (in compressor) E, G 16. Valve overhaul H

4 Telescopic intake correct mounting C 17. Maintenance of drive motor/engineaccording to motor/engine operating5 Function of final pressure valve C manual

6 Condensate to be drained A. B, C7. Condensate drain valve to be 4.2. Periodicity

checked for air tightness C8 Intake filter. O-ringe packing, cap F Every 15 minutes during cylinder filling

at high humidity A9 intake filter cartridge F. G Every 30 minutes during cylinder filling B

tO Function and tightness of filling valves F Before each cylinder filling C

It Check Zero position on final pressure Daily Dgauge, with depressurized purificationassembly F After first 25 operating hours E

12 Check tightness of all tube fittings Every 25 operating hours to be cleanedand fixations F and checked F

13 Check temperature gauge on Every 125 operating hours to be exchanged Gpurification assembly F Every 500 600 operating hours H

4.3. Trouble shooting

Trouble Cause Remede

Motorl/engine does not start see molor/engine operating see motor/engine operatingmanual manual

Compressor does not pipes or condensate drain leaking tighten up. sealteach final pressure final pressure safety valve blows turn out lifting screw cap

off too earlyfinal pressure safety exchange valvevalve defective

Air delivery drops intake filter soiled clean filter cartridge or exchange

pipes leaky tighten upfilling valve blows off throdgh exchange filling valveventilation during fillingpiston clearance 3rd stage too big exchange complete piston bushing

Intermediate pressure blows off intermediale pressure too high, check intake and dischargebecause intake and pressure valve, exchangevalve 3rd stage defectiveintermediate safety valve leaky exchange valve

Compressor gets too hot cooling air supply restrained check operating site, ambientambient temperature too high temperature max 105 F (40 C)intake and pressure valve check valves, exchangeof one stage reaky

sense of rotation incorrect adjustOil taste in the air filter cartridge used up exchange cartridge

unqualified lubricant change to approved oil

Motor runs non-circular and leaps V-belts used up exchange

56

Appendix D. Manufacturer's Manual (Con?.Inued)

f . Technical Data Vi

5M pgPWPN300 bav VG 3 VE2H VEI H

~ .rc f ~n~sa3 3

wu- (Yocoss 3SIAq. 3sla" 30890~

,-,w 60w28J12 60,28,1 2?81

66)660w ,pe 2600 2450 1300)

3200. , PN 200 b 60O Ps 555 bwlI poo 00' is 0 15 i so. O 6 ,(5 5 55 Owl* 0%

WW00 ps-gPN* 30W ba' W6942PIP (6 5.65 ball 94, 42 ps, 6 5,65 bill 9442?ps6 "S 'bw?

A.1ff? 3201)psq'PN 200 ba 2755 PSghI(90all 27Slipik,1ObW? 2755 5.g (190bW'1 0%, -

5000 psg'PN 300 ba, 4060 PSg 260 ball 4060 f~ot' psq1 0mr66 peq s200 ball

A, -1 1.111k t.Ihrg Capa''ty? C,, I Cr ,n-1 2 3 i64 '07 (53' 0 t2Sf4 '. "-1J Thte pho86 swflg* Phase a C8'.g9S A Sllaff,, 230 460 V W kit 115 230 V'4,0 Nz

,v -perof engnemo 3 HP,22 KWI 2HPI 5.%' IHP 10 5 kwi

(flI ,,, wfl (4301 14 14-0 14', (4301

bs 50 F?.ID C? SAL 3050 F I - 1 Cl lo 5 F~ 15 C~ SAE 20

BA f. R Co-Pre6Ic 0,1 MAOb De'vac 1.0w See.,,,lBAUER. SAMPI CaItan edsO ,4r 5

...",". S,.' ,,?. Coa11m, 0. Teoe3.W-Aae.o 7I

57