WG
WG
WG
WG COMPRESSOR SC
FRAME SERIAL NUMBER
WG 00G1
CYLINDER SIZE
XX" 00D
Customer: XX
WG Instruction Manual
Table of Contents
Section 1
Introduction................................................................................................. 1-1
About this manual ...................................................................................................................................... 1-1
Identifying your compressor frame and cylinder serial numbers............................................................... 1-2
Compressor Frame Overview .................................................................................................................... 1-2
Crankshaft Rotation ................................................................................................................................... 1-3
General Compressor Specifications ........................................................................................................... 1-5
Compressor System Vibration ................................................................................................................... 1-6
Balancing Compressor Frames .................................................................................................................. 1-7
Additional information-website ................................................................................................................. 1-7
Prerequisites ............................................................................................................................................... 1-8
How to use this manual .............................................................................................................................. 1-8
Related Publications................................................................................................................................... 1-9
Standards .................................................................................................................................................... 1-9
Our Quality Policy ..................................................................................................................................... 1-9
Warranty..................................................................................................................................................... 1-9
Section 2
Safety Precautions and Guidelines ............................................................ 2-1
Important safety information...................................................................................................................... 2-1
Note, caution, and danger symbols ............................................................................................................ 2-1
Warning signs and labels ........................................................................................................................... 2-2
Specified precautions ................................................................................................................................. 2-3
Temporary shipping plugs in compressor equipment ................................................................................ 2-3
Compressor frame crankcase rapid pressure relief valves ......................................................................... 2-3
General precautions.................................................................................................................................... 2-4
General maintenance precautions .............................................................................................................. 2-4
Compressor system maintenance precautions............................................................................................ 2-5
Pressurized air and water precautions ........................................................................................................ 2-5
Fluid precautions........................................................................................................................................ 2-5
Asbestos precautions.................................................................................................................................. 2-6
Pipes, connectors, fittings, lines, tubes and hoses...................................................................................... 2-6
Burn precautions ........................................................................................................................................ 2-7
Coolant Precautions ................................................................................................................................... 2-7
Oil precautions ........................................................................................................................................... 2-7
Fire and explosion precautions................................................................................................................... 2-7
Crushing or Cutting precautions ................................................................................................................ 2-8
Mounting and dismounting precautions..................................................................................................... 2-8
Section 3
Lubrication And Cooling ........................................................................... 3-1
Compressor frame lubrication specifications............................................................................................. 3-1
Section 5
Installation ...................................................................................................5-1
General........................................................................................................................................................5-1
Preparing The Foundation ..........................................................................................................................5-1
Foundation Bolts ..................................................................................................................................5-2
Placement And Leveling ......................................................................................................................5-3
Coupling Installation And Alignment.........................................................................................................5-5
Rexnord Flexible Coupling Torque Values .........................................................................................5-6
Crankshaft Web Deflection..................................................................................................................5-6
Cylinder Mounting......................................................................................................................................5-6
Sliding Rod Through Packings ............................................................................................................5-7
Setting Piston End Clearance ...............................................................................................................5-7
Piston Rod Runout ...............................................................................................................................5-8
Vertical runout tolerances ....................................................................................................................5-9
Section 6
OperationStart-up ......................................................................................6-1
Startup ........................................................................................................................................................ 6-1
Preparation for Initial Startup .............................................................................................................. 6-1
Initial Startup ....................................................................................................................................... 6-3
Normal Startup .................................................................................................................................... 6-4
Shutdown.................................................................................................................................................... 6-4
Normal Shutdown................................................................................................................................ 6-4
Emergency Shutdown.......................................................................................................................... 6-5
Recommended Operating Conditions ........................................................................................................ 6-5
Section 7
Maintenance ................................................................................................ 7-1
General ....................................................................................................................................................... 7-1
Acceptable Tolerance Clearance Values.................................................................................................... 7-1
Torque Recommendations ......................................................................................................................... 7-2
Critical Bolt Torques ........................................................................................................................... 7-3
Precautions........................................................................................................................................... 7-3
Component Maintenance ........................................................................................................................... 7-4
Base (Crankcase) ................................................................................................................................. 7-4
Crankshaft, Thrust And Main Bearings............................................................................................... 7-5
Connecting Rod And Bearings ............................................................................................................ 7-6
Crosshead Guide .................................................................................................................................. 7-7
Crosshead removal and installation..................................................................................................... 7-7
Auxiliary End Cover............................................................................................................................ 7-8
Drive End Cover .................................................................................................................................. 7-8
Lube Oil Supply (Sump)...................................................................................................................... 7-9
Drive Coupling Hub ............................................................................................................................ 7-9
Flexible Drive Coupling .................................................................................................................... 7-10
Troubleshooting Rexnord Couplings................................................................................................. 7-11
Elongated Bolt Hole.................................................................................................................... 7-11
Scored Body on Bolt ................................................................................................................... 7-11
Misalignment Failure .................................................................................................................. 7-11
Fatigue Failure ............................................................................................................................ 7-12
Compression................................................................................................................................ 7-12
Elongation ................................................................................................................................... 7-12
Torque Overload (Visible only with strobe light while running) ............................................... 7-12
Cylinder Body.................................................................................................................................... 7-13
Cylinder Head.................................................................................................................................... 7-13
Piston, Piston Rings And Piston Rod ................................................................................................ 7-13
Piston Rod Packing ........................................................................................................................... 7-14
Valves ................................................................................................................................................ 7-17
Valve Installation ........................................................................................................................ 7-17
Valve Replacement ..................................................................................................................... 7-18
Special Tools ............................................................................................................................................ 7-20
Alarms And Shutdowns ........................................................................................................................... 7-20
Recommended Maintenance Schedule .................................................................................................... 7-21
Section 8
Frame "as built" Bills of Materials ...........................................................8-1
Section 9
Cylinder "as built" Bills of Materials .......................................................9-1
Section 1
Introduction to the WG Series Compressor and
Specifications
About This Manual
Thank you, for purchasing Cooper Energy Services equipment! This Instruction Manual
contains safety, operating and basic maintenance instructions for the Superior® WG series
compressor frames.
This manual contains confidential and proprietary information from the Superior
Compressor Products Group of Cooper Energy Services, a division of Cooper Cameron
Corporation. This manual is given to users for the limited purpose of providing
All specifications and ratings are subject to change without notice. Superior® is a trademark
of Cooper Cameron Corporation.
maintenance and dependable service. The balance-opposed design, with two crank throws
separated by a crank cheek, is a modern standard for reciprocating compressor frames. This
manual describes the WG series compressor frame. These compressor frames are designed
for oil and gas production, gas transmission, process, cogeneration and power generation
applications.
Precision designed main and connecting rod bearings are thick walled, steel backed and split.
The crankshaft is removed through the top of the base without disturbing the cylinders. The
lube oil pump and the force feed lubricator are gear or shaft driven and mounted on the
auxiliary end cover. Either may be maintained independently.
Lube Oil is drawn from the sump through a strainer that protects the lube oil pump. A full-
flow lube oil filter with a differential pressure indicator capable of identifying a plugged filter,
protects all compressor frame running parts.
Although piston and rod lengths may vary according to the stroke and model, all cylinders
will fit interchangeably on the standard crosshead guide. Careful attention is given to the
cooling of cylinders designed for a 1.5:1 to 5:1 pressure ratio.
V
o
l
u
m 00748
00749
e
Pockets are furnished as standard equipment on all cylinder classes, except the model #602
through #605 forged steel cylinders. On these cylinders, other methods of adding clearance,
such as fixed heads, fixed volume heads, or valves spacers can be furnished when required.
Crankshaft Rotation
When facing the oil pump end of the frame, the crankshaft rotates in a counterclockwise
direction.
Figures 1-6 and 1-7 show the general configuration of the WG compressor
Breather
Connecting Rod
Crankshaft
Frame
Variable
Volume
Pocket
I CAUTION N DANGER
Since the goal is to produce a balanced opposed
compressor, it is necessary to make the
Balancing of the unit is accom- reciprocating weight on each pair of opposing
plished by using both an Failure to verify and correct
throws approximately the same.This is quite a
appropriate weight crosshead compressor balance can
assembly and piston rod jam task, in view of the large number of cylinder result in excessive mechani-
nut (balance nut) The maxi- sizes and throw location combinations that are cal vibration, frame crack-
mum allowable variation is possible, and because each piston and rod ing, piping vibration,
two pounds (0.90 kg) on the
reciprocating weights and one assembly (piston, rings, piston rod and cap foundation cracking and
pound (0.45 kg) on the con- screws) has a certain combined weight which other damage to the com-
necting rod weights, but not to will probably be different from the weight of the pressor. It also creates a
exceed one pound net, for each potentially unsafe operating
piston assembly that it will oppose.
pair of opposing throws. condition for the operator.
I CAUTION
The crosshead assembly consists of a pair of
shoes, the bolts and nuts to attach the shoes, and the crosshead. There are
When replacing crossheads,
connecting rods, pistons, or
two different weight crossheads available.
changing piston ring material,
Also available are balance nuts in 2.5 and 5-pound increments. Consult an
the new parts should be
Authorized Unit Distributor for details concerning the use of the special
weighed, in order to reaffirm
the actual unit balance. weight nuts. In addition to the above mentioned balance parts, the
connecting rod weight is also involved in the balance. Connecting rods
vary in weight and when the units are assembled at the factory, care is taken to select the connecting
rods so that the weight variation for opposing throws does not exceed 1 pound (0.45 kg).Every effort
should be made to achieve as near equal balance between opposite throws as possible.This does not
apply to adjacent throw pairs, which sometimes vary by 100 pounds (45 kg) or more, depending on
cylinder sizes.
• Section 5: Installation. This section provides an in-depth functional description guidelines for the
foundation, coupling installation, crankshaft web deflection, cylinder mounting, setting piston end
clearance, piston rod run out.
• Section 6: Operation Start-up. This section provides procedure for startup, recommended operat-
ing conditions, and form to request for performance curves.
• Section 7: Maintenance. This section contain precautions, tolerance limits, and recommended
torque values.
• Section 8: Frame "as built" Bills of Materials unique to your compressor. Included are exploded
views of the assemblies.
• Section 9: Cylinder "as built" Bills of Materials unique to your compressor. Included are
exploded views of the assemblies.
Related Publications
The following related publications contain more information about the Superior WG Series Compres-
sor:
•Superior MH, WH, W7, & WG Compressor Frame Technical Data Book.
•Superior Compressor Cylinders Technical Data Book
Standards
Cooper Energy Services has developed several standards for our compressor addressing cooling
water quality, lubrication, and packaging. CES recommends that users of Superior compressor
understand and follow these standards to get the best performance possible from the equipment. CES
also recommends that oil and gas production service packagers follow the guidelines for prime mov-
ers described in the American Petroleum Institute’s Specification for Packaged Reciprocating Com-
pressors for Oil and Gas Production Services (API Specification 11P). American Petroleum
Institute http://www.api.org will default you to http://www.global.ihs.com 1-800-854-7179 ext.
7969 for a copy of API 11P.
Warranty
The Seller warrants to the Buyer that the equipment to be delivered hereunder will be free from
defects in material, workmanship and title and will be of the kind described in the contract. THE
FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES
Section 2
Safety Precautions and Guidelines
Important Safety Information
DO NOT OPERATE OR ATTEMPT TO REPAIR THIS EQUIPMENT UNLESS YOU
HAVE HAD THE PROPER TRAINING APPROVED BY SUPERIOR. FOR TRAINING
INFORMATION, CONTACT THE COOPER ENERGY SERVICES TRAINING
DEPARTMENT IN HOUSTON, TEXAS, PHONE (713) 354-4062.
Do not operate, work, or perform any lubrication, maintenance or repair on this equipment
unless you have read and understand the operation, lubrication, maintenance and repair
instructions and warnings in this Operations Manual. Failure to follow the instructions or
heed the warnings could result in injury or death. Contact your authorized Cooper Energy
Services Distributor for replacement manuals. Proper care is your responsibility.
Most accidents involving equipment operation, maintenance and repair are caused by failure
to observe basic safety rules or precautions. An accident can often be avoided by recognizing
potentially hazardous situations before an accident occurs. A person must always be alert to
potential hazards. Equipment operators should also have the necessary training, skills and
tools to perform these functions properly.
Safety precautions and warnings are provided in this manual and on the equipment. If these
hazard warnings are not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by a safety alert symbol and followed by a signal word such as
"DANGER!" as shown in the Note, Caution and Danger Symbols portion of this section.
Cooper Energy Services cannot anticipate every possible circumstance that might involve a
potential hazard. The warnings in this publication and on the equipment are therefore not all
inclusive. If a tool, procedure, work method or operating technique not specifically
recommended by Cooper Energy Services is used, you must satisfy yourself that it is safe for
you and others. You should also ensure that the equipment will not be damaged or made
unsafe by the operation, lubrication, and maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are presented on the basis
of information available at the time it was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These
changes can affect the service given to the equipment. Obtain the complete and most current
information before starting any job. Authorized Cooper Energy Services Distributors have the
most current information available.
Make sure that you can read all safety signs. Clean or replace these if you cannot read the
words or see the pictures. When cleaning the labels use a cloth, water and soap. Do not use
solvents, gasoline, etc., to clean safety signs. The use of solvents, gasoline, etc., could loosen
the sign's adhesive and cause the sign to fall off.
You must replace a label if it is damaged, missing or cannot be read. If a label is attached to a
part, and that part is replaced, make sure a new label is installed on the replaced part. See your
Authorized Cooper Energy Services Distributor for new labels.
Specified Precautions
It is important that these precautions be read and clearly understood. All of the precautions
that follow are interpreted as having a CAUTION or DANGER status.
Ports that are not used must be filled with a properly installed steel plug. If the existing plugs
are painted, scrape off enough paint to verify that the plug is made of steel and not plastic. If
any plug is in question, replace it.
Pressurizing the compressor equipment while temporary plugs are in place may result in
serious injury or death and may damage the equipment.
Cooper Energy Services recommends the installation of Bicera crankcase rapid pressure
relief valve. These valves protect the compressor frame from excessive pressure.
The Bicera valve has a 120 o exhaust port opening through which pressure is vented. Due to
the content and high temperature of the vented gas, proper orientation of the exhaust port is
critical for a safe operating environment. Vented gas could be dangerous to both operator and
equipment. The 120o exhaust port must always be directed towards the drive end of the
compressor frame. It must never be directed toward an area where the vented gases could
come into contact with operators or other personnel.
Be absolutely sure the remote starting system is disabled and/or If Poisonous or suffocating
disconnect the starting system on the equipment being serviced. gases are being com-
pressed, follow all plant
safety procedures prior to
Use caution when removing cover plates. Gradually loosen (do not and during maintenance on
any gas equipment or pip-
remove) the last two bolts or nuts located at opposite ends of the ing to avoid injury or death
cover or device. Pry cover loose to relieve any spring or other due to inhalation of such
pressure, before removing the last bolts or nuts. substances.
or checks. To help prevent an accident caused by parts in rotation, work carefully around
them.
•Make sure all nearby personnel are aware of the start-up and do not allow unauthorized per-
sonnel on or around the equipment when maintenance or repair is being performed.
• Do not disable or bypass automatic alarm/shutoff circuits. They are provided to prevent per-
sonal injury and equipment damage.
•Before replacing any studs, measure the stud's height from the machined surface and install
the replacement stud to the identical height.
Fluid Precautions
Always use a board or cardboard when checking for a leak. Escaping fluid under pressure
(even a pinhole size leak) can penetrate body tissue, causing serious injury or possible death.
If fluid is injected into your skin, a doctor familiar with this type of injury must treat it
immediately.
Caution should be used to avoid breathing dust when handling components containing
asbestos fibers. If this dust is inhaled, it can be hazardous to your health. The asbestos used in
components is usually bound in a resin or sealed in some way. Normal handling is not
hazardous as long as airborne asbestos dust is not generated.
If dust, which may contain asbestos, is present, there are several common sense guidelines
that should be followed.
•Never use compressed air for cleaning. Avoid areas where airborne asbestos particles may be
present.
•Avoid brushing or grinding of asbestos containing materials.
•For clean up, use wet methods or a vacuum equipped with a high efficiency particulate air
(HEPA) filter.
•Use exhaust ventilation on permanent machining jobs.
•Wear an approved respirator.
•Comply with applicable rules and regulations for the work place. (i.e. U.S.A. OSHA require-
ments 29 CFR 1910.1001).
•Follow environmental rules and regulations for disposal of asbestos.
Repair any loose or damaged fuel and oil pipes, fittings, connectors, lines, tubes or hoses.
Leaks can cause fires.
Inspect all pipes, fittings, connectors, lines, tubes and hoses carefully. Do not use your bare
hands to check for leaks. Tighten all connections to the recommended torque (Section 5).
Burn Precautions
Do not touch any part of operating equipment. Allow the equipment to cool before any repair
or maintenance is performed on the equipment.
Make sure that all clamps, guards and heat shields are installed correctly to prevent vibration,
rubbing against other parts and excessive heat during operation.
Relieve all pressure in air, oil, fuel or cooling systems before any lines, fittings or related
items are disconnected or removed.
Coolant Precautions
Remove the cooling system filler cap slowly to relieve pressure. Use caution when removing
vent release valve, grease fittings, pressure taps, breathers or drain plugs. Hold a cloth over
the cap or plug to prevent being sprayed or splashed by liquids under pressure.
At operating conditions, the equipment coolant is hot and under pressure. The cooling system
and all lines to heaters or the equipment contain hot water. When pressure is relieved rapidly,
this hot water can turn into steam.
Allow cooling system components to cool before draining. Any contact with hot water or
steam can cause severe burns. Check the coolant level only after the equipment has been
stopped and the filler cap is cool enough to remove with your bare hand.
Cooling system additive (conditioner) contains alkali. To prevent personal injury, avoid
contact with the skin and eyes and do not drink. (Remember: Antifreeze/glycol solutions, as
well as most lubricants, are flammable.)
Oil Precautions
Hot oil and components can cause personal injury. Do not allow hot oil or components to
contact the skin.
Chips or other debris can fly off objects when struck. Take care to insure no one can be
injured by flying debris before striking any object.
Section 3
Lubrication And Cooling
The complete lubrication system of the compressor is divided into two parts, of equal
importance:
1.) The system that provides lubrication to the frame running parts ( see the compressor Frame
Technical Data Book).
2.) The system that provides lubrication for the cylinders and packing.
Both systems can use oil from the frame sump. However; if required, the cylinder system may
use oil from an external tank. (This is especially done when the oil for cylinder and packing
system is different type compared to the frame oil).
Compressor Frame Lubrication:
A gear driven lubricating pump is mounted on the auxiliary end of the frame. The pump
delivers the oil from the frame sump to the bearings, connecting rods and the crosshead
guides. An adjustable pressure relief valve is installed in the delivery cavity of the frame for
cold start protection. An off-mounted shell and tube type oil cooler is provided with
connections for water inlet and outlet. Other features include a connection port for low oil
pressure shutdown switch. An oil level sight gage with low oil indicator is installed on the
frame.
General Specifications
The general specification for lubricating oil for use in Superior® compressor frames is as
follows:
Table 3-2 Viscosity Information-this information is equivalent to the ranges above and provid-
ed for information only
Specification Range Test Procedure
t
Figure 3-3 The
compressor frame
lubrication system
consists of a gear
driven pump,
pressure relief valve,
check valves, oil
cooler and oil filter.
This Figure
illustrates the
lubrication oil system
flow.
The viscosity of the oil should be selected on the basis of operating pressure conditions of the
cylinder. For multi-stage applications, the viscosity required for the highest pressure cylinder
can also be used in lower pressure cylinders. The viscosities listed in Table 3-4 are the
suggested minimum requirements. These values will be adequate for most oils. However, oils
of the same viscosity may not necessarily have identical lubricating qualities. Periodic
examination of the cylinder bores during the first few weeks of operation is recommended to
assure that lubrication is adequate.
Table 3-4 Minimum viscosity and specifications for Superior® cylinder lubri-
cants
Table 3-4A
Discharge Oil Viscosity Viscosity SUS
Pressure Specification @ 210 F Remarks
0-499 psi ISO 100 (SAE 30) 55-70 Crank Case Oil
500-1199 psi ISO 150 (SAE 40) 70-85 Crank Case Oil
1200-1999 psi ISO 220 (SAE 50) 85-110 External Oil
2000-3999 psi ISO 320 (SAE 60) 105-125 External Oil
4000-up psi ISO 460 (SAE 70) 125-150 External Oil
Table 3-4-B
Discharge Oil Viscosity Viscosity Remarks
Pressure Specification SUS @ 210 F
0-499 psi ISO 220 (SAE 50) 85-110 External Oil
500-1199 psi ISO 220 (SAE 50) 85-110 External Oil
1200-1999 psi ISO 220 (SAE 50) 85-110 External Oil
2000-3999 psi ISO 320 (SAE 60) 105-125 External Oil
4000-up psi ISO 460 (SAE 70) 125-150 External Oil
Table 3-4-C
Discharge Oil Viscosity Viscosity Remarks
Pressure Specification SUS @ 210 F
0-499 psi ISO 220 (SAE 50) 85-110 External OIl
500-1199 psi ISO 220 (SAE 50) 85-110 External Oil
1200-1999 psi ISO 320 (SAE 60) 105-125 External Oil
2000-3999 psi ISO 460 (SAE 70) 125-150 External Oil
4000-up psi ISO 680 (SAE 80) 140-200 External Oil
Application Requirements
Many applications require special attention in addition to that given to most natural gas and
similar services. The process in which a gas is being utilized will often influence the
lubricating oil selected. The following recommendations will provide basic guidelines in
selecting the proper lubricant for these special applications. Final selection should be made
only after consultation with an Authorized Unit Distributor and the desired oil supplier:
Table 3-5 Minimum Qualities of a Compressor Cylinder Lubrication
Service Recommendations
Natural Gases Saturated With Water and/or Requires compounding with 3% to 5% acid less tallow or other suitable
“Wet” With Higher Ended Hydrocarbons fatty oils. Increase supply over normal.
These gases are dilutents of oil. Use the next higher viscosity over
Butane, Propane, Ethylene, Carbon Dioxide Table 3-4 recommendations. Increase supply quantities over normal.
Lubricant must be dry.
Hydrogen, Nitrogen, Helium, Carbon Mon- There are inert gases relative to lubricating oils. Use the recommenda-
oxide, Exhaust Gas, Ammonia Synthesis tions in Table 3-4.
Experience has shown that the quantity of the oil required to properly lubricate compressor
cylinders is dependent upon bore diameter, stroke, and speed. For the Superior® compressors
1/5 (0.2) pint per day for each inch of cylinder bore diameter has normally proven to be an
adequate quantity.
The piston rod and packing is considered as Figure 3-6 Force Feed Lubricator
a separate cylinder but with double the
lubrication rate required. Packings then
require 2/5 (0.4) pints per day for each inch
of rod diameter. Minimum should be 0.45
pints per day per packing.
The gas being compressed, its cleanliness and tendencies to act as an oil dilutent, and the type
of the oil being used all influence the lubrication rate required.
Many applications may require more or less than the calculated feed rates. To assure that
adequate lubrication is being achieved, a periodic visual inspection of the cylinder bore and
piston rod are recommended. Initial setting and adjustments to the feed rate should also be
accomplished on a 24-hour basis since the drop size varies with the viscosity of the oil.
Synthetic Lubricants
Synthetic lubricants have higher flash points than conventional lubricants. This makes them
highly desirable from a safety and fire reduction standpoint. However, synthetics impose
problems which are usually not associated with natural mineral oils. They dissolve paints, are
corrosive to common bearing materials such as lead and tin, and have low viscosity indexes.
For these reasons, when synthetics are considered for use in compressor cylinders or frames,
consult an Authorized Unit Distributor.
Multi-Grade Lubricants
Multi-grade oils provide the same protection as heavier single grade oils and do not put undue
stresses on the compressor cylinder lubrication system. However, all multi-grade oils do not
provide the same protection. For this reason, if a multi-grade oils is being considered for use a
a cylinder lubricant, consult an Authorized Unit Distributor.
For wet and saturated gas conditions and 0-1000 PSIG, use a minimum viscosity of 85 SUS at
210oF with 3% to 8% compounding with acid less tallow, or two grades heavier than normally
used for the pressure conditions involved.
For heavy hydrocarbon and sour gases, use the next higher viscosity as shown in Table 3-4,
with a minimum of 85 SUS at 210oF.
For refrigeration service, use the highest possible viscosity that should be used and still retain
the pour point 15 oF below gas suction temperature.
Whenever there is any question as to viscosity selection, always use the heavier oil.
For oil viscosities over 100 SUS at 210oF, take measures to maintain lubrication pump inlet
temperatures at or above 120 oF.
If a cylinder has more than one feed point, and more than one pump, the requirements for
lubrication must be split evenly. On a normal force feed lubricator (Figure 3-6), the proper
proportioning of oil to cylinders and packings should, as a first approximation, be adjusted by
the drops per minute method. To validate the lubrication rate, it must be measured using
actual oil consumption for a 24 hour period. A visual inspection of the lubrication rate is
required for this type of system. This is done by removing a valve at each end of the cylinder
after 48 hours of continuous operation at the final lubrication settings. There should be a film
of oil over the entire circumference of the ring travel section of the cylinder bore.
As a result of the inspection, individual pumps may be adjusted “up” or “down” in the same
proportion as the size of the cylinders being fed to improve the lubrication rate.
Operation
The cylinder lubrication system consists of a force-feed lubricator and distribution block
system that provides lubrication for the cylinder walls and piston rod packing (see Fig 3-8 for
a typical setup).
The lubricator is directly driven off the compressor shaft through a right-angle-drive worm
and spur gear set mounted on the lubricator box. Lubricator pump(s) fed directly from the
crankcase lube system or from an external tank are used to provide oil to the cylinders.
(Note that oil from the lubricator box is not used.) A packager-supplied external tank is
used when the requirements of the cylinder oil are different from those of the crankcase. A
shutoff valve is supplied to isolate the external tank and the lubricator box. The oil flows to
the pumps and then pumped to a common manifold feeding the automatic divisioning
system. The automatic divisioning system consists of a rupture indicator (set for the job),
a 10-micron strainer, a digital no-flow and counter, divider blocks and optional pin
indicators (shows which points are over-pressurized and sets accordingly). Each
lubrication point (cylinder and packing case) has a double ball check valve.
The lubricator box uses the same oil as in the frame or external tank to lubricate its cams
and bearings. The right-angle-drive gear on the lubricator box requires a gear oil that meets
ISO 680 AGMA-8 (Exxon TK-680 Cylesstic is acceptable).
If a blockage or other anomaly occurs, and the system pressure continues to build up, the
safety rupture relief in the collector manifold bursts, relieving pressure throughout the
entire system and causing the no-flow shutdown to activate and stop the compressor. The
protruding pin in the indicator on the distribution block gives a visual indication of the point
where the blockage occurred. Before restarting, new rupture discs of the same color and
thickness as originally installed must be replaced at the location where rupture occurred. It
is the thickness of the “color coded” discs that determine the rupture pressure. Refer to
rupture disc data sheet in Auxiliary Equipment section of this manual.
Figure 3-8 General Cylinder Lubrication Logic
In order to operate properly, the lubrication system must be completely purged of air. This is
done by LOOSENING, BUT NOT REMOVING the nuts of the lube lines at the point of
injection to permit purging of oil and air. The nut at the entry to the distribution block, all pin
indicators and 1/8-inch pipe plugs in the face of the block must be loosened also, for the same
reason.
! Caution
High pressure oil streams may puncture skin. Use proper wrench and keep hands away from the
immediate point where the system is purging air.
Loosen the vent screws in the top section of the distribution block. Continue to operate the
lubricator pump manually until clear, air-free oil appears at either of the two loosened vent
screws. Retighten this vent screw and continue pumping until air-free oil emerges at the other
vent screw. When this occurs, retighten second vent screw. Continue to operate the pump
manually until air-free oil has emerged from tubing nuts at every injection point. Then, and
only then, tighten the nuts on the tubing lines, the pin indicators, and pipe plugs.
Note
If distribution block must be disassembled for cleaning, observe the following:
a. Record order of manifold sections and outlet positions in order to facilitate reassembly.
c. Avoid vise marks; protect ground surfaces, and NEVER grip the ground mating surfaces
in a vise.
The distribution block type lubrication system is a metered, positive, displacement method of
lubricating the compressor cylinders and packing.
The force feed lubricator pumps oil into a single main line leading to a proportional
distribution block. Hydraulically balanced pistons in the block divide the oil into accurate
metered amounts for each lubrication point it serves. Selection and make-up of the
distribution block allows for accurately measured “shot” sizes, and precise proportioning to
meet different or equal oil requirements.
Because of the positive, metered operation, central warning equipment can sense trouble
anywhere in the system.
Safety equipment includes pin fault indicators, in each outlet from the distribution block, a
pneumatic or electric shutdown switch in the event of lubricant flow failures, and a rupture
disk in the lubricator collector manifold.
Since the system operates on a proportional basis, a single adjustment at the force feed
lubricator pump increases or decreases the flow to every lubrication point.
Oil flow rates given in percent of lubricator pump stroke accompany each compressor. These
settings must be followed and checked to provide adequate lubrication for both “break-in” and
normal operation.
When starting a compressor for the first time, or after servicing, be sure that the gear box is
filled with Exxon TK-680 Cylesstic Worm Gear Oil (ISO680 AGMA-8). It is advisable to
check periodically to be certain that the supply of gear oil is maintained. New units are filled
with oil at the factory, and should not need filling. See Figure 3-9.
t
The compressor frame is lubricated by the pressurized lubrication system. The oil must be cooled
by the shell and tube cooler provided with the compressor (shipped separate for mounting by the
packager). Oil should be circulated through the shell side and coolant through the tube side of the
cooler.
The maximum recommended oil temperature for oil returning to the frame is 175 oF (79o C). To
insure this oil temperature, coolant temperature and flow must be selected to remove heat
according to Table 3-10.
Some Superior compressor cylinders are built with cooling water jackets. These cylinder jackets
can be cooled by one of three ways: (1) dry jacket, (2) standpipe, or (3) circulated water cooling.
1. Dry jacket cooling is generally used where the gas discharge temperature is less than 140 oF
(60o C) and gas inlet temperature is greater than 60o F (16oC). In this form of cooling, the
air present inside the cylinder water jacket is the medium which transfers heat out of the
cylinder. The cylinder jackets must be vented when this form of cooling is used.
2. In standpipe cooling, a water with corrosion inhibitor and/or antifreeze solution is used as
the medium for heat transfer. The cylinder jackets are filled with the coolant and then
vented to the atmosphere at their highest point. The vent (or standpipe) should be a 6-inch
(15 cm) long vertical section of pipe which will contain the coolant when it expands. The
pipe must be topped with a vented cap to prevent dirt from entering the coolant. This form
of cooling may be used when the gas discharge temperature is less than 250°F (121°C). and
the rise between gas suction and discharge temperature is less than 170°F (77°C). The
temperature of the liquid coolant will reach a mean temperature somewhere between the
suction and discharge gas temperatures. Accordingly, a coolant must be chosen whose
boiling point is at least 25°F (14°C) greater than the mean temperature and whose freezing
point is at least 25°F (14°C) less than the suction gas temperature (or ambient, whichever
is lower).
3. The third form of cooling is by coolant circulation through the cylinder jackets. This form
of cooling must be used on compressor cylinders having gas discharge temperatures greater
than 250°F (121°C) or a gas temperature rise greater than 170°F (77°C).
Packing Cooling
In the majority of applications, rod packings will perform satisfactorily without a coolant
being circulated through the packing case and therefore don’t have coolant passages. Some
applications, however, do require that the packing cases be cooled in order to achieve
adequate packing ring life. These applications usually involve high pressures and
temperatures, marginal lubrication (characteristically encountered with wet and sour gases),
and unclean gases. On these units, the packing cases are provided with internal coolant
passages. (Figure 3-11 & 3-12).
Adequate cooling flow through the packing cases at a satisfactory temperature is required to
properly conduct the heat out of the packing. Inlet coolant temperatures should be as cool as
possible, but no higher than 90°F (32°C) is recommended to achieve optimal cooling. The
coolant flow required is normally 1 GPM (4 lpm) for each inch of rod diameter with a
minimum of 2 GPM (8 lpm). A pressure drop with water coolant of approximately 30 to 50
psig (207-345 kPag) should be expected across each packing case at the required flows.
t Figure 3-12 Crosshead Guide and Distance Piece - Lube and Non-Liquid Cooled
Coolant Requirements
I CAUTION
The primary purpose of any water treatment is to protect the surfaces Cleanliness is critical.
of the cooling system from cavitation, corrosion, scaling, or sludge protect cooling water
deposits that would reduce the transfer of heat to the coolant. from impurities and
always use clean tools.
Corrosion
Corrosion is a chemical reaction in a metal such that the surface of the metal exposed to cooling
water is changed into one or more of its various compounds, especially iron to iron oxide (rust).
As the depth of the corrosion increases iron oxide particles will flake off, exposing more new
surface material to attack. Where it will occur in the cooling system and to what degree it will
progress depend on factors such as quality of water, metals in the cooling system, surface
temperature, and mechanical conditions of surfaces. The types of corrosion commonly found in
cooling systems can be crevice, cavitation and erosion, fretting or galvanic.
The most important consideration for the cooling system is good water quality. Table 3-13
shows the range of maximum limits for raw cooling water quality. If raw water is tested and is
found to have higher concentrations than those shown on the chart, the water will require
treatment or deionizing. If concentrations are below those shown, the water is suitable for use
with inhibitors added.
Table 3-13 Raw Cooling Water Specifications
Corrosion inhibitors vary in the chemical make-up and concentrations depending upon the
manufacturer. Most of the products will do an adequate job when quality water (deionized and
demineralized) is used. Corrosion inhibitors are ineffective in hard or sub-quality water. The
key to adequate cooling water is to begin with clean water and use a reliable water treatment
specialist.
Chemical treatment of a closed water system is simplified by the use of proprietary inhibitor
compounds. The low make-up water requirements of closed systems and, therefore, minimum
compound additions place a minimum burden on the user for materials and maintenance.
Periodic testing of the coolant, whether by the user or the vendor of the treatment system, is
absolutely necessary in order to assure that a proper level of protection is maintained. The
equipment user must obtain the specific instructions for the use and testing requirements of
the inhibitor compounds from the supplier or manufacturer.
A clean system is a prerequisite for establishing protection of any cooling system. Adequately
protected closed cooling systems seldom, if ever, present problems caused by scaling,
corrosion, deposits or cavitation.
Cooling System
There are three types of cooling systems used for stationary equipment: open, closed and
combination.
Open systems involve cooling towers, spray ponds, etc., and cool the water by evaporation.
Closed systems involve heat rejection through or shell and tube-type or radiator-type heat
exchangers.
Combination systems have the engine and compressor jacket water in a closed system using
shell and tube-type heat exchangers to transfer the heat to an open system using cooling
towers, etc, as above.
Closed type systems are commonly used and approved cooling methods; however, because
open-type systems involve not only large volumes of make-up water, but also the ease of
airborne contamination, Cooper Energy Services do not recommend using these for this
equipment.
Section 4
N DANGER
Sour Gas Compressor Sour gas or hydrogen sul-
fide (H2S) is a highly cor-
Applications rosive and extremely toxic
gas. Every precaution
reguarding life and equip-
This section defines additional compressor hardware and special ment must be taken in a
materials for use when the compressor is applied in sour gas or hydrogen sulfide applica-
corrosive gas service. The requirements listed are based on tion. Read and understand
American Petroleum Institute (API) Production Equipment the United States Depart-
ment of Labor’s Occupa-
Standard 11P, National Association of Corrosion Engineers’ tional Safety and Health
(NACE) Standard MR0175, and Cooper Energy Services Administration (OSHA)
experience. Additional specifications may apply to pulsation regulations for Air Con-
dampers, piping and other equipment used in conjunction with this taminants (standard
compressor. Copies of API 11P and NACE MR0175 can be 1915.1000) and the Con-
purchased on line: fined Space Pre-Entry
Check List (standard
American Petroleum Institute http://www.api.org will default 1910.146 App D). These
you to http://www.global.ihs.com 1-800-854-7179 ext. 7969 for a regulations are available
copy of API 11P. online at the OSHA web-
site:www.osha-slcgov.com
National Association of Corrosion Engineers-A copy of specifi- Cooper Energy Services
cation MR0175 can be purchased online at www.nace.org or by recommends that Superior
calling (281) 228-6200. equipment users and oil
and gas service equipment
These specifications apply to equipment only! Follow safe packagers follow the
operating and maintenance procedures associated with personnel guidelines set forth by the
National Association of
around sour gas machinery as dictated by your company Corrosion Engineers in
procedures. Sour gas is poisonous and attacks the nervous system specification MR0175:
and can cause paralysis, permanent injury or death! Sulfide Stress Cracking
Resistant Metallic Materi-
als for Oilfield Equipment.
Hazards of Hydrogen Sulfide or “Sour Gas”
Caution should be taken when working in or around hydrogen sulfide (H 2S). This chemical is
dangerous and can cause harm to personnel. H2S is colorless and smells like rotten eggs. In
higher concentrations it will kill your sense of smell and impede your ability to detect it. DO
NOT relay on your sense of smell as a detection method.
Table 4-1 gives some general information on the concentrations levels of H2 S and its effect on
the body. This should be thoroughly read and understood before working in an H2S
environment.
100 ppm (0.01%) Kills sense of smell in 3 to 5 minutes. May burn eyes and throat.
200 ppm (0.02%) Kills sense of smell rapidly. Burns eyes and throat.
500 ppm (0.05%) Loss of reasoning ability and sense of balance. Respiratory distur-
bances will occur within 12 to 15 minutes of exposure. Requires
prompt artificial respiration.
700 ppm (0.07%) Rapid loss of consciousness and breathing. Death will result if not re-
moved quickly. Immediate artificial respiration is required.
1,000 ppm (0.10%) Immediate unconsciousness. Permanent brain damage may result if
not rescued immediately.
The equipment specifications are based on three levels of sour gas plus additional National
Association of Corrosion Engineers’ (NACE) requirements as defined by the following
percentages of H2 S:
Trim Requirements
For Hydrogen Sulfide (H 2S) Concentrations Up To 2% By Volume:
•For any concentration of H2S up to 2% by volume in lubricated service, special trim will not
be required. Standard material is acceptable and special lubrication practices are recom-
mended.
•The frame lubricant used must have a total base number (TBN) of 15 or higher to help pre-
vent the lubricant from turning acid and damaging bearings and bushings. This alkalinity
must be maintained during operation in the machine at no less than approximately 30% of
the original TBN number by appropriate timely make-up or complete oil changes.
•The frame lubricant must meet or exceed the requirements of MIL-L-2104B, Supplement
No1.
•A complete oil analysis program on the frame lubricant is required to determine proper oil
change intervals as well as to monitor the condition of the lubricant and the unit.
•Compressor cylinder lubricants must adhere to the requirements of Superior Engineering
Standard ES1002. Viscosities are to be on the high side of the pressure conditions normally
required and a 3% to 5% compounding (similar to steam cylinder oils) is also required.
•The compressor cylinder lubricant rate is to be double the normal rate for equivalent non-sour
gas applications.
•All brass, bronze, copper and other copper alloys are to be avoided on hardware for all gas
wetted parts.
•The distance piece is to be properly vented in accordance with local safety standards to pro-
vide maximum safety to personnel.
•Soft iron or aluminum gaskets are to be used between the valve and valve seat.
•The O-ring material used for standard equipment is Viton (Spec. 473) and this is also accept
able for H2S service. For lower temperature operations (< 27°F (<-3°C) Neoprene (Spec.
479) can be specified as an option.
The following requirements should be followed when H2 S trim in excess of API 11P
requirements is needed to meet NACE. This enhanced level of trim can also be used for any
concentration of H2S as required by the customer.
Section 5
Installation
General
Installation of the compressor will be determined by the fabricator and the end customer.
Since the method employed will vary due to application, the following is offered as a guide to
aid in the installation. These instructions are based on previous installations that have proven
satisfactory.
There are two basic compressor mountings: the baseframe or skid mount and the direct to
block mount. (See Figures 5-1 and 5-2.) The baseframe/skid mount is most commonly used
whereby the fabricator sets up the complete installation as a package. This package is then
moved to location and placed on a foundation. With the block mounting, there is no
intermediate (baseframe) between the compressor and foundation, thus the compressor is
mounted direct to the foundation (block). This type installation is of a more permanent nature.
If you have a choice as to the location of the compressor, select a site where the ground under
and around the unit will be firm and dry at all times. Filled ground, wet clay, unconfined sand
and gravel, or similar soils provide poor support. Be sure that sufficient space is available for
necessary maintenance. For instance, there should be ample space to permit removing the
piston and rod assembly out the outboard end of the cylinder. See that provisions can be made
for an overhead hoist, or that a portable crane can be moved into position as necessary for
removal or installation of major parts or assemblies. Electrical outlets, lighting and cleanliness
are other important factors. Adequate ventilation is essential to safety and the welfare of the
operating personnel.
The responsibility for an adequate foundation is that of the customer. Thus, it is suggested that
a foundation engineer be called in where soil conditions are questionable or where the
location of the compressor is such that transmitted vibration would have detrimental effects
not only to the compressor installation, but on surrounding machinery, buildings, or
personnel. Often times, a neighboring installation on similar soil will serve as a clue to the soil
conditions.
However, unless the nature of the ground is well known, it is advisable to dig several test pits
at the proposed site. CES will gladly furnish data on weights and unbalanced forces required
for calculations by a foundation engineer. In any case where increasing the size of the
standard minimum foundation is necessary, the area of the base should be increased to
00757
00758
Foundation Bolts
To locate the foundation bolts, make a wooden template to temporarily position the bolts
according to the dimensions given on the foundation plan. Set up the template in the exact
position to be occupied by the compressor, allowing space for the grout as indicated. (Figure
5-3). Fasten the template firmly in position.
The next step is to attach the bolts to the template so that they will extend into the foundation.
There are two important items which should be considered at this point:
a. Make sure the bolts project far enough through the frame hole to allow two full threads
beyond the nut. Allow for thickness of grout, frame, nut, etc.
b. Provide allowance for misalignment. A piece of 2-1/2 to 3-inch (6 to 8 cm) pipe or metal
tube positioned around each bolt (Figure 5-3) will prevent the bolts from being cemented
into a fixed position and thus allow slight movement of the bolts for alignment with the
holes in the frame. Stuff paper or rags around the bolts at the top of the pipe to prevent
cement from entering when the foundation is poured. The length that the bolts extend into
the foundation is indicated on the foundation plans.
WG-4/3/03
c. With engine and compressor moved into position, as shown on the outline drawing,
reassemble coupling. Dimension (D) must be maintained during the following alignment
procedure.
t Figure 5-5 Dial Indicator Method of Alignment
00761
WG-4/3/03
The recommended procedure for establishing final alignment is called the “indicator method.”
Proper lining up may take a little time, but it is absolutely essential. Flexible couplings should
not be required to compensate for any misalignment that can be eliminated. The closer the
initial alignment, the greater the capacity of the coupling to take care of subsequent
operational misalignment.
d. Attach dial indicator as shown in Figure 5-5 (view B). Rotate coupling 360 degrees to
locate point of minimum reading on dial; adjust indicator to zero.
g. Reset indicator to zero and repeat steps (d), (e), and (f); if either, the engine or
compressor is moved during aligning trials.
h. The coupling should be turned several revolutions to make sure no “end-wise creep” in
the crankshaft is measured.
i. Mount dial indicator (Figure 5-5 (view C)) to check for parallel misalignment. Set
indicator stem on outer diameter surface of flange B and adjust to zero.
j. Rotate coupling 360 degrees. Move and/or shim the units until
the indicator reading comes within the maximum allowable
variation of 0.004 inch (0.010 cm).
i Coupling bolts
are tightened at
the factory for
shipping purposes only.
k. Torque all bolts. See Table 7-2 for recommended torque values. When installing cou-
After several hours of operation, recheck both alignment and bolt pling, the below values
apply to bolts and lock-
torque.
nuts as they are received
from the factory. If any
l. When proper alignment is attained within the previously additional lubricant is
specified limits, the laminated rings A must appear vertical and used or if the threads are
wiped dry, these values
undistorted. There must be no end thrust due to poor initial must be modified.
assembly of the coupling.
Cylinder Mounting
When reassembling the cylinder to the crosshead guide, use a criss-cross pattern nut
tightening sequence. See Table 7-2 for recommended torque values.
Outer end cylinder supports, if supplied, are intended to support the weight of the cylinder
only. Do not use them to force the cylinder into alignment. If a cylinder cannot be aligned,
check for dirt, burrs, or other irregularities at the mounting surfaces.
WG-4/3/03
Obtain a piston rod starter tool before attempting to slide the rod through packing. This tool
consists of a split sleeve cone and capscrew. The piston rod should be coated with grease
before and after installing it on the rod. This tool is designed to protect the packing rings from
damage during removal and installation of the rod from the cylinder.
b. Bar over the compressor, at least one revolution in Figure 5-9 Measuring the Piston
the normal operating direction, to insure all parts are End Clearance
working freely.
d. Check the crank end using the same method. For a cold compressor, the crank end
clearance should be 0.030 to 0.050 inch (0.76 to 1.27 mm).
e. If any adjustment is needed, loosen the balance nut and screw the piston and rod assembly
in or out of the crosshead. The WG piston rods are threaded with 12 threads per inch. Thus
one complete turn of the piston and rod assembly moves it 0.083 inch (2.11 mm).
g. After setting the piston end clearance, re-torque (Table 7-2 torque values) the balance nut.
Once the piston and rod assembly and cylinder head are assembled, and the piston end
clearances are set, a check can be made for the piston rod runout. Proceed as follows:
a. Bar over the compressor until reaching the crank end dead center position.
e. If the horizontal run out exceeds acceptable limits, loosen the packing and re-torque. If the
crisscross pattern of torquing is not followed, this may cause the packing case to seat at an
angle, causing the rod to deflect to one side. A second technique would be to loosen the rod-
to-crosshead nut, and rotate the piston one quarter turn before re-torquing. If the runout still
exceeds limitations, contact your Cooper Energy Services Aftermarket facility for
assistance.
f. If the vertical runout exceeds acceptable limits, check the packing case as explained for
horizontal runout. Also, check the piping and bottles attached to the cylinder to see if they are
distorting the cylinders. If runout still exceeds limits, loosen the cylinder to crosshead guide
nuts and re-tighten them. If the runout is still beyond acceptable limits, contact your Cooper
Energy Services Aftermarket facility for assistance.
WG-4/3/03
Section 6
Operation Start-up
Complete Superior® Compressor Start-Up Checklist and Report
Control Procedures Engineering Standard ES30 and forward to the
address included in procedure.
The following procedure is suggested before starting the unit for the first time, after an
overhaul of the frame or cylinders, or after an extended (over 6 months) shutdown.
a. Check the alignment between the driver and the compressor.
c. Remove the top cover of the base and the covers for the
crossheads and distance pieces on each crosshead guide.
NDANGER
Thoroughly wipe the interior of the compressor with a lint free cloth
to remove any water or foreign material that may have accumulated Vent the compressor and the pro-
cess system to the atmosphere
during shipment or storage. before removing any gas-con-
taining part of the compressor or
d. Check the crankshaft for web deflection. its associated piping.
NDANGER
e. Check the piston rod runout.
j. Adjust all force feed lubricator pumps to full stroke for cylinder and packing break-in.
k. Disconnect ends of force feed lubricator lines as close as possible to cylinders and
crosshead guides. Hand pump the lubricators to fill lines and eliminate air.
l. Connect the force feed lubricator lines and operate pumps ten more strokes to force oil
into cylinders and rod packing.
m. Prime the frame oil system with the lube oil priming pump. Operate the pump a
minimum of 100 strokes or run automatic pre-lube pump. This should fill all empty oil
lines.
n. Hand lubricate the piston rod next to the packing. (This does not
apply to non-lubricated applications.) i Oil level in frame
should be filled to
the level in the Kenco level
o. Replace all covers with their respective gaskets and tighten regulator NOT the level in
the frame bull’s-eye.
screws according to Table 7-2. Distance piece covers may be left
off to check for packing leaks on start up if not using sour gas. For
sour gas applications, see warnings in sour gas trim Section 4.
p. Check to see that all crosshead guides or distance pieces and packings are individually
vented with the proper size of vent lines. Refer to Engineering Standard ES3 for the most
up-to-date recommendations.
q. Verify that all safety switches, shutdown devices, and relief valves are properly set and
operational. See Table 7-16 for normal operation, alarm, and shutdown settings.
s. Unload the compressor for startup by placing the bypass line between the first stage
suction and last stage discharge lines.
The frame lubricant must be capable of operating with the type of gas being handled by the
compressor cylinders. For viscosity requirements see page 3-3 and Table 3-2 & 3-2.
Lube oil header pressure should be 50 psi (345 kPa) and is maintained at this level by the
pressure relief valve. If adjustment is required, it can be done by removing the cap which
provides access to the spring loaded adjusting screw. This should be adjusted while at normal
operating speed and temperature.
WG-4/3/03
When starting the compressor, verify a lube oil header pressure of 20 psi (138Kpa) or greater
occurs within 5 seconds of compressor startup. To prevent damage to the crankshaft and other
lubricated parts, all compressors are equipped with low oil pressure shutdowns. This is
triggered when the oil pressure falls below 20 psi (138 kPa).
The oil level in the frame is normally at the center of the sight glass. An alarm should sound if
the oil level rises 1 inch during compressor operation, this will submerge the gaskets on the
bottom of the front and rear covers. A shutdown should occur if the oil level rises an
additional 1.5 inch (3.8 cm) or if the oil level falls 1 inch (2.5 cm) from normal level.
The oil level in the frame sump should be checked while the compressor is running. The
correct level is shown by the round sight gauge on the auxiliary end of the compressor. Oil
level (while running) should be no higher than the top and no lower than the bottom of the
sight gauge. Oil may be manually added through the breather cap hole in the top cover. The
breather cap is designed to be threaded into its bushing by hand and no wrenches should be
used. Make up oil may also be continuously added through an optional, frame mounted oil
level controller connected to an oil supply tank.
Initial Startup
1. Open the valves supplying water to the compressor cooling I CAUTION
system (when required). Running compressor at
speeds less than 600 RPM
2. Start up and operate the unit under no-load conditions at for longer than 12 minutes
may result in unusual wear
reduced speed where possible (600 RPM for engine driven units). of the piston rings.
Check the oil pressure. When the compressor is started, an oil
pressure of 20 psi (138 kPa) must be experienced within 5 seconds or the compressor must
be immediately shut down. Do not restart until adequate oil pressure can be assured. The
oil level in the frame is normally at the center of the sight glass.
3. Run compressor for 2 to 5 minutes at 600 RPM. If driver is a constant speed electric
motor run compressor for only 1 to 2 minutes.
4. Shut system down and check all bearings and packings for high temperatures.
5. Remove crosshead guide covers and check all lubricated surfaces for high temperatures.
7. Start system and compressor up again and run for approximately 20 to 30 minutes. Add
oil to the crankcase to bring the oil level (while running) up to the middle of the sight glass.
Shut down and recheck as above.
Normal Startup
Not all of the instructions provided for initial startups are required for routine starting. The
following notes comprise the normal starting procedure:
1. Set all clearance devices at positions suited for the planned operating conditions. Unload
the fixed volume pockets or suction valve unloaders.
NDANGER
2. Operate the force feed lubricator pumps, by hand, for ten
strokes. (Be sure the lubricator tank is kept full.)
3. Hand prime the frame lube oil system by priming 40 strokes Improper setting of variable vol-
with the lube oil hand priming pump or automatic priming pump ume pockets, fixed volume pock-
ets, valve unloaders, or other
(to prevent oil starvation in the bearings for compressor life). unloading devices can result in
damage and/or injury to equip-
ment and/or personnel.Operating
4. Turn on cooling water supply. the system without clearance and
loading information can result in
5. Start the unit. Check frame lube oil pressure. equipment failure due to overload,
excessive rod loads, and high tem-
peratures.
6. Operate at low speed (600 RPM where possible) and no load
for several minutes. Check force feed lubricator sight glasses for
feed (Figure 3-6). Check lube oil for proper level, at sight gauge.
Normal Shutdown
1. Decrease speed to 600 RPM (engine driven units only).
2. Unload the compressor by opening the bypass line between the first stage suction and the
last stage discharge lines.
WG-4/3/03
6. Relieve pressure by venting compressor cylinders, suction piping, and discharge piping
to remove any remaining gas.
Emergency Shutdown
In an emergency situation, the shutdown devices will shut down the system. In such as case,
the cause of the shutdown must be identified and corrected before restarting the compressor.
Refer to the Troubleshooting Page 7-23 thru 7-31 to troubleshoot compressor.
The compressor should only be operated at speeds, pressures, and temperatures listed on the
data sheets or performance curves. The unit should never be operated at conditions other than
those specified on the data sheets without contacting the manufacture.
Note
Superior attempts to furnish performance curves and/or computer printouts to assist you with com-
pressor operation. If they have been omitted please fill out the following form and new curves will
be provided to you. If compressor operating conditions change, contact your Cooper Energy Ser-
vices Aftermarket Sales Office.
Model
Elevation
Specific Gravity
“N” Value
Section 7
Maintenance
General
The diligent observation of the inspection and maintenance procedure, given in this section,
will go a long way toward insuring satisfactory operation of the compressor. Superior®
recommends planned periodic inspections of equipment. Regardless of the gas compressors,
malfunctions can occur. Faithful preventive maintenance and the use of genuine Superior®
parts will help prevent costly down time, repairs, and replacement costs. Planned shutdowns
for doing preventive maintenance will result in minimum maintenance costs and maximum
mechanical efficiency of your equipment. Good preventive maintenance practice includes a
periodic check of critical bolt torques, such as compressor main and connecting rod bolts and
drive coupling bolts.
Gear Backlash-Aux End Lube Oil Pump (WG) 0.003-0.007 (0.08 - 0.18)
Lube Oil Pump Drive Gear Backlash 0.010 - 0.014 (0.25 - 0.36)
Piston to Piston Rod Nut 2" - 8 UNF (for through rod) 1180 - 1265 (1598 - 1713)
1 260-290 (353-393)
Cylinder Number Cylinder Diameter in inches Valve Cap Nut Torque Ft.-Lbs. (N-m)*
Torque Recommendations
I CAUTION
To insure satisfactory compressor performance and to minimize When tightening nuts and
costly failures, it is extremely important to tighten all nuts and bolts bolts on compressor valve
to the recommended torque values specified in Table 7-2. caps, bottles, and flanges
care must be taken to avoid
Additional information is given in Service Bulletins SB168 and excessive tightening. Over-
SB175. Follow the following general recommendations. tightening can result in
unnecessary stress in the
•Torque wrenches should not be used to “break loose” fasteners. Use cylinder body and, in the
an appropriate wrench or breaker bar. case of valve caps, can
result in valve seat distor-
•Hand position is critical. Only pull from the hand hold to assure tion.
accuracy.
•Occasionally clean and lubricate the ratcheting head with light oil, NOT GREASE.
•Periodic calibration is essential to ensure accuracy.
All torque values shown in Table 7-2 are based on threads which are clean, free of burrs,
paint, etc. and lubricated with engine oil or similar petroleum base lubricants. Unless
specified, DO NOT USE any compounds containing molybdenum disulfide as a thread
lubricant. Due to its high lubricity, excessive stresses will result if used with the torque values
given in Table 7-2.
Precautions
Follow the precautions listed below when any maintenance is performed. Damage to the
equipment, personal injury or death may result if these precautions are not followed.
b. Remove all gas by unloading, venting, and then “blinding” the compressor. Blinding
means to shut off all block valves so there can be no process gas flow to the compressor.
d. Prevent clogged oil lines or filters by using only lint free cloths.
e. Ensure all tools and work areas are clean and free of oil, water,
When work is being done on
dirt, dust or grit. the compressor, the driving
unit must be blocked in such
f. Never file, grind or scrape any lubricated parts (i.e. bearing a way that the compressor
cannot turn over. Block
shells or saddles). valves must be closed on the
suction and discharge lines.
g. Never distort or mark the piston rod with any tool or device. Air or gas must be bled off
from the cylinders. Precau-
Rods that are bent or have burrs will damage the packing or tion must be taken to prevent
prevent it from sealing. In severe cases, the rod could break. the opening of any valve
which would release pressure
against a piston, causing it to
h. Never torque or tighten any nut, cap screw or stud if threads or rotate the unit at a critical
moment.
mating threads are covered with paint or other materials that are
not specified by Superior® for use on threads.
i. Genuine Superior® parts must replace any components which are changed.
k. When reassembling parts during maintenance, replace all worn or damaged gaskets and
seals.
m. Check and clean all lubricating oil passages when the unit is down for repair or normal
maintenance.
n. After a long period of shutdown or a major overhaul, frequently check the unit during
the first 300 hours of operation.
Component Maintenance
Base (Crankcase)
The base is made of high strength alloy iron and is heavily ribbed and reinforced for maximum
rigidity. Large spacer bars provide further stability and ease reassembly. The top and end covers
are individually removable to provide easy access to moving parts. Our open-top design allows
the crankshaft to be easily removed. An oil sump is provided in the lower portion of the base.
The line-bored main bearing supports have caps which are match-marked and numbered and
must be assembled accordingly.
The complete crankshaft assembly includes the drive end oil slinger and the auxiliary end
drive gear. Both of these are shrunk onto the crankshaft, eliminating the need for keyways
and keys. The crankshaft is drilled to carry lubrication from the main bearings to the
connecting rod bearings.
The thrust bearing is a “half washer” type. It fits into a groove machined in the main bearing
saddle and is held captive by the crankshaft, the main bearing saddle and the main bearing
cap.
The upper and lower main bearing shells are interchangeable. After
the compressor has been run, it is preferable that the shells be placed
back in their original position. Therefore, upon removal of the
I CAUTION
bearing shells, they should be so marked. Only use a pencil for mark-
ing on the parting line faces
or in the groove of the bear-
After removing the main bearing cap and the upper bearing shell, the ing shells.
lower bearing shell can be rolled out from underneath the crankshaft
with the help of the main bearing removal tool. This is done by inserting the neck of the tool
into the oil passage hole in the crankshaft journal. When the compressor is barred over, the
tool will push the bearing shell out from underneath the journal and around to the top where it
can be removed. A new bearing shell can be installed using the same procedure.
Carefully clean the crankshaft, bearing shells and saddles before attempting to replace the
bearing shells. Under no circumstances should any filing, scraping, or other fitting be done on
either bearing shells or saddles. The bearing cap nuts should be tightened uniformly (using a
crisscross pattern) to the proper torque given in Table 7-2.
The main bearing clearance (tolerance value) can be checked by using a dial indicator and a
hydraulic jack. Proceed as follows:
a. Remove the top cover to gain access to the crankshaft.
b. Attach the dial indicator to the bearing cap via a magnetic base. Mount the indicator so
the button comes in contact with the crankshaft at its highest point. Depress the button until
the dial makes one complete revolution and set the pointer top to zero.
c. Use a hydraulic jack that will fit between the crankshaft and frame bottom. Position it as
close as possible to the bearing being checked.
e. Compare the clearance reading with the tolerance value given in Table 7-1. If the
clearance reading exceeds the maximum limit, the bearing needs to be replaced.
NDANGER
The connecting rod is a steel forging, rifle-drilled to provide
lubrication to the crosshead pin bushings. The crankpin end of the rod
is split and retains the precision type bearing shells by means of four
Take extreme caution to ade-
alloy steel bolts and nuts clamping the cap and rod together. The cap is quately support the rod. If care
aligned to the rod by dowels and both parts are precision machined as is not taken during the bearing
an assembly. A complete assembly must be ordered, if replacement is removal process, personal
injury and equipment damage
necessary. could result.
The upper end of the connecting rod carries one pressed in bushing. When the bushing is
replaced in the field, extreme care should be used in shrinking the new bushing in place.
To change the connecting rod bearings (crankpin end), bar the compressor over until the
connecting rod cap rises to its highest point. This will offer easy access to the cap bolts.
Support the connecting rod so it will not drop after the cap has been removed.
With the connecting rod supported, remove the rod cap and its bearing half. In order to get
access to the other bearing half, bar the compressor over so the crankshaft moves slightly
away from the connecting rod.
NDANGER
Install a new bearing half against the back wall of the connecting rod.
The tang recess within the rod should support the bearing until the
crankshaft can be moved back into position. Complete the assembly
Always support the connect-
process by putting the other bearing half and rod cap in position and ing rod so it can not drop and
tighten the bolts (using a crisscross pattern) per the torque values given damage equipment or cause
in Table 7-2. injuries.
Crosshead Guide
The fasteners holding the crosshead guide to the base must be torqued uniformly (using a
crisscross pattern) to prevent cocking of the guide relative to the base and crankshaft. (See
Table 7-2 for torque values). Large side covers on the crosshead guide allow easy access to
the crosshead, connecting rod, and rod packing. The crosshead can be removed through these
openings without disturbing the cylinder mounting.
The crosshead is made of ductile iron and has removable top and bottom shoes which have
durable bearing material on the sliding surface. Screws and locknuts hold the shoes firmly in
place. These must be torqued uniformly to the figure specified in Table 7-2. Like all bearing
maintenance, cleanliness is an important factor during the assembly of shoes to the crosshead
and placing the crosshead in to the guide.
a. Vent compressor clearance bottles, unloaders and all associated gas piping to
atmospheric pressure.
e. Use the piston puller to turn the piston and rod assembly out of the crosshead. Do not
use directly on the piston rod.
f. After the piston rod is free of the crosshead, remove the balance nut from the rod.
g. Prepare the piston rod for moving through the packing. (Section 6.) Pull the piston and
rod assembly out far enough to allow the crosshead to be removed.
h. Remove the crosshead pin assembly by loosening the center bolt, nut, and retainer plates,
switching them from end to end, and torquing the nut to pull the pin free.
i. Support the connecting rod and carefully remove the crosshead pin.
j. With the pin removed, slowly bar over the compressor to innermost position. Be careful
to support the small end of the connecting rod so it cannot score or dent the bottom slide.
k. Support the crosshead weight, roll the crosshead the rest of the way over and lift it out.
Care should be used to prevent damage to the shoes or slides.
During the reassembly procedure, the machined face of the balance Crossheads and
nut must be toward the crosshead. Check piston end clearances and i balance nuts are
stamped with throw
then make sure that the balance nut is torqued properly (Table 7-2) numbers and must
against the crosshead. be replaced accordingly.
The auxiliary end cover is aligned to the base and located by a dowel. Additional dowels in
the auxiliary end cover provide proper location for attaching the lube oil pump drive carrier
and the force feed lubricator drive carrier.
If it is desirable to remove the crankshaft from the base without removing the drive coupling
hub, this can be done. First, remove the screws holding the drive end cover. Then support the
drive end cover in place on the crankshaft, while lifting out the crank. Remove the screws
holding the seal cover. The drive end cover can now be snaked off the crankshaft toward the
auxiliary end - leaving the seal cover on the slinger hub. It must be supported to prevent it
from moving.
The oil circulating system is of the pressure, wet sump type, where the lubricating oil supply
is carried in the compressor frame and circulated by means of a gear type pump - gear driven
from the crankshaft.
The pump takes oil from the frame sump, through a suction strainer and delivers it into the
lubricating oil header, or manifold on the compressor - the oil first passing through an oil
cooler and full flow filter.
The precision built, gear type lube oil pump provides full pressure lubrication for all moving
parts in the frame. The pump, with its drive gear, can be removed from the base end cover -
independent of the cover or other gear drives. When installing the pump, observe the
following:
b. Assemble key, drive gear and lock plate. Tighten screws holding the lock plate to the
gear, and fasten with lock wire. Add a slotted nut to the rotor shaft and lock in place with a
cotter pin.
c. Add gasket for carrier assembly. Slide carrier assembly into place on the end cover, using
the dowel to locate.
The main drive coupling hub has a shrink taper fit on the compressor crankshaft.
Additionally, the hub is held in place by a round locknut which threads onto the end of the
crankshaft and is locked in place by “Nylock” setscrews.
The coupling hub is removed as Figure 7-3 Removing Crankshaft Coupling Hub
follows (Figure 7-3):
a. Loosen lock nut (E), after
first unlocking its setscrews,
until there is 1/8 inch (3mm)
of space at dimension (X).
d. Torque jackscrew (J) up against the crankshaft per torque values given in Table 7-2.
e. Connect a 10,000 psi hand hydraulic pump to the 3/8-inch pipe tap (F) in the hub.
h. Remove nut (E); the hub can then be lifted off by crane or by hand.
If the proper equipment is not available, the most practical method of removing the coupling
hub from the crankshaft is by first removing the crankshaft from the base. The crankshaft and
drive end cover plate may now be taken to a suitable work area where the locknut is removed,
the hub heated and pressed off the crankshaft.
a. When at room temperature, push the hub on the crankshaft taper as far as possible.
b. Push the crankshaft all the way to one side to take up any thrust clearance that may be
present.
c. Use gage blocks and shims to fill the space between the coupling and the compressor
end cover.
d. Remove the amount of shims needed to provide an advance of the hub on shaft of 0.050
inch (1.27 mm).
e. Heat the coupling hub and slide it on the shaft until it engages the gage block (with the
reduced amount of shims as defined in item d above).
g. When hub has cooled to room temperature, install lock nuts and Nylock setscrews.
Obtain the most recent version of Service Bulletin SB149 for detailed information on flexible
drive couplings. The flexible drive coupling will give you relatively trouble-free service and
long life if installed and maintained properly. The coupling was selected based on known
loads and operating conditions of the driver and driven equipment.
Initial alignment is one of the most critical factors affecting coupling performance. It should
be remembered that the couplings are basically in-line devices which are intended to
compensate for small amounts of shaft misalignment caused by bearing wear, foundation
settling, thermal growth, etc.
The more attention paid to initial alignment, the larger the reserve margin that will exist for
accomplishing the intended purpose of the coupling. See page 5-4 to 5-5 for the
recommended limits. These limits represent about one-third of the total misalignment capacity
of the coupling and are generally adequate for most installations. It should be kept in mind
that there are definite advantages to be gained from aligning the equipment to more precise
values than those shown. The primary advantage is that the reserve margin for accepting
misalignment during the life of the machinery is thereby increased. Exceeding the Table 5-6
values for alignment will reduce the service life of the coupling.
Another factor to be considered, and one of the most important to good performance is
adherence to the bolt torquing recommendations Table 5-6. Loose bolts can induce fretting
corrosion, hammering, and pounding which will eventually destroy the bolts and coupling
discs.
The Rexnord disc coupling is easily inspected. A visual analysis may point to possible drive
system problems. Proper evaluation of the disc packs and connecting parts may save
considerable maintenance costs and down time. Here are some of the more evident visual
inspection criteria and recommended corrective procedures. Consult Superior® or your
nearest Cooper Energy Services Aftermarket facility for further assistance.
The disc pack has a bulge near the center or is bowed toward one flange in every other chord
position Figure 7-10. This condition is a result of a large torque overload induced into the
system above the peak overload capacity of the coupling. The remaining disc pack chordal
t
! Caution
Figure 7-10 Torque Overload If bulged or bowed condition
only appears in one chordal section there may be a loose bolt on
one side of the distortion. Loosen coupling locknuts and turn bolt
slightly to remove friction. Bulge should flatten out. Re-torque
locknuts. If distortion does not disappear, replace disc pack.
sections will be very straight and tight. Check the driven equipment loading. If not
correctable, contact the Cooper Energy Service facility immediately.
Cylinder Body
A wide range of cylinder sizes is available. Each cylinder is conservatively designed for very
low stress at rated working pressures.
Some cylinder bodies are provided with drilled water passages, top and bottom, which
connect the water inlet and outlet with the cooling muff, which surrounds the ring travel area
of the bore. Whenever the water jacket covers on the cylinder sides are removed to clean out
deposits, the drilled passages should also be cleaned out. If the pipe plugs in the crank end of
the drilled passages are removed, they should be coated with good waterproof sealer and
replaced. This will prevent water seepage into the atmospheric vent space.
Lube oil, from the force feed lubricator tubing system, passes through a check valve and into a
fitting on the outside should be cleaned out and all steel tubing checked for soundness and
tightness. This paragraph does not apply to non-lube operation.
Plugs are provided, on all size of cylinders, which can be removed and indicator cocks
inserted to take pressure readings, if desired.
Cylinder Head
The piston is attached to the piston rod with six capscrews (for most piston sizes) and with
four capscrews on remaining sizes. Some pistons have a through rod and nut while others
have a one piece piston and rod. See Table 7-2 for proper torque values.
Prior to passing the piston rod through the piston rod packing, prepare the rod as described in
Section 5.
The piston end clearances are adjusted as specified in Section 6 and should be checked with
the balance nut torqued to its proper value.
In non-lubricated applications, the rider compression rings, rider rings and the piston rod
packing will wear with time. Replacing these elements before they wear beyond allowable
limits will contribute to the successful operation of a non-lubricated cylinder. Contact the
Superior ® Engineering Department for wear limits for your specific cylinder size and
application.
Definite lubrication rates and time intervals for packing “wear in” are difficult to prescribe.
Experience has indicated that these factors may vary widely on different applications. If there
is concern about proper lubrication rate, contact the nearest Cooper Energy Service
Aftermarket office.
Before disassembling a
packing case, note all
identification marks to ensure
components are reassembled properly. If components are not marked, identify each cup’s
position relative to the adjacent cup or flange by numbering or marking them together. While
disassembling a packing, record the position of each ring and the direction each ring faces for
proper reassembly.
Refer to Figure 7-13 for aid in identifying packing rings. Knowing your packing rings is very
helpful when ordering new ones.
00776
The packing cups and glands that are not being replaced by new ones
must be soaked and thoroughly cleaned in a non-acid solvent. They
should then be blown dry and examined closely for unusual nicks or
I CAUTION
burrs which might interfere with the rings free floating or contact As a general guide,
with the rod. Particular care must be taken with rings made of soft temperatures not
metals and it is very important that wiper rings be handled and tolerated by resting
installed carefully to prevent damage to the scraping edges. your hand on the
packing case flange,
Before installing new packing assemblies, it is important that the after the unit is shut
piston rod be carefully checked. If the rod is worn, rough, pitted or down, indicate to
has a taper, it must be replaced. fast of a wear rate.
For a lubricated
The bore for the pressure packing nose cup must be cleaned and packing, check to
examined for burrs. If found, burrs should be removed. Also, replace see if the lubrication
the o-ring in the outside diameter of the wiper packing flange with a rate is set properly
new one. per Section 3.
After installing the packing cases and before connecting the oil tubing to the packing flange
(for lubricated packing), hand pump the force feed lubricator (when supplied) until oil runs
from one of the disconnected tubes. Connect this tube to the respective hole in the packing
flange and continue to pump the lubricator 12 to 15 more strokes.
After the piston and rod assembly has been reinstalled, the piston end clearance must be set
and the piston rod runout must be checked per Section 5.
Valves
Valve Installation
Suction and discharge valves must be installed in the proper direction. This can be determined
by first inspecting the valve to see which direction the valve plates move while opening or
compressing the springs. Gas will flow in that same direction (Figure 7-14).
To replace a valve in a bottom port (assume that this is a discharge port), proceed as follows:
j. Invert retainer. Place valve on top of retainer with valve guard facing out (away from the
cylinder). Slip gasket on valve.
k. Lift the valve, retainer, and gasket up into the bottom port, making sure that the valve
seat enters first.
l. Tighten the retainer lock screw just enough to hold retainer and other parts in place.
t Figure 7-15 Valve Replacement
00778
Special Tools
Refer to the section 9 and 10 of this manual for information on special tools.
Several safety devices may be employed on compressor units. The most common ones and their
recommended set points are listed in Table 7-16. Questions regarding these and other devices and
their set points may be referred to the Cooper Energy Services Aftermarket office.
Table 7-16 Recommended Alarm Set point
Alarm/Shutdown Normal Condition Alarm Point Shutdown Point
Oil Pressure in Header 45-55 psig (310-380 kPag) 25 psig (173 kPag) 20 psig (138 kPag)
Oil Temperature out of 160-180°F (71-82°C) Out 185°F (85°C) Out 190°F (88°C) Out
the Frame
Vibration Nominal 1/4-3/8 turn from normal 3/8 - 1/2 turn from normal
condition condition
Gas Temperature Suction (TS) or Discharge 20°F (11°C) above TS or 25°F (14°C) above TS or
(TD) TD TD
Water Temperature Tin or Tout 20°F (11°C) above Tout or 25°F (14°C) above Tout or
Tin Tin
a. Determine what general area is affected - frame, cylinders, lubricating system, etc.
b. Analyze the symptoms (clues) to pinpoint the exact location of the problem valves,
bearings, etc.
d. Return the unit to service and verify that normal operation is resumed.
Tables 7-18 through 7-22 list many typical symptoms, causes and corrective measures. It may
be necessary to refer to more than one symptom to locate the entire difficulty. The suggested
corrective actions are supposed to direct you to those areas most likely to be at fault.
However, do not limit your analysis only to those areas found in the table. If symptoms
persist, contact your nearest Cooper Energy Services Aftermarket office for possible field
assistance.
Table 7-18 Compressor Frame Troubleshooting
Symptom Possible Cause Potential Damage Corrective Measure
Compressor Mechanical Seized crosshead, rods, main Replace all defective parts. Check compressor for proper
will not turn
seizure of bearings. crankshaft alignment, piston rod runout, and lube oil
over compressor. system operation.
Tripped Defective shutdown device. Check the control system and device for proper operation.
shutdown
device.
Foreign material Cylinder scoring, valve Replace damaged parts and take measures to prevent
(water, non-lube damage, possible bent piston future foreign material entrapment in the compressor
packing, etc.) in or connecting rods. cylinders.
cylinders.
Improper piston- Possible piston or rod damage. Replace any damaged parts and properly set the piston-
to-cylinder end to-cylinder end clearances.
clearance.
Compressor Opposing Foundation cracking, weld Total weight of crosshead, balance nuts, piston rods,
vibration cylinders are out cracking, or foundation bolt connecting rods, and rings must be within 3 lbs. (1.4 kg) of
of balance. failure. same components on opposite throw. Replace balance
nuts or crossheads to obtain this balance.
Worn bearings. Possible broken frame, Verify crankshaft alignment, piston rod runout, and
connecting rods, crankshaft, or bearing clearances. Replace bearings as needed.
piston rods. Reverify alignment and runout.
Improper Foundation damage, Realign the compressor per Section 5.
compressor foundation bolt failure, grout
installation and cracking, or broken frame and
alignment. crankshaft.
Gas pulsation. Excessive vibration causing Analyze compressor with a vibration or indicator analyzer.
cracked welds, foundations, Install orifices at the cylinder flange, change piping,
grout, and parts. Also possible change cylinder operating configuration, or change
foundation bolt breakage. operating speed.