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Operation
Maintenance
Parts
Instruction Manual
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
Table of Contents
Cooper Compression
6/1/04
Page c
Section 3
Lubrication And Cooling ............................................................................3-1
Compressor frame lubrication specifications .............................................................................................3-1
General specifications.................................................................................................................................3-2
Lubrication system maintenance ................................................................................................................3-2
Compressor Cylinder and Packing Lubrication..........................................................................................3-3
Lubrication Rate .........................................................................................................................................3-3
Pump Per Point System ..............................................................................................................................3-4
Operations ...................................................................................................................................................3-4
Maintenance ................................................................................................................................................3-5
Proportional Lubrication System ................................................................................................................3-6
Lubricator Worm and Gear Drive...............................................................................................................3-7
Compressor Frame Lubrication Oil Cooling ..............................................................................................3-7
Coolant Requirements.................................................................................................................................3-8
Corrosion ....................................................................................................................................................3-8
Scales and Sludge .......................................................................................................................................3-8
Cooling System .........................................................................................................................................3-10
Section 4
Sour Gas Compressor Applications...........................................................4-1
General Information....................................................................................................................................4-1
Hazards of Hydrogen Sulfide or "Sour Gas" ..............................................................................................4-1
Concentration Levels ..................................................................................................................................4-2
Trim Requirements .....................................................................................................................................4-2
Hydrogen Sulfide (H 2S) Concentrations Up To 2% By Volume ........................................................4-2
Level 1-11p Trim (H2S) Concentrations of 2% - 5% By Volume.......................................................4-3
Level 2-11 p Trim (H 2S) Concentrations > 5% ...................................................................................4-3
Enhanced H 2S Trim Requirements ......................................................................................................4-4
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
Page d
Cooper Compression
Section 7
Maintenance ................................................................................................ 7-1
General ....................................................................................................................................................... 7-1
Acceptable Tolerance Clearance Values.................................................................................................... 7-1
Torque Recommendations ......................................................................................................................... 7-2
Specific Torque Values ....................................................................................................................... 7-2
General Torque Values ........................................................................................................................ 7-2
Thomas Coupling ................................................................................................................................ 7-2
Hoebiger Valve .................................................................................................................................... 7-2
Acceptable Tolerance Cylinder Clearance Values..................................................................................... 7-3
CT Valves................................................................................................................................................... 7-3
Torque Recommendations ......................................................................................................................... 7-3
Diagram and Torque for Proportional Lubrication System ....................................................................... 7-4
Piston-to-Cylinder Bore Clearance ............................................................................................................ 7-5
Valve-in-Head Cylinder Torque Values .................................................................................................... 7-6
Typical Miscellaneous Flanging ................................................................................................................ 7-7
Precautions........................................................................................................................................... 7-7
Maintenance Frame.................................................................................................................................... 7-8
Main and Connecting Rod Bearings.................................................................................................... 7-8
Bearing Clearance................................................................................................................................ 7-9
Changing Main/Connecting Rod Bearings........................................................................................ 7-10
Connecting Rods................................................................................................................................ 7-11
Clearances for Connecting Rod Components Inspection Purposes Only.......................................... 7-12
Crankshaft.......................................................................................................................................... 7-16
Force-Feed Lubricator ....................................................................................................................... 7-19
Oil Filter ............................................................................................................................................ 7-21
Hand Pump ........................................................................................................................................ 7-23
Measuring Oil Pump Gear Lash ........................................................................................................ 7-26
Crankcase Pressure Relief Valve....................................................................................................... 7-28
Disc Pack Flexible Coupling ............................................................................................................. 7-29
Drive Coupling Hub .......................................................................................................................... 7-29
Flexible Drive Coupling .................................................................................................................... 7-30
Troubleshooting Rexnord Couplings................................................................................................. 7-31
Elongated Bolt Hole .................................................................................................................... 7-31
Scored Body on Bolt ................................................................................................................... 7-31
Misalignment Failure .................................................................................................................. 7-31
Compression................................................................................................................................ 7-32
Elongation ................................................................................................................................... 7-32
Fatigue Failure ............................................................................................................................ 7-32
Torque Overload (Visible only with strobe light while running) ............................................... 7-32
Table of Contents
Cooper Compression
6/1/04
Page e
Section 8
Frame "as built" Bills of Materials ...........................................................8-1
Section 9
Cylinder "as built" Bills of Materials .......................................................9-1
Page f
Cooper Compression
Section 1
Introduction to the RAM 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 RAM 52 and
RAM54 series compressor frames.
Cooper Energy Services is committed to continuous improvements and design advancements.
Because of this commitment, changes may occur in your compressor frame that may not appear in
this instruction manual. Some photographs or illustrations in this manual show details or options
that may not appear on your compressor frame. Guards, covers or other protective mechanisms
may have been removed for demonstrative or illustrative purposes. Any time a question arises
concerning your compressor or this instruction manual, please contact an authorized Cooper
Energy Services Distributor for the latest available information.
It is very important that
Figure 1-1 RAM Compressor
personnel associated with
Piston bore
ground to micro
operation maintenance of the
finish
RAM series compressor read
Compact
Rods ground to
variable
tight specifications
this manual and support
volume pocket
Standard
documentation. Keep this
ASA flange
sizes
non-reversible and
manual with related literature
non-interchange-able
High
valves
temperature
and compressor information.
O-ring seals
Store it so it is easily found
Valve spacers in all
by maintenance or service
cylinders 6-1/2"
diameter and larger
Air cooled
personnel. It is also
Packing & wiper
cylinders
rings in same case
important that users carefully
study the safety information Internally
Rolled threads
drilled
balance
provided in Section 2.
Carbon filled TFE
lines
piston rings and rider
Always use good safety
rings
practices at all times to
prevent injury to personnel or damage to equipment.
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 information to facilitate use and
maintenance of RAM series compressor frames purchased from Cooper Energy Services. By
Section 1: Introduction to Servicing the RAM Series Compressor
5/27/03
Page 1-1
receiving this document, you agree not to use such confidential information for any purpose
other than limited purpose stated herein and further agree not to disclose such information to
others except in accordance with the limited purpose stated herein.
All specifications and ratings are subject to change without notice. Superior is a trademark
of Cooper Cameron Corporation.
Correspondence concerning your cylinder must include the Cooper Energy Services cylinder serial
number.
Page 1-2
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 fullflow 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
Figure 1-4
to the 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.
Crankshaft Rotation
When facing the oil pump end of the frame,
the crankshaft rotates in a
counterclockwise direction.
Figure 1-5
Figure 1-6
5/27/03
Page 1-3
Page 1-4
Type Of Unit
RAM52
RAM54
12.0 (304.8)
12.0 (304.8)
9.750 (247.65)
9.75 (247.70)
3.5020 (88.95)
3.5020 (88.95)
External
Internal
300 lbs
300 lbs
262 lbs
262 lbs
CAUTION
CAUTION
When replacing crossheads,
connecting rods, pistons, or
changing piston ring material,
the new parts should be
weighed, in order to reaffirm
the actual unit balance.
DANGER
Failure to verify and correct
compressor balance can
result in excessive mechanical vibration, frame cracking, piping vibration,
foundation cracking and
other damage to the compressor. It also creates a
potentially unsafe operating
condition for the operator.
5/27/03
Page 1-5
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.
00752
Additional Information
Please visit the Cooper Energy Services web site: http://www.cooperenergy.com
Unrestricted copies of Service Bulletins are available at the Cooper Energy Services web site.
You must have Adobe Acrobat Reader version 3.0 or later in order to view the bulletins:
http://www.cooperenergy.net
Prerequisites
Personnel using this guide should be familiar with compressor systems, standard mechanical service
tools, and compressor terminology. Service personnel should have adequate experience in good
maintenance and troubleshooting techniques. Cooper Energy Services recommends that all personnel
using this manual should complete CES Superior Reciprocating Compressor Training. Training
includes the following:
Page 1-6
Related Publications
The following related publication contain more information about the Superior RAM Series Compressor
Superior RAM 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 movers
described in the American Petroleum Institutes Specification for Packaged Reciprocating Compressors for Oil and Gas Production Services (API Specification 11P). American Petroleum Institute
Section 1: Introduction to Servicing the RAM Series Compressor
5/27/03
Page 1-7
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
WHETHER WRITTEN, ORAL OR IMPLIED (INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR PURPOSE). If it appears within one year from the date the
equipment is placed in service but no later than eighteen (18) months from the date of delivery to the
Buyer, whichever first occurs, that the equipment does not meet the warranty specified above and the
Buyer notifies the Seller promptly, the Seller shall correct any defect, at the Seller's option, either by
repairing any defective part or parts or by making available, at the Seller's factory, a repaired or
replacement part.
The liability of the Seller to the Buyer (except as to title) arising out of the supplying of the equipment, or its use, whether on warranty, contract or negligence, shall not in any case exceed the cost of
correcting defects in the equipment or part thereof and upon expiration of the warranty period all such
liability shall terminate. The foregoing shall constitute the sole remedy of the Buyer and the sole liability of the Seller.
The preceding paragraph shall not apply and the Seller assumes no liability whatsoever for breach of
warranty when there is evidence that the defect arose as the result of (a) abuse or negligence in the
operation of the equipment, (b) failure to maintain the equipment properly, (c) overloading or overspeeding, or (d) use of repair parts not approved by Seller.
The warranty given to the Seller by its supplier of special equipment, including but not limited to generators, is hereby assigned without recourse by the Seller to the Buyer. AS TO THIS SPECIAL
EQUIPMENT, WHICH GENERALLY BEARS THE NAMEPLATE OF THE SELLERS SUPPLIER, THE SELLER ASSUMES NO LIABILITY WHATSOEVER FOR BREACH OF WARRANTY, WHETHER WRITTEN, ORAL OR IMPLIED (INCLUDING ANY WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PURPOSE).
Copyright 2002 Cooper Cameron Corporation. All rights reserved.
Copyright 2002 Adobe Systems Incorporated. All rights reserved.
Page 1-8
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.
Improper operation, lubrication, maintenance or repair of this equipment can be dangerous
and could result in injury or death.
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.
RAM-5/27/03
Page 2-1
The following safety alert symbols and signal words are used
throughout this manual and are intended to highlight items or advise
you of special circumstances.
The NOTE symbol is an alert indicating an essential operating
procedure or condition. The following is an example of a NOTE:
CAUTION
D A N GER
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.
Page 2-2
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.
DANGER
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.
RAM-5/27/03
Page 2-3
General Precautions
Attach a DO NOT OPERATE or similar warning tag to the start
button or controls before performing maintenance or repairing the
equipment. When appropriate, attach tags at the equipment and at
each operator's position and disconnect starting controls.
Be absolutely sure the remote starting system is disabled and/or
disconnect the starting system on the equipment being serviced.
Use caution when removing cover plates. Gradually loosen (do not
remove) the last two bolts or nuts located at opposite ends of the
cover or device. Pry cover loose to relieve any spring or other
pressure, before removing the last bolts or nuts.
DANGER
If Poisonous or suffocating
gases are being compressed,
follow all plant safety procedures prior to and during
mainenance on any gas
equipment or piping to
avoid injury or death due
to inhalation of such substances.
Page 2-4
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 personnel 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 personal 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.
RAM-5/27/03
Page 2-5
Asbestos Precautions
Cooper Energy Services equipment and replacement parts shipped from the factory are
asbestos free. Cooper Energy Services recommends the use of ONLY genuine Superior
parts. If any replacement parts containing asbestos are used, the following guidelines should
be used in handling these parts and asbestos debris.
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 requirements 29 CFR 1910.1001).
Follow environmental rules and regulations for disposal of asbestos.
Page 2-6
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.
RAM-5/27/03
Page 2-7
Fire may result from lubricating oil or fuel sprayed on hot surfaces causing personal injury
and property damage. Inspect all lines and tubes for wear or deterioration. They must be
routed, supported or clamped securely. Tighten all connections to the recommended torque
(Section 7). Leaks can cause fires.
Page 2-8
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 packings.
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 the cylinder and packing system is a
different type compared to the frame oil).The lube oil sump capacity for a RAM52 is 10 US gals and
RAM54 is 30 US gals.
6/2/04
Superior Compressors
Page 3-1
suitable. In applications where the compressor cylinders are handling corrosive gases such as H2S or
CO 2, a lubricant with a higher TBN or method for adequate retention of the original TBN is recommended for service in the frame.
General Specifications
The general specification for lubricating oil for use in Superior compressor frames is as follows:
(Reference Superior Engineering Standard ES-1002).
Table 3-1 General Specifications
Specification
Range
Test Procedure
12.5 to 16.3
ASTM D 445
Viscosity: cSt @ 40 oC
204 Maximum
ASTM D 445
Viscosity Index
70 Minimum
ASTM D 2270
Flash Point
ASTM D 92
Pour Point
ASTM D 97
Table 3-2 Viscosity Information-this information is equivalent to the ranges above and provided for
information only
Specification
Range
Test Procedure
75 to 85
ASTM D 88
1100 Maximum
ASTM D 88
Page 3-2
Cooper Compression
I CAUTION
Low lube oil pressure alarm
and shut down device(s)
must monitor compressor
frames lube oil pressure
down stream of the compressor frames lube oil filter, recommended location
is at driver end of lube oil
header when possible.
Superior Compressors
Lubrication Rate
I CAUTION
IT IS IMPORTANT that during start up safe and ample lubrication should The lubrication rate
be provided. This is accomplished by properly adjusting the force feed
for break-in should be
lubricator pump(s). Observe the detailed instructions, given in Section 6,
double that for norwhen first starting up the compressor. With all lubricator pumps set at full mal operation.
stroke, bring the cylinder pressure up slowly until the unit is running at full
rated speed and load. Watch for any signs of malfunction. After the first 48 hours at full load, the
lubrication rate should be gradually reduced to the amount necessary for correct lubrication.
Adjustment should be made slowly, a little each day, and should take several days to accomplish.
Refer to Lubrication Schematic for rate and amount on the compressor.
See Figure 3-4 for an example of a force feed lubricator. A quantity of 1/5 (0.2) pint per inch of
cylinder bore is equivalent to one drop per minute per inch of bore for a very heavy oil and ranges up
to two drops per minute per inch of bore for very light oils. See section 6-2 thru 6-3 for information
on the sight glass oil level.
6/2/04
Superior Compressors
Page 3-3
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 3-5 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
Page 3-4
Cooper Compression
Superior Compressors
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 3-5 General Cylinder Lubrication
Maintenance
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.
Section 3: Lubrication and Cooling
Cooper Compression
6/2/04
Superior Compressors
Page 3-5
! 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.
b. Have a clean work area.
c. Avoid vise marks; protect ground surfaces, and NEVER grip the ground mating surfaces in a vise.
d. Pistons are not interchangeable - - each piston is match-honed to its
cylinder.
e. Pistons are removed by hand-punching with a brass rod (either way).
f. Clean all sections with an approved solvent.
g. Do not disassemble check valves - - clean with compressed air. Replace
defective parts, as required.
h. Use all new gaskets when reassembling manifolds.
ICAUTION
If the distribution block is
disassembled, carefully
observe the torque used
when reassembling manifolds:
Distribution Block Tie
Rod Nuts = 20-25ft.
lbs. (27-34Nm)
Check Valves = 15-20
ft. lbs. (20-27 Nm)
End Plugs = 15-20
ft.lbs. (20-27 Nm)
Alternate Outlets and
Pin indicators = 10-15
ft. lbs. (14-20Nm)
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.
Page 3-6
Cooper Compression
Superior Compressors
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.
00752
Filling Instructions
1. Remove vent/fill plug.
2. Loosen
upper plug.
.
3. Fill with Exxon TK-680 Cylessic oil
.
(ISO680
Agma-8) until it begins to leak at
upper plug.
4. Tighten upper plug. Install vent/fill plug.
Drain Plug
6/2/04
Superior Compressors
Page 3-7
Heat Rejection
Model
RAM 52
RAM 54
@1200 RPM
@1500 RPM
The maximum recommended oil temperature for oil returning to the frame is 175 oF (79oC). To
insure this oil temperature, coolant temperature and flow must be selected to remove heat according
to Table 3-7.
Coolant Requirements
I CAUTION
The primary purpose of any water treatment is to protect the surfaces of the
cooling system from cavitation, corrosion, scaling, or sludge deposits that
would reduce the transfer of heat to the coolant.
It is the responsibility of the operators/users to consult with reliable vendors of cooling system
treatments in order to adequately protect the equipment from damage caused by cavitation, corrosion,
scale and sludge formation and other water treatment related problems.
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.
Page 3-8
Cooper Compression
Superior Compressors
The most important consideration for the cooling system is good water quality. Table 3-8 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 3-8 Raw Cooling Water Specifications
Category
Standard System
Steam System
pH Level
100.0-170.0 MAX
5.0 MAX
Chlorides PPM
25.0 MAX
25.0 MAx
Sulfates PPM
20.0-100.0 MAX
20.0-100.0 MAX
300.0-400.0 MAX
300.0-400.0 MAX
Silica PPM
-----
50.0 MAX
An inhibitor is a chemical part of coolant treatment that reduces corrosion by forming a protective
film on the metallic surfaces of the cooling system. These protective films can be of anti foam or
coating nature. The anti foam nature reduces the formation of air bubbles in the coolant. The coating
effect gives a protective layer between the metal surfaces and the coolant. During cavitation, the
violent collapse of the vapor bubble literally blasts small holes in the film. The job of the inhibitor is
to recoat these areas. Because the inhibitor is recoating the metal surfaces, its concentration levels
must be maintained to continue adequate protection. Therefore, the coolant inhibitor concentration
must be checked periodically, and added when needed.
Good industrial grade antifreeze should be used in all closed-type cooling systems. All industrial
grade antifreezes have some corrosive inhibitors. When exposed to heat, these inhibitors break down.
This characteristic requires periodic adjustments to maintain the corrosion protective qualities of the
coolant.
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.
6/2/04
Superior Compressors
Page 3-9
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 cooling 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 Compression do not recommend using these for this equipment.
Page 3-10
Cooper Compression
Superior Compressors
Section 4
Sour Gas Compressor
Applications
This section defines additional compressor hardware and special
materials for use when the compressor is applied in sour gas or
corrosive gas service. The requirements listed are based on
American Petroleum Institute (API) Production Equipment
Standard 11P, National Association of Corrosion Engineers
(NACE) Standard MR0175, and Cooper Energy Services
experience. Additional specifications may apply to pulsation
dampers, piping and other equipment used in conjunction with this
compressor. Copies of API 11P and NACE MR0175 can be
purchased on line:
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.
National Association of Corrosion Engineers-A copy of specification MR0175 can be purchased online at www.nace.org or by
calling (281) 228-6200.
These specifications apply to equipment only! Follow safe
operating and maintenance procedures associated with personnel
around sour gas machinery as dictated by your company
procedures. Sour gas is poisonous and attacks the nervous system
and can cause paralysis, permanent injury or death!
DANGER
Sour gas or hydrogen sulfide (H2S) is a highly corrosive and extremely toxic
gas. Every precaution
reguarding life and equipment must be taken in a
hydrogen sulfide application. Read and understand
the United States Department of Labors Occupational Safety and Health
Administration (OSHA)
regulations for Air Contaminants (standard
1915.1000) and the Confined Space Pre-Entry
Check List (standard
1910.146 App D). These
regulations are available
online at the OSHA website:www.osha-slcgov.com
Cooper Energy Services
recommends that Superior
equipment users and oil
and gas service equipment
packagers follow the
guidelines set forth by the
National Association of
Corrosion Engineers in
specification MR0175:
Sulfide Stress Cracking
Resistant Metallic Materials for Oilfield Equipment.
Caution should be taken when working in or around hydrogen sulfide (H2S). 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 H2S and its effect on
the body. This should be thoroughly read and understood before working in an H2S
environment.
RAM-5/27/03
Page 4-1
Effects
1 ppm (0.0001%)
Loss of reasoning ability and sense of balance. Respiratory disturbances will occur within 12 to 15 minutes of exposure. Requires
prompt artificial respiration.
Rapid loss of consciousness and breathing. Death will result if not removed quickly. Immediate artificial respiration is required.
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 H2S:
Level I
Level 1-11P
Level 2-11P
Enhanced Trim
Trim Requirements
For Hydrogen Sulfide (H2S) 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 recommended.
The frame lubricant used must have a total base number (TBN) of 15 or higher to help prevent 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.
Page 4-2
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 provide 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 (< 27F (<-3C) Neoprene (Spec.
479) can be specified as an option.
Level 1-11P trim (H2S Concentrations of 2% - 5% By Volume) include all of the
requirements applicable to concentrations of less than 2% apply plus the following additional
requirements:
A suitable corrosion inhibitor should be added to the cylinder lubricating oil.
Cylinders are to be equipped with a suction flushing system (injection of cylinder lubricating
oil into the suction nozzle of each cylinder). This is in addition to the regular cylinder lubrication. This helps to resist the natural solvent action of the sour gas and insures a thorough
distribution of oil for better lubrication. It also helps to better form a barrier to corrosion by
coating all the valve surfaces with an oil film.
Oil slingers are to be used on each compressor rod in the distance piece compartment to
insure that none of the H2S contaminated cylinder or packing lubricant works its way back
into the crankcase and contaminates the frame lubricating system.
Packing and piston ring material shall either be non-metallic or contain no copper bearing
metals.
Compressor valves will be standard construction and hardness.
All carbon steel, alloy steel, or 12CR steel parts which are gas wetted (come into contact with
the process gas stream) are to have a maximum hardness of 22 HRC. This is to include all
internal fasteners and V.V. pocket screws as a minimum, but excludes valve fasteners.
The piston rods are 17-4 pH stainless steel with a hardness of 28 - 33 HRC (Heat Treat Spec
ZA).
Forged steel cylinder bodies made of AISI 4142 are to have a maximum hardness of 235 HB.
Engineering will evaluate these applications on an individual basis as some cylinder pressure ratings may have to be reduced because of the mechanical properties restrictions.
RAM-5/27/03
Page 4-3
Level 2-11p Trim (H2S Concentrations > 5%) All of the requirements for H2S
concentrations of 2%-5% apply plus the following:
Valve components made of carbon steel or AISI 4140 alloy steel shall have a maximum hardness of 22 HRC (Heat Treat Spec. H2S). This reduces the pressure differential capability of
any specific valve design and thus the pressure differential capability of the cylinders. Engineering will evaluate these on an individual basis and select appropriate alternative designs
to meet the application requirements.
This reduced hardness requirement also includes steel valve cages (retainers) when they are
used.
Compressor valve components may also be made of AISI 416 stainless steel with a maximum
hardness of 22 HRC.
Valve plates wherever possible are to be plastic to better prevent seat wear against the softer
valves seats.
When metallic plates are required, 410 stainless steel with a hardness of 17 to 22 HRC will
be used.
Nimonic 90 valve spring material will be used.
Two compartment configuration of distance pieces is required. The outer compartment must
be purged with inert gas to a pressure of 3 to 5 inches (7.6 to 12.7 cm) H2O.
All compressor cylinder and distance piece critical bolting, capscrew, studs, and nuts which
come in contact with the process gas stream shall conform to ASTM A913-B7M (bolts and
studs) and ASTM A194-2HM (nuts).
All instrumentation that comes into contact with the process stream (liquid level controls,
shutdowns, bourdon tubes, process valving, relief valves, etc.) shall meet the full requirements of NACE MRO175 except stainless steel tubing fittings. This requirement is the
packagers responsibility.
The distance piece shall be purged with inert gas. The packager is responsible for purging
per these requirements. If other venting or purging systems are desired the details are to be
negotiated between the purchaser and the packager (i.e., vacuum systems or sweet natural
gas purge). The final detailed system should provide for the safety of persons around the
equipment and should prevent contamination of the frame oil with sour gas. Packing cases
will not be purged unless required by the customers.
Page 4-4
The following requirements should be followed when H2S 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.
The requirements are as follows:
A suitable corrosion inhibitor should be added to the cylinder lubricating oil.
The cylinders are to be equipped with a suction flushing system (injection of cylinder lubricating oil into the suction nozzle of each cylinder).
Two compartment distance pieces are required. The outer compartment must be purged with
inert gas to a pressure of 3 to 5 inches (7.6 to 12.7 cm) H2O. The inner compartment can
either be separately vented as described previously or purged with inert gas to a pressure of
3 to 5 inches (7.6 to 12.7 cm) H2O.
Oil slingers are to be used on each compressor rod in the distance piece compartment to
insure that none of the H2S contaminated cylinder or packing lubricant works its way back
into the crankcase and contaminates the frame lubricating system.
Compressor valve springs are to be Nimonic 90.
Packing garter springs are to be Inconel.
The piston rods are stainless steel with a hardness of 28 - 33 HRC (Heat Treat Spec. ZA).
Tungsten carbide coating is required in the packing travel area of the piston rods.
The valve components are to be made of carbon steel or AISI 4140 alloy steel with a hardness
of 22 HRC maximum (Heat Treat Spec H2S). This reduces the pressure differential capability of any specific valve design and thus the pressure differential capability of the cylinders.
Engineering will evaluate these on an individual basis and select appropriate alternative
valve designs to meet the application requirements. Compressor valve components may
also be made of AISI 416 stainless steel with a maximum hardness of 22 HRC.
This reduced hardness requirement also includes steel valve cages (retainers) when they are
used.
Forged steel cylinder bodies are to be made of AISI 4142 with a maximum hardness of 235
HB. Engineering will evaluate these applications on an individual basis as some cylinder
pressure ratings may have to be reduced.
All steel gas wetted parts are to have a maximum hardness of 22 HRC. This is to include all
internal fasteners and V.V. pocket screws as a minimum.
Valve plates wherever possible are to be plastic to better prevent seat wear against the softer
valve seats.
When metal plates are required, 410 stainless steel with a hardness of 17 to 22 HRC shall be
used.
All compressor cylinder and distance piece critical bolting, capscrews, studs, or nuts which
come into contact with the process gas stream shall conform to ASTM A193-B7M (bolts
and studs) and ASTM A194-2HM (nuts).
Section 4: Safety Precations and Guidelines
RAM-5/27/03
Page 4-5
Page 4-6
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.
5/27/03
Page 5-1
loading and the possibility of rocking. When freezing temperatures are likely to occur, the
foundation must be carried well below the lowest expected frostline as determined by the
foundation engineer.
Figure 5-2
Figure 5-1
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.
5/27/03
Page 5-2
Figure 5-3
CAUTION
Responsibility for the grout
belongs with the customer
or their contractor. Grouting
material instructions should
be carefully followed. Failure to comply with this
warning may result in damage to your unit.
Section 5: Installation
Cooper Energy Services Superior Compressors
5/27/03
Page 5-3
Figure 5-4
Figure 5-5
00761
5/27/03
Page 5-4
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.
e. Rotate coupling 360 degrees. Observe misalignment reading.
f. Move engine or compressor, or both, until dial indicator reading
does not exceed 0.0003 inch for each inch of diameter at indicator
stem (0.0003 cm per each cm of diameter at indicator stem). This
is approximately 0.006 inch (0.015 cm) at outside diameter of
flange B. This corrects angular misalignment.
Bolt heads
should be held
and locknuts
only turned, when tightening coupling bolts.
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).
k. Torque all bolts. See Table 7-2 for recommended torque values.
After several hours of operation, recheck both alignment and bolt
torque.
l. When proper alignment is attained within the previously
specified limits, the laminated rings A must appear vertical and
undistorted. There must be no end thrust due to poor initial
assembly of the coupling.
Coupling bolts
are tightened at
the factory for
shipping purposes only.
When installing coupling, the below values
apply to bolts and locknuts as they are received
from the factory. If any
additional lubricant is
used or if the threads are
wiped dry, these values
must be modified.
Section 5: Installation
Cooper Energy Services Superior Compressors
5/27/03
Page 5-5
3/4
7/8
1
1-1/8
1-1/4
1-3/8
1-1/2
--
16
14
14
12
12
12
12
--
260 (353)
350 (475)
490 (529)
630 (855)
830 (1125)
1100 (1492)
1400 (1898)
1800 (2440)
Cylinder Mounting
Cylinders are normally mounted on the
compressor frame when shipped to a location. Sometimes, because of shipping and packaging
restrictions, cylinders may be shipped separately. If that is your case, the cylinder head and the
piston and rod assembly maybe installed prior to shipment.
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.
5/27/03
Page 5-6
Section 5: Installation
Cooper Energy Services Superior Compressors
5/27/03
Page 5-7
f. After adjusting the piston and rod assembly, recheck the head end and crank end clearances.
g. After setting the piston end clearance, re-torque (Table 7-2 torque values) the balance nut.
5/27/03
Page 5-8
Section 5: Installation
Cooper Energy Services Superior Compressors
5/27/03
Page 5-9
5/27/03
Page 5-10
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.
Preparation For Initial Startup
Prior to startup, the frame lubrication system should be primed by
using the lube oil hand priming pump or automatic priming pump.
Use of this pump will prevent oil starvation in the bearings during
startup, prolonging compressor life. Compressor design, operating
conditions, and the gases being handled all have a significant effect
on how well a lubricant performs in the given application.
CAUTION
Read this manual and familiarize yourself with the
compressor, auxiliary
equipment, and your companys safety procedures
before attempting to start
the equipment.
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.
b. Verify the proper torquing of the foundation bolts.
c. Remove the top cover of the base and the covers for the
crossheads and distance pieces on each crosshead guide.
Thoroughly wipe the interior of the compressor with a lint free cloth
to remove any water or foreign material that may have accumulated
during shipment or storage.
d. Check the crankshaft for web deflection.
e. Check the piston rod runout.
DANGER
Vent the compressor and the process system to the atmosphere
before removing any gas-containing part of the compressor or
its associated piping.
DANGER
Section 6: Installation
Cooper Energy Services Superior Compressos
5/27/03
Page 6-1
i. Check the force feed lubricator for cleanliness and fill to the proper level with oil.
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.)
o. Replace all covers with their respective gaskets and tighten
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.
r. Visually verify that all guards are in place.
s. Unload the compressor for startup by placing the bypass line between the first stage
suction and last stage discharge lines.
t. Verify that suction and discharge block valves are open.
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.
5/27/03
Page 6-2
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
system (when required).
CAUTION
Running compressor at
speeds less than 600 RPM
for longer than 12 minutes
may result in unusual wear
of the piston rings.
Section 6: Installation
Cooper Energy Services Superior Compressos
5/27/03
Page 6-3
DANGER
Do
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.
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
with the lube oil hand priming pump or automatic priming pump
(to prevent oil starvation in the bearings for compressor life).
4. Turn on cooling water supply.
5. Start the unit. Check frame lube oil pressure.
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.
DANGER
Improper setting of variable volume pockets, fixed volume pockets, valve unloaders, or other
unloading devices can result in
damage and/or injury to equipment and/or personnel.Operating
the system without clearance and
loading information can result in
equipment failure due to overload,
excessive rod loads, and high temperatures.
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.
3. Shutdown the compressor driver.
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Page 6-4
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.
Note
Superior attempts to furnish performance curves and/or computer printouts to assist you with compressor 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 Services Aftermarket Sales Office.
Section 6: Installation
Cooper Energy Services Superior Compressos
5/27/03
Page 6-5
5/27/03
Page 6-6
Model
Compressor Cylinder Sizes
Elevation
Ambient Temperature (F or C)
Suction Gas Temperature (F or C)
Specific Gravity
N Value
Design Suction Pressure
Anticipated Suction Pressure
Design Discharge Pressure
Alternate Discharge Pressure
A complete gas analysis must also be supplied.
Send Performance Curves To:
Section 6: Installation
Cooper Energy Services Superior Compressos
5/27/03
Page 6-7
5/27/03
Page 6-8
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. Malfunctions can occur regardless of the designed reliability of the gas compressors. 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.
Crosshead To Guide
0.004 - (0.102)
Section 7: Maintenance
Cooper Energy Services Superior Compressors
5/27/03
Page 7-1
All torques based on lubricated threads, S.A.E. Grade 5 fasteners or better. Subject to change without notice.
Fastener (S.A.E.) Grade 5 or Better)
SIZE
1"-8
350 (475)
1"-14
460 (623)
2"-8
1100 (1491)
1/2"-20
20 (25)
7/8" - 9
300 (407)
5/16"-18
15 (20)
7/8" - 9
200 (271)
5/8"-11
62 (84)
1/2" NPT
20 - 25 (27 - 33)
Check Valves
1/4" NPT
15 - 20 (20 - 27)
Pin Indicators
1/8"-BSP
10 - 15 (13 - 20)
5/8" - 11
62 (84)
3/4" - 10
110 (149)
7/8" - 9
180 (244)
7/8" - 9
200 (271)
7/8" - 9
200 (271)
Handwheel Nut
7/8" - 14
180 (244)
Piston Nut
1-1/2"-12
1200 (1627)
End Plugs
1/4" NPTF
15 - 20 (20 - 27)
3/8"
12 - 18 (16 - 24)
Foundation Bolt
All Fasteners
Size in Inches
1/4
4-6 (5-8)
3/8
12-18 (16-24)
1/2
35-45 (47-61)
5/8
60-70 (81-95)
3/4
120-140 (163-190)
7/8
200-220 (271-298)
260-290 (353-393)
1-1/8
370-410 (502-556)
1-1/4
520-570 (705-773)
1-3/8
700-770 (949-1044)
1-1/2
930-1030 (1261-1397)
THOMAS COUPLING Use when coupling furnished by Superior. All other Thomas recommendations take precedence if
specified otherwise. Refer to Service Bulletin #149 for additional information.
Coupling Sizer
Size in Inches
500
3/4 - 16
265 (359)
550
7/8 - 14
350 (474)
600
1 - 14
490 (664)
3/8-24" UNF
17 - 21 (23 - 28.4)
25 - 30 (33.8 - 40.6)
Page 7-2
0.030 (.762)
0.010 (0.254)
0.008 (0.203)
Maximum cylinder wear factor is a general figure for Superior ductile iron cylinders. Beyond this point of wear the
cylinder may become unsafe for operation. Consult with an authorized Superior machine shop for reconditioning
information.
2Maximum rod wear generally is found in the packing areas. The wear is a general figure that indicates a point at which
the packing will no longer seal and leakage or "blow-by" will occur.
Valve Type
Dimension
(inches)
3 -1/4 "
4"
4-3/8"
4-7/8"
5-1/4"
5-3/4"
6-1/2"
7"
8"
75CFT
90CFT
102CFT
116CGT
127CGT
137CHT
158CJT
169CJT
190CKT
Seat
Retirem
ent
(inches)
1.060
1.060
1.060
1.060
1.060
1.060
.870
.870
.870
Seat
Land
Widths
(inches)
.060
.060
.060
.060
.060
.060
.060
.060
.060
Profile
Depth(P.D.)
(inches)
Pin Height
(P.H.)Recess
Dia.1
Counter
Bore Guide
Ring
Center Stud
and Torque
(ft-lbs)
.020
.020
.020
.020
.020
.020
.020
.020
.020
.335
.335
.335
.315
.315
.315
.315
.315
.315
.512/.516
.512/.516
.512/.516
.670/.673
.670/.673
.670/.673
.670/.673
.670/.673
.670/.673
3/8-24(17-21)
3/8-24(17-21)
3/8-24(17-21)
7/16-20(25-30)
7/16-20(25-30)
7/16-20(25-30)
7/16-20(25-30)
7/16-20(25-30)
7/16-20(25-30)
Torque Recommendations
To insure satisfactory compressor performance and to minimize costly
failures, it is extremely important to tighten all nuts and bolts to the
recommended torque values specified in this section. Additional information
is given in Service Bulletins SB168, SB175, and SB253. Follow the
following general recommendations.
Torque wrenches should not be used to break loose fasteners. Use an
appropriate wrench or breaker bar.
Hand position is critical. Only pull from the hand hold to assure accuracy.
CAUTION
When tightening nuts and bolts
on compressor valve caps, bottles, and flanges care must be
taken to avoid excessive tightening. Over-tightening can result in
unnecessary stress in the cylinder body and, in the case of valve
caps, can result in valve seat distortion.Inadequately torqued
bolts can damage crankshafts,
frames and rods.
Occasionally clean and lubricate the ratcheting head with light oil, NOT
GREASE.
Periodic calibration is essential to ensure accuracy.
Section 7: Maintenance
Cooper Energy Services Superior Compressors
5/27/03
Page 7-3
Page 7-4
Ring
Type*
End Gap
(inches)
4-1/2
0.040 - 0.046
RC
0.095 - 0.105
0.009 - 0.014
0.040 - 0.046
RC
0.106 - 0.116
0.009 - 0.014
5-1/2
0.040 - 0.044
RC
0.127 - 0.137
0.009 - 0.013
0.050 - 0.054
RC
0.139 - 0.149
0.009 - 0.013
6-1/2
0.050 - 0.054
RC
0.139 - 0.149
0.008 - 0.012
0.050 - 0.054
RC
0.151 - 0.161
0.009 - 0.014
7-3/4
0.048 - 0.055
RC
0.168 - 0.178
0.005 - 0.010
8 - 1/4
0.048 - 0.055
RC
0.179 - 0.189
0.005 - 0.010
0.050 - 0.053
RC
0.202 - 0.212
0.008 - 0.013
9 - 1/2
0.050 - 0.053
RC
0.213 - 0.223
0.008 - 0.013
10 - 1/2
0.094 - 0.098
R
C
0.293 - 0.313
0.178 - 0.198
0.017 - 0.025
0.009 - 0.013
11
0.094 - 0.098
R
C
0.307 - 0.327
0.188 - 0.208
0.017 - 0.025
0.009 - 0.013
12
0.094 - 0.098
R
C
0.328 - 0.348
0.268 - 0.288
0.013 - 0.022
0.009 -0.017
12 - 1/2
0.094 - 0.098
R
C
0.341 - 0.361
0.279 - 0.299
0.017 - 0.022
0.009 -0.017
13 - 1/2
0.094 - 0.098
R
C
0.368 - 0.388
0.301 - 0.321
0.013 - 0.022
0.009 - 0.017
14
0.094 - 0.098
R
C
0.382 - 0.402
0.312 - 0.332
0.013 - 0.022
0.009 - 0.017
15 - 1/2
0.094 - 0.097
R
C
0.432 - 0.452
0.353 - 0.373
0.015 - 0.023
0.009 - 0.017
16
0.094 - 0.097
R
C
0.446 - 0.466
0.364 - 0.384
0.015 - 0.023
0.009 - 0.017
17 - 1/2
0.110 - 0.113
R
C
0.486 - 0.506
0.396 - 0.416
0.015 - 0.024
0.010 - 0.017
18
0.110 - 0.113
R
C
0.499 - 0.519
0.408 - 0.428
0.015 - 0.024
0.010 - 0.017
19 - 1/2
0.110 - 0.113
R
C
0.532 - 0.552
0.434 - 0.454
0.015 - 0.024
0.010 - 0.017
20
0.110 - 0.113
R
C
0.546 - 0.566
0.445 - 0.465
0.015 - 0.024
0.010 - 0.017
Section 7: Maintenance
Cooper Energy Services Superior Compressors
5/27/03
Page 7-5
Valve-in-Head Cylinders
Class
Fastener
Size
Torque
14.00"
438 DC
1" - 8
290 ft-lb*
14.75"
437 DC
1" - 8
290 ft-lb*
15.50"
436 CC
1" - 8
290 ft-lb*
15.50"
417 CC
7/8" - 9
300 ft-lb*
16.00"
418 CC
7/8" - 9
300 ft-lb*
17.50"
419 CC
1" - 8
375 ft-lb*
18.00"
420 CC
1" - 8
375 ft-lb*
19.50"
421 CC
1" - 8
375 ft-lb*
20.00"
422 CC
1" - 8
375 ft-lb*
Repeat this schedule when the compressor is rebuilt, overhauled, or has major repairs.
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.
The nuts holding the compressor cylinder heads must be torqued in a specific pattern. Use the
diagonal (Figure 7-9) or cross pattern sequence for all bolting except for the valve-in-head(Table 7-7
& Figure 7-8).
Page 7-6
Precautions
DANGER
When work is being done
on the compressor, the
driving unit must be blocked in such a way that the
compressor cannot turn
over. Block valves must be
closed on the suction and
discharge lines. Air or gas
must be bled off from the
cylinders. Precaution must
be taken to prevent the
opening of any valve which
would release pressure
against a piston, causing it
to rotate the unit at a critical moment.
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.
a. Block the flywheel to prevent rotation of the compressor and driver.
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.
c. Eliminate all internal pressures by removing cylinder indicator plugs or vent through indicator
cocks, if provided.
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, dirt, dust or grit.
f. Never file, grind or scrape any lubricated parts (i.e. bearing shells or saddles).
g. Never distort or mark the piston rod with any tool or device. Rods that are bent or have burrs will
damage the packing or prevent it from sealing. In severe cases, the rod could break.
h. Never torque or tighten any nut, cap screw or stud if threads or 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.
j. Do not refinish worn valve plates.
k. When reassembling parts during maintenance, replace all worn or damaged gaskets and seals.
l. Always install new cotter pins or lock wire.
Section 7: Maintenance
Cooper Energy Services Superior Compressors
5/27/03
Page 7-7
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.
o. After completing maintenance, remove any locking or blocking devices before attempting to rotate
the equipment.
Maintenance
Page 7-8
Bearing Clearance
To check bearing clearances, use a dial indicator along with a hydraulic jack proceeding as
follows:
a. Remove the top cover of the frame to gain access to the Figure 7-13 Dial Indicator
bearings and crankshaft.
b.Use a magnetic base to secure the dial indicator
(Figure 7-13) to the bearing cap. Mount the indicator
so the button contacts the crankshaft at its highest
point. Depress the button until the dial makes one
complete revolution, then set the pointer to zero.
c. Use a suitable hydraulic jack that will fit between the
crankshaft and frame bottom (about 4"-102mm).
Position it as close as possible to the bearing being
checked.
d. Support the jack with a piece of wood. Jack the crankshaft up and down sufficiently to get a
clearance reading on the indicator.
e. Compare the clearance reading with the tolerance value given in Table 7-1. If the clearance reading
exceeds the maximum limit, replace the bearing with two new bearing shells.
Section 7: Maintenance
Cooper Energy Services Superior Compressors
5/27/03
Page 7-9
CAUTION
The main bearing and connecting rod cap bolts must be properly torqued and maintained at all
times. Under no circumstances
should the compressor be
allowed to run without the proper
torque applied to these critical
components.
a. Remove a bearing shell by inserting the neck of the main bearing removal Figure 7-14
tool (Figure 7-14) into the oil passage hole in the crankshaft journal.
Main Bearing
When the unit is rolled over, the tool pushes the shell out from underneath Removal Tool
the journal and around to the top where it can be removed. Using the same
steps, you can install a new set of bearings.
b. Change the connecting rod bearings by following the same precautions in
Section 2. Roll the connecting rod until it reaches its highest point on the
journal shaft. This offers easy access to the rear cap bolts. Support the
shaft with a sling or some safe means of suspending the rod for easy access to both bearing halves.
c. With the rod supported, remove the bearing cap and bearing half. Taking
extreme care and keeping clear of the rod assembly, continue to roll the
crankshaft slightly back to access the other bearing half.
DANGER
Always support the connecting rod so it can not drop and
damage equipment or cause
injuries.
d. Carefully install the new bearing against the exposed half bore in the
connecting rod. The tang recesses within the rod should support the bearing
so you can roll the crankshaft carefully back into position against the supported rod.
e. Complete the assembly process by putting the other half of the bearing and
the cap back into position and tightening the two bolts to their proper
torque as stated in Table 7-2.
Page 7-10
Connecting Rods
CAUTION
Take extreme caution to adequatedly support the connecting rod.
If care is not taken during the
bearing removal prcess, personal
injury and equipment damage
could result.
j. Bar the compressor over until the crosshead pin is accessible through the
crosshead cover opening.
Section 7: Maintenance
Cooper Energy Services Superior Compressors
5/27/03
Page 7-11
Inspection
Inspect the connecting rod and compare the
results to the data in Table 7-18 to assure that parts have not exceeded
maximum wear limitations. If you discover the crosshead pin bushings need
changed or the rod needs re-bored to restore proper running clearance, send
the rod to the nearest CES authorized distributor for prompt attention.
Table 7-18 Clearances for Connecting Rod Components Inspection
purposes only
Item
.0005 (0.0127)
Operating Clearance
CAUTION
If you need to change the crosshead pin bushings, contact your
nearest CES distributor to
arrange for transportation or possible route truck pickup. The
bushings need to be frozen into
the connecting rod, then bored
for proper running clearance by
an authorized machine shop.
Page 7-12
Installation
Press-fitting bushings into the connecting rod assembly is sufficient in most cases. But we
recommend that you shrink-fit the bushings by freezing the bushings in dry ice for 30 minutes.
During this time, preheat the eye of the rod to 300-350 F. When the rod is preheated, lay it flat on a
smooth surface. This allows the edge of the bushing to fit flush with the edge of the eye of the rod.
Since you're installing two bushings (one for each side of the eye), it's important to align them
properly. Insert the bushings so that the joint of the bushings rests either on top of the eye (0) or on
the bottom of the eye (180). Face the open end of the bushings'oil grooves toward the inside of both
bushings. This allows lubrication to travel from the lubricating point within the eye of the rod to the
entire pin area. The bushings are now ready to be bored.
At assembly, "mike" the crosshead pins to assure they're the correct size and
that the proper pin-to-bushing clearance is held. The following procedure
guides you through reinstallation of the connecting rod assembly:
a. Have bushings (1) (Figure 7-15) installed into connecting rod (3) at a
CES authorized distributor.
CAUTION
The complete bearing set (two
halves) must be replaced as a set.
Replacement of only one bearing
half may cause serious damage to
the connecting rod and/or crankshaft.
CAUTION
The main bearing and connecting
rod cap bolts must be properly
torqued and maintained at all
times. Under no circumstances
should the compressor be allowed to run without the proper
torque applied to these critical
components. Damage to equipment may result if the torque
specification on any item is
ignored.
Section 7: Maintenance
Cooper Energy Services Superior Compressors
5/27/03
Page 7-13
l. Install the top cover (1) using screws (4) and washers (2) and (3) (Figure 7-16).
CAUTION
Do not place any wrenches
directly on the piston rod surface.
Damage to the rod surface, which
contacts the rod packing, may
result in a bad seal.
Page 7-14
Name
Valve removal bracket
Valve removal tool
Main bearing removal tool
Crankshaft seal expander
Rod insertion tool
Auxiliary lube drive shaft seal installer
Crosshead tool handle
Crankshaft seal installer
Crosshead tool
Spanner wrench
Jam nut wrench
i. Turn the piston and rod assembly out of the crosshead using the spanner wrench (Figure 7-20).
j. Position the crosshead as nearly aligned with the crosshead cover opening as possible
k. Carefully rotate the crosshead with special tools (Figure 7-20) until you can remove it between the
edges of the crosshead guides and out the crosshead cover opening.
l. Referring to (Figure 7-19), remove screws (1) and crosshead shoes (2)
m. Remove screws (8) and balance weight(s)(6).
Inspection
Complete your crosshead inspection by following these steps:
a. Clean all parts before inspecting.
b. Check all parts for physical distortion, wear, cracks, and pitting.
c. Check sealing surfaces for nicks, burrs, and scratches which may damage seals and O-rings.
d. Refer to Table 7-1 check important clearances.
Installation
The following procedure describes how to reinstall the crosshead components:
a. Install the balance weight(s)(6) onto the crosshead (3) and secure with screws (8) (Figure 7-15).
b. Install crosshead shoes (2), securing with screws (1). Refer to Table 7-2 for correct torque.
c. With access through the crosshead cover opening, use the special tools shown in Figure 7-20 to
install the crosshead onto the connecting rod.
Section 7: Maintenance
Cooper Energy Services Superior Compressors
5/27/03
Page 7-15
d. Tighten the jam nut (7) with the wrench provided. See Table 7-2 for proper torque.
e. Install crosshead pin (4) and snap rings (5).
f. Referring to Figure 7-17, install crosshead cover (10) and O-ring (9),
securing with screws (13) and washers (11) and (12).
Crossheads and
balance weights are
stamped with throw
numbers and must
be replaced accordingly.
g. Re-check the pin-to-bushing and shoe-to-guide clearances, and compare these measurements to
those recommended in this section.
When using the crosshead installation handles, more care and feel is required. DO NOT USE
FORCE as this is the first indication that the job is being done incorrectly and damaged crosshead
shoes may result. The correct procedure is to stand to one side of the crosshead guide and feed the
crosshead across, attempting to roll it in at short intervals. From the proper position, the crosshead
will roll in easily without damage to the shoes.
During the reassembly procedure, the machined face of the jam nut must be toward the crosshead.
Check piston end clearances and then make sure that the jam nut is torqued properly (Table 7-2)
against the crosshead.
Crankshaft
The crankshaft Figure 7-21 is a one-piece design. Drilled holes carry lubricating oil from the main
bearings to the crank pin journals and bearings. Lubrication continues from this point to the crosshead
end of the connecting rod. Ample lubrication is also provided to the pin and rod bushings.
The crankshaft extends beyond the frame at
the opposite end of the oil pump. A hub
mounted on this extension allows the
compressor to be coupled with the driver.
At the point where the crankshaft extends
beyond the frame wall, a seal prohibits oil
leakage. This seal allows removal and
maintenance using special tools (Figure 720). Remove the crankshaft to replace this
seal. We recommend crankshaft removal be
performed by authorized CES distributor.
The crankshaft seal should be changed
whenever you detect leakage. The steps for
removal, inspection, and installation are
presented in the following procedures.
Page 7-16
DANGER
Take extreme caution to adequately support the rod. If care
is not taken during the bearing
removal process, personal
injury and equipment damage
could result.
e.Referring to Figure 7-16, remove screws (4), washers (2) and (3), and top cover (1).
f. Referring to Figure 7-17, remove screws (1), lockwashers (2) and drive-end cover (3).
g. Again referring to Figure 7-17, remove spacer bar nuts (7) and o-rings (6).
h.While holding the spacer bar (4) with one hand, withdraw the spacer bar stud (5) and remove both
the bar and stud.
i. Referring to Figure 7-15, bar the compressor over to access the connecting rod bolt nuts. Remove
nuts (7), washers (6) and rod caps (5).
j. Bar the compressor over to separate the crankshaft from the connecting rod, carefully laying the rod
end in the bottom of the base sump.
k. Referring to Figure 7-21, remove bolts (1), washers (2) and main bearing caps (3).
l. Remove bearing shells (4) from the bearing caps.
m. Remove the force-feed lubricator as described later in this section.
n. Remove the lube oil pump as described later in this section.
o. Referring to Figure 7-22, remove screw (10), lockwashers (9) and auxiliary end cover (7).
p. Remove screws (4) and stub shaft gear assembly (1).
q. To remove the crankshaft, attach a strong web lifting strap to the crankshaft (7) at two points.
Place the stap over the hook of a hoist and slowly raise the crankshaft out of the base. Be careful
not to damage any bearing surfaces. Make sure the hoist lifting capacity exceeds 600 lb (272 kg).
r. Remove bearing shells (4) and thrust bearings (8) from the base.
Section 7: Maintenance
Cooper Energy Services Superior Compressors
5/27/03
Page 7-17
Inspection
Follow these steps to complete crankshaft inspection:
a. Clean all parts before inspecting.
b. Check all parts for physical distortion, wear, cracks, and pitting.
c. Check sealing surfaces for nicks, burrs, and scratches which may damage seals and O-rings.
d. Examine sediment adhering to the drain plug for accumulations of grit or fine metal particles,
which may indicate actual or potential component failure.
e. Examine bearings for rust, pitting, brinelling, abrasion and serious discoloration. Also inspect for
cuts or grooves parallel to bearing rotation.
f. Check gears for wear that prevents correct meshing.
CAUTION
b. Install the new crankshaft and lubricator drive shaft seals using appropriate tools.
c. Attach a strong web lifting strap to the crankshaft (7) at two points. Place the strap over the hook of
a hoist and slowly lower the crankshaft into the base. Be careful not to damage any bearing
surfaces.
d. Assembly gear (2) onto stub shaft (3) (Figure 7-22).
e. Install stub shaft assembly (1) with screws (4).
f. Apply sealant to the auxiliary end opening.
g. Install auxiliary end cover (7), securing it with the top four lockwashers (9) and screws (10).
h. Inspect and install the lube oil pump (Figure 7-28).
i. Inspect and install the force-feed lubricator (Figure 7-22).
j. Install the bottom four lockwashers (9) and screws (10) to the auxiliary end cover (7) (Figure 7-22).
Page 7-18
The RAM compressor cylinders are lubricated with a force-feed lubricator (Figure
7-22). It is driven directly by a coupling off
the crankshaft drive gear. During periodic
overhauls, check the coupling for wear.
Refer to ES1002 for the amount of cylinder
oil required by a particular packing case or
cylinder. A gradual pressure loss or leaking
O-ring seals requires that the lubricating
pump be rebuilt.
Removal
Steps to remove the force-feed lubricator:
a. Shutdown the driver and compressor, and isolate it from the power source.
b. Place a suitable container under the lubricator and remove drain plug to drain the oil. Dispose of
the oil according to local or offshore regulations.
Section 7: Maintenance
Cooper Energy Services Superior Compressors
5/27/03
Page 7-19
Inspection
c. Check sealing surfaces for nicks, burrs, and scratches, which may damage the seal.
d. Examine sediment adhering to the drain plug (Figure 7-24) for accumulations of grit or fine metal
particles. They may indicate actual or potential component failure.
e. Examine tubing for kinks or leaks. Inspect fitting threads for damage.
Installation
Refer to Figure 7-22 as you replace the lubricator, and follow these steps:
a. Install the lubricator bracket with screws and lockwashers.
CAUTION
When heating anything to a
high temperature, take the
necessary precautions to
prevent burns.
b. Heat the drive gear to between 470 F and 600 F (243 C and 316 C). Install the gear onto the
stub shaft.
Page 7-20
Section 7: Maintenance
Cooper Energy Services Superior Compressors
5/27/03
Page 7-21
d. Remove screws (15), lockwashers (7) and oil header flange (14).
e. Remove the reducer bushing (2) from the reducing tee (1).
f. Remove the reducing tee and close nipple (3).
g. Remove the elbow fitting (8) and nipple (9).
h. Unscrew the filter housing (18) from the filter head (4).
i. Remove the filter element (19) and O-ring (20) from the housing.
j. Remove the oil filter head (4) from the bracket (5) by removing screws (6) and lockwashers (7).
k. Remove the bracket (5) by removing screws (6) and lockwashers (7) that secure it to the base.
Inspection
Follow these steps to inspect the oil filter:
a. Examine the filter and housing for metal particles, foreign material, or other contamination.
b. If metal particles are found, search the frame further for the source of the debris before restarting.
c. Check all parts for physical distortion, wear, cracks and pitting.
d. Inspect fitting threads for damage.
Page 7-22
Section 7: Maintenance
Cooper Energy Services Superior Compressors
5/27/03
Page 7-23
Page 7-24
f. Remove nipple (19), elbow (18), nipple (15), threaded tee (21), nipple (23) and bushing (24).
g. Remove screws (5) and lockwashers (6).
h. Carefully pull pump (2) and gear (4). Leave adapter (9) doweled in place.
i. Pry gear (4) from the pump shaft.
j. Remove bushing (13), magnetic plug (14) and strainer screen (12) from strainer (11).
Inspection
Steps for inspecting the lube oil pump.
a. Examine the strainer screen (12) and magnetic plug (14) for debris. If you discover debris, inspect
the oil filter housing and element (see parts 18 and 19 in Figure 7-25). Check the frame for source of
the debris.
b. Clean all other parts before inspecting.
c. Check all parts for physical distortion, wear, cracks, and pitting.
d. Check sealing surfaces for nicks, burrs, and scratches which may damage seal.
e. Examine tubing for kinks or leaks.
f. Inspect fitting threads for damage.
g. Check gears for wear that prevents correct meshing.
Installation
Section 7: Maintenance
Cooper Energy Services Superior Compressors
5/27/03
Page 7-25
c. Install the pump to the adapter plate (9) with screws (5) and lockwashers (6).
d. Apply sealant to the auxiliary drive opening of the base.
e. Install the pump so that gear (4) meshes with the auxiliary end of the crankshaft. You may have to
twist the pump a little to allow the gears to mesh.
f. Check the gear backlash (see the gear lash measuring procedure below). Compare the reading to
the recommended value in Table 7-1.
g. Reassemble strainer (11), strainer screen (12), bushing (13) and magnetic plug (14).
h. Install bushing (24) and nipple (23).
i. Install threaded tee (21), nipple (15), elbow (18) and nipple (19).
j. Install nipple (10), strainer (11), nipple (15), check valve (16), nipple (17), elbow (18) and nipple
(19) - if these components were removed.
k. Refer to Figure 7-27 and install tubing (3) and (8).
l. Install coupling (20).
Page 7-26
CAUTION
If the spacer plate and/or end
plate are adjusted, you must
re-dowel pin them before
operating the compressor.
If you change the pump gear,
it must be heated to 470F 600F and shrunk fit onto
The correct sequence for measuring the oil pump gear backlash on a RAM 54
compressor frame is 2, 1, 4 and 3. Since the oil pump gear on a RAM 52
compressor frame is smaller, the correct sequence for measuring backlash is 2,
1, 4, 3, 2 and 1. The backlash at each position should be 0.0006 to 0.014 inch,
with a variation of no greater than .004"
.
i. Repeat adjustments until the backlash readings are 0.006 to 0.010 inch at all
positions as prescribed for each RAM model.
j. If backlash is more than .014 on a new and over .020 on an old compressor
change the parts. Repeat the backlash process after parts are replaced. The
readings should be .010 to .014 with a variation of .004.
Section 7: Maintenance
Cooper Energy Services Superior Compressors
5/27/03
Page 7-27
Page 7-28
Section 7: Maintenance
Cooper Energy Services Superior Compressors
5/27/03
Page 7-29
b. Mount steel bar (G) in the manner illustrated. Putting a 1-1/2-6 UNC tapped hole at its midpoint will
permit a standard 1-1/2 UNC cap screw to be used as a jackscrew.
c. Tighten nuts on cap screws (H) per torque values given in Table 7-2.
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" pipe tap (F) in the hub.
f. Operate the hand pump until the hub becomes loose and slides against the lock nut (E).
g. Remove the jackscrew and bar arrangement.
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.
Install the coupling hub onto the crankshaft as follows:
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" (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).
f. Hold hub in position until it is cool enough to engage the crankshaft.
g. When hub has cooled to room temperature, install lock nuts and Nylock setscrews.
Page 7-30
00768
00769
Section 7: Maintenance
Cooper Energy Services Superior Compressors
5/27/03
Page 7-31
t
o
r
q
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e
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v
00770
er face with heavy corrosion along area of break. This failure is typical of discs that have been in service for years or have been operating
in an offshore environment. Breaks will first appear in the outer discs
and will progress into the disc pack. If excessive corrosion exists, they
should be replaced with stainless steel plating.
! Caution
Figure 7-41 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.
Page 7-32
CAUTION
The cylinder head must be
properly indexed on the mounting studs so that the valve cutouts in the head align with valve
locations in the cylinder body.
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.
Section 7: Maintenance
Cooper Energy Services Superior Compressors
5/27/03
Page 7-33
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 order to reduce cylinder bore wear, Superior designed every piston to operate with rider
compression rings or rider rings. The rider compression rings and rider rings are not collapsible in the
piston groove, thus supporting the piston in the cylinder bore.
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 CES authorized distributor for wear
limits for your specific cylinder size and application.
Page 7-34
Section 7: Maintenance
Cooper Energy Services Superior Compressors
5/27/03
Page 7-35
Figure 7-45
00776
Page 7-36
CAUTION
As a general guide,
temperatures not
tolerated by resting your
hand on the packing case
flange, after the unit is
shut down, indicate to
fast of a wear rate. For a
lubricated packing,
check to see if the
lubrication rate is set
properly per ES1002.
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 7-45).
Valve Replacement
Proceed with valve removal in the following manner(Figure 7-46):
Section 7: Maintenance
Cooper Energy Services Superior Compressors
5/27/03
Page 7-37
a. Loosen bolts or nuts holding valve cap. DO NOT remove completely until after cap is pulled out far
enough to vent any pressure trapped under cap.
b. Remove valve cap, inspect o-ring, place
o-ring if defective.
Figure 7-46
Valve Installation
Before removing
any gas containing
part of the compressor or associated gas piping system, vent
compressor and system to
atmospheric pressure.
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.
m. Grease or oil the o-ring on the valve cap. Place new gasket in place on valve cap, as applicable.
Force the cap into place by torquing the nuts or screws evenly to the values listed in Table 7-2.
Page 7-38
Section 7: Maintenance
Cooper Energy Services Superior Compressors
5/27/03
Page 7-39
Table 7-48
Alarm/Shutdown
Alarm Point
Shutdown Point
Vibration
Nominal
Gas Temperature
Water Temperature
Tin or Tout
Gas Pressure
5% below PS
5% above PD
10% below PS
10% above PD
Page 7-40
Daily
Weekly
X
X
LUBRICATION SYSTEM
Check oil levels, oil level regulator, and oil sight level.
X
X
Change compressor oil and filters elements after the first 400 hours of compressor operation. Oil and filter change periods can then
be extended out to 2000 hours of operation. Change lube oil filters when differential pressure reaches 12 to 15 psi.
Replace O-rings.
X
X
Check temperatures of coolant to and from cylinders, lube oil cooler, and
packings.
X
X
Check one compressor valve on each stage. Inspect for broken plates, broken springs, and trapped solids or liquids.
Remove the distance piece cover from the crosshead guide and inspect the
packing area on each piston rod.
X
X
Remove head and piston of the first stage cylinder. Check cylinder bore,
piston rings, packing rings, piston, and rod bearing.
Visually inspect frame interior for bearing material in frame, gear tooth
condition, crosshead shoe and guide condition.
X
X
Section 7: Maintenance
Cooper Energy Services Superior Compressors
5/27/03
Page 7-41
Troubleshooting
Troubleshooting is the process of finding operational problems. This section describes the difficulties
which may arise during operation of a compressor, the typical origins or sources of these problems
and suggestions on how to repair the trouble. The following steps should be followed in all
troubleshooting activities:
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.
c. Replace all defective or damaged parts.
d. Return the unit to service and verify that normal operation is resumed.
Tables 7-50 through 7-54 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 CES
distributor for possible field assistance.
Table 7-50 Compressor Frame Troubleshooting
Symptom
Compressor
will not turn
over
Possible Cause
Mechanical
seizure of
compressor.
Tripped
shutdown
device.
Foreign material
(water, non-lube
packing, etc.) in
cylinders.
Improper pistonto-cylinder end
clearance.
Compressor Opposing
vibration
cylinders are out
of balance.
Worn bearings.
Improper
compressor
installation and
alignment.
Gas pulsation.
Loose valves.
Page 7-42
Potential Damage
Seized crosshead, rods, main
bearings.
Defective shutdown device.
Corrective Measure
Replace all defective parts. Check compressor for proper
crankshaft alignment, piston rod runout, and lube oil
system operation.
Check the control system and device for proper operation.
Possible piston or rod damage. Replace any damaged parts and properly set the pistonto-cylinder end clearances.
Foundation cracking, weld
cracking, or foundation bolt
failure.
Possible Cause
Lack of oil
Potential Damage
Scored bearings, crankshaft,
crosshead shoes and pins.
Possible seizure of
compressor.
Same as above.
Clogged strainer or
filters.
Lube oil pump or drive Same as above.
gear.
Air leak in suction piping. Same as above.
Low lube oil Low oil level.
pressure
Corrective Measure
Check all lubricated surfaces and replace parts as
required. Fill with oil to the proper level.
Scored bearings, crankshaft, Check all lubricated surfaces. Fill with oil to the
crosshead shoes, and pins. proper level.
Seizure of compressor is
possible.
Same as above.
Check all lubricated surfaces and replace parts as
needed. Replace filter element and/or strainer.
Same as above.
Find and stop leak.
Same as above.
Same as above.
Corrective Measure
Clean suction line and screen, if
dirty.
Defective or
missing valves
Deposits on
valves
Open or
defective
clearance pocket
Defective piston High discharge temperatures
rings
Low compressor cylinder Worn piston
Piston, ring, and bore overheating
discharge pressure
rings
Defective or
Insufficient rod load reversal. This can cause
missing valves damage to the crankshaft from excessive
heating, seizure of the crosshead pin, as well
as damage to the piston rods, crossheads,
crosshead guides, and connecting rods.
Collateral damage from broken parts
entering the cylinder bore
Open or
Same as above
defective fixed/
variable pocket
head
Section 7: Maintenance
Cooper Energy Services Superior Compressors
Replace rings
Replace with new rings
Replace plates, springs, or any
other worn, broken or missing
parts
5/27/03
Page 7-43
Corrective Measure
Insufficient capacity
Same as above. Also, check for valve seat Remove valve and retainer;
damage, broken valve bodies and retainers replace any broken parts. Dye
check the cylinder valve seat.
Install new valves and properly
torque down valve caps
Improper setting High rod loads, insufficient rod load reversal, Increase setting of variable
of volume
or discharge temperatures exceeding the
volume pocket(s) or open fixed
pockets.
maximum working pressure.
volume pocket(s) until discharge
pressure decrease to a proper
level. Unload the crank ends if this
does not reduce pressure. Open
all pockets before starting. Always
follow performance curves
provided with your compressor.
Improper
Same as above.
Open valve.
positioning in
piping
downstream of
the compressor.
Clogged cooler. Same as above.
Clean coolers.
Dirty suction
Possible cylinder heat buildup.
Clean scrubber.
scrubber.
Worn piston
Piston, rings, and bore overheating.
Replace rings.
rings.
Restricted
Clogged suction screens.
Clean suction line and screen, if
suction line or
dirty. Replace screen if damaged.
filter screens.
Defective or
Insufficient rod load reversal. This can cause Replace plates, springs, or other
missing valves. damage to the crankshaft from excessive
worn or broken parts.
heating, seizure of the crosshead pin, as well
as damage to the piston rods, crossheads,
crosshead guides, and connecting rods.
Collateral damage from broken parts
entering the cylinder bore.
Open or
Same as above.
Replace defective parts.
defective fixed/
variable pocket
head.
Suction valve in Same as above.
Properly install valves. Replace
discharge or
any damaged parts.
discharge valve
in suction.
DANGER
Loose valves.
Page 7-44
Corrective Measure
Defective
discharge valves
High discharge
pressure
Low suction
pressure
High suction
pressure
Improper water
cooling
Possible Cause
Suction side air leak.
Potential Damage
Pump rotor and drive gear
damage and lubricated part
damage.
Damage to relief valve and
lubricated parts damage.
Cylinder scoring, valve damage,
scored or bent rods and
crankshafts. Blown off cylinder
head.
Bent rods and crankshaft.
Corrective Measure
Find and stop leak in line.
Piston seizure.
Loose piston.
Same as above
Same as above
Section 7: Maintenance
Cooper Energy Services Superior Compressors
5/27/03
Page 7-45
Table 7-54
Symptom
Vibration
Low capacity
High load
Possible Cause
Piping system improperly
supported.
Loose piston or piston rod.
Page 7-46
Replace gear.
Gear damage.
General Troubleshooting
High discharge
temperature
Potential Damage
Corrective Measure
Damage to gasket seal surface Tighten head.
Potential Damage
Potential failure of piping
system.
Piston seizure, contact between
piston and cylinder heads, bent
piston rods, or failure of running
gear.
Same as above.
Corrective Measure
Install proper piping support to raise
the frequency of the vibrations.
Replace all damaged components.
Tighten components properly.
Piping strain.
Tighten.
Loss of production.
Failure of individual
components.
Causes abnormal cylinder
capacity performance.
Overload.
Tighten nuts.
Same as above.
Same as above.
Same as above.
Same as above.
Damage to cooler.
Table 7-54
Symptom
High discharge
temperature
(continued)
Liquid in cylinder
General Troubleshooting
Possible Cause
Insufficient lubrication
(lubricated cylinder only).
Potential Damage
Same as above.
Corrective Measure
Increase lubrication.
Same as above.
Same as above.
Same as above.
Same as above.
Improper assembly.
Same as above.
Insufficient control. Pressure Same as above.
or leaking seal in variable
volume pocket unloader.
Rupture disk ruptures Disk rating incorrect.
Overheated and/or damaged
packing. Scored cylinder walls.
Clogged filter.
Same as above.
Blocked main line.
Same as above.
Blocked secondary line.
Same as above.
Divider block does not cycle. Same as above.
Section 7: Maintenance
Cooper Energy Services Superior Compressors
5/27/03
Page 7-47
Page 7-48
ICAUTION
Proper length of
studs and bolts is
important for
proper thread
engagement.
Before removing
any studs, measure stud height
from machined
surface and position replacement
stud to same
height.
RAM-6/1/04
Page 8-1
Illustration
5500-002
RAM52
Item Material
Z5500-COMA-002
1 Z11TB1210MA
2 Z03PP1000CA
4 Z620-155-001
5 Z00FW0616P0
6 Z01LW0600P0
7 Z01CS0610PC
9 Z904-181
10 Z914-176-001
11 Z01VS0604C0
12 Z600-055
13 Z900-835-070
14 Z600-054
25 Z04SS1228PC
29 Z600-062
30 Z600-053
42 Z600-038
43 Z04CS0508PC
67 Z02PP0600SP
Z620-244-001
Z5500-T01A-002
26 Z600-370
Z5500-T02A-002
39 Z600-327
Z5500-T03A-002
40 Z600-520-001
41 Z600-006
Z5500-T04A-002
3 Z600-465-001
15 Z625-500-001
16 Z02MS5206PC
Z5500-T05A-000
18 Z600-533-001
19 Z600-044-001
31 Z600-028
33 Z01CS0614PC
34 Z01DP041200
44 Z600-044-002
Z5500-T07B-000
46 ZBM-10046
47 Z600-123
48 Z600-329-001
49 Z620-116-004
50 Z600-121
51 Z600-122
52 Z600-124
53 Z600-318
54 Z600-187
55 Z600-306
56 Z600-307
Serial #04R1024/04R1027/04R1030
Material description
COMMON PARTS
BUSHING PIPE REDN
PLUG PIPE
NAMEPLATE
WASHER PLAIN
LOCKWASHER SPLIT
BOLT HEX HEAD
BREATHER
PLATE WARNING
SCREW DRIVE
NUT
SEAL O RING
STUD DOUBLE END
SCREW SET
GAUGE
SPACER SLEEVE
GEAR
SCREW SOCKET HD
PLUG PIPE
NAMEPLATE COMPRESSOR
FRAME
FRAME COMPRESSOR
CRANKSHAFT
CRANKSHAFT COMPRESSOR
MAIN BEARINGS
SHELL BEARING
BEARING THRUST
TOP COVER
COVER RECP COMPR
HANDLE
SCREW MACHINE
END COVERS - RAM52/4
COVER
SEAL
COVER RECP COMPR
BOLT HEX HEAD
PIN DOWEL
SEAL
SPECIAL TOOLS - RAM
FITTING GREASE
WRENCH OPEN END
ADAPTER TOOL
PROTECTOR
TOOL
TOOL
WRENCH SPANNER
TOOL
TOOL
TOOL VALVE PL
BRACKET
Qty
1
2
3
1
30
68
38
1
1
4
4
4
2
4
1
2
1
3
2
1
1
1
1
1
1
4
2
1
1
2
12
1
1
1
1
12
2
1
1
1
1
1
1
1
1
1
1
1
1
1
UOM
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
57
58
59
60
61
62
65
66
68
69
5501-002
1
2
4
5
11
12
13
14
19
a
b
c
d
e
3
5502-002
1
5
6
7
133
134
10
11
a
b
c
15
16
18
19
20
24
25
26
29
Z600-308
Z600-309
Z600-322
Z600-323
Z600-324
Z600-460-001
Z620-199-001
Z620-200-001
Z620-203-001
Z600-557-001
Z5501-COMA-000
Z625-434-004
Z600-018-001
Z600-017
Z024-876
Z029-281
Z01VS0808P0
Z600-034
Z900-835-071
Z5501-T01A-000
Z600-524-001
600-523-001
01en1600pf
01dp060800
600-019-002
034-575-003
Z5501-T02A-000
Z600-014
Z5502-T01A-002
Z600-472-004
Z03CS0812PC
Z01LW0800P0
Z03CS0618PC
Z01RP241600
Z01RP163200
Z900-835-033
Z5502-T02A-000
Z028-026-03
Z600-049
z600-319
z600-321
z600-320
Z11TN1013SP
Z600-335
Z11TE1000MA
Z028-006-29
Z031-863-006
Z11TT1000MA
Z12TN1036SP
Z11TB1210SP
Z12TT1006MA
Z5502-T03A-000
BRACKET
BRACKET
BRACKET
BRACKET
BRACKET
TOOL
GAUGE
GUIDE
PULLER
WRENCH OPEN END
COMMON PARTS
SCREW SOCKET HD
SHOE CROSSHEAD
PIN CROSSHEAD
RING RETAINING
NAMEPLATE
SCREW DRIVE
COVERDOOR CROSSHEAD
SEAL O RING
CONNECTING RODS
CONN ROD MAST COMPR
BOLT HEX HEAD
NUT
pin
BUSHING
washer
CROSSHEAD - LIGHT - 57 LB.
CROSSHEAD
LUBE OIL PUMP - RAM52
PUMP ASSY LUBE OIL - RAM52
SCREW SOCKET HD
LOCKWASHER SPLIT
SCREW SOCKET HD
PIN ROLL
PIN ROLL
SEAL O RING
LO PIPING - UPSTREAM - STL
PIPE STEEL
STRAINER OIL
screen
bushing
plug magnetic
NIPPLE PIPE
VALVE CHECK
ELBOW PIPE THDED
NIPPLE PIPE
JOINT
TEE PIPE THDED
NIPPLE PIPE
BUSHING PIPE REDN
TEE PIPE THDED
LUBE OIL FILTER - MOUNTED
1
1
1
1
1
1
1
1
1
1
2
8
4
2
4
2
4
2
2
2
2
2
2
2
2
2
2
2
1
1
4
4
6
6
2
1
1
1
1
1
1
1
5
1
4
2
2
1
1
2
1
1
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
34 Z600-338
Z01CS0608PC
37 Z600-346-001
38 Z758-220
Z5502-T04A-000
Z028-006-41
41 Z13TE1000MA
47 Z12TN1032SP
49 Z12TN1038SP
50 Z600-334
51 Z01CS0612PC
ZBM-11959-10
Z620-228-001
Z900-902
Z620-227-001
Z11TB0403SP
Z12TN0112SP
Z061-652-035
Z11TB1004SP
Z5502-T06B-000
69 Z600-276
70 Z600-275
73 Z061-385-008
76 Z11TB0802MA
77 Z600-059
Z5502-T07A-000
15 Z03PP0300SP
28 Z03PP1200CA
Z5502-T08A-000
23 Z03PP1600CA
Z5502-T09A-002
99 Z919-142
Z5502-T10A-000
100 Z01CS0508PC
101 Z01LW0500P0
102 Z00FW0511P0
103 Z033-218-004
104 Z033-219-004
105 Z600-042
133 Z025-100-004
134 Z909-524-004
135 Z600-337
136 Z600-063
138 Z03MS5020PC
Z5502-T11A-000
115 Z11TB0604SP
117 Z061-652-015
118 Z06TU040240
119 Z061-369-023
121 Z12TN0216SP
122 Z061-538-004
124 Z01CS0505PC
BRACKET -FILTER
BOLT HEX HEAD
FILTER OIL
CARTRIDGE FILTER
PIPING DWNSTRM OF MTD FLTR-STL
PIPE STEEL
ELBOW PIPE THDED
NIPPLE PIPE
NIPPLE PIPE
FLANGE FF SQ
BOLT HEX HEAD
TEE PIPE THDED
ELBOW TUBE COMPN
ORIFICE PLATE
ADAPTER TUBE COMPN
BUSHING PIPE REDN
NIPPLE PIPE
FITTING
BUSHING PIPE REDN
LOW L O PRESS S/D-ELEC-MURPHY
BRACKET
SWITCH
ELBOW TUBE COMPN
BUSHING PIPE REDN
FLANGE FF SQ
L. O. LEVEL REGULATOR - NONE
PLUG PIPE
PLUG PIPE
PLUG - L O HEATER OPENING
PLUG PIPE
LUBE OIL COOLER - RAM52
EXCHANGER HEAT
LUBRICATOR BRACKET AND DRIVE
BOLT HEX HEAD
LOCKWASHER SPLIT
WASHER PLAIN
SHIM LAMINATED
SHIM STEEL
SUPPORT
KEY SQUARE
COUPLING FLEXIBLE
GUARD COUPLING
PLATE MOUNTING
SCREW MACHINE
FF LUBR OIL SUPPLY-FROM BASE
BUSHING PIPE REDN
FITTING
TUBING STAINLESS
CONNECTOR TUBE COMPN
NIPPLE PIPE
ELBOW PIPE THDED
BOLT HEX HEAD
1
4
1
1
1
2
1
1
1
1
8
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
4
6
4
2
2
1
1
1
1
1
2
1
1
1
1
1
1
1
2
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
FT
EA
EA
EA
EA
126 Z061-369-011
113 Z061-625
114 Z11TB0302SP
Z5502-T12A-002
140 Z061-397-008
141 Z04TU070240
142 Z061-369-009
145 Z061-397-010
148 Z061-410-007
149 Z061-053-002
151 Z060-079
152 Z061-581-005
154 Z061-454
Z620-159-001
5503-002
Z5503-COMA-000
1 Z600-400
2 Z600-401
3 Z09SS1008PF
LSB-04r1024
ZLSB-04R1024
5503-002-SP 11 Z03CS1620PC
7 ZH-4797-A
10 Z600-442-001
EA
EA
EA
EA
EA
FT
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
ICAUTION
Proper length of
studs and bolts is
important for
proper thread
engagement.
Before removing
any studs, measure stud height
from machined
surface and position replacement
stud to same
height.
6/1/04
Page 9-1
Qty
2
1
1
2
1
1
1
1
13
1
4
1
1
2
1
1
1
1
26
1
14
8
8
2
4
2
2
1
4
4
1
1
1
8
12
1
1
1
4
1
64
2
2
2
2
2
1
2
1
1
UOM
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
FT
EA
EA
EA
EA
FT
EA
EA
EA
A
B
C
D
E
F
21
24
25
26
27
28
29
30
31
32
34
53
56
57
58
88
40
41
42
44
48
89
49
47
PA
PB
PC
PD
PE
PF
Z600-512-001
BODY COMPR CYL
Z913-935-032
STUD DOUBLE END
Z03PP0200SP
PLUG PIPE
Z01PP0200SP
PLUG PIPE
Z03PP0400SP
PLUG PIPE
Z01RP081200
PIN ROLL
ZC15FC-T02A-0000-0HEAD END HEAD - VV POCKET
Z600-515-001
HEAD COMPRESSOR
Z600-128-019
PISTON/ROD ADJ CLEAR
Z600-077-003
RING
Z900-838-029
SEAL O RING
Z926-404-001
RING BACK UP
Z01EN1600PF
NUT PLAIN HEX
Z03PP0100SP
PLUG PIPE
Z902-042
HANDLE
Z904-463-002
NUT
Z06WK140011
KEY WOODRUFF
Z01PP0200SP
PLUG PIPE
ZC15FC-T05A-0000-0RETAINER/CAP/GSKTS-SUCTION
Z600-120-001
CAP COMPR VLV
ZC15FC-T06A-0000-0RETAINER/CAP/GSKTS-DISCHARGE
Z04SS0410PC
SCREW SET
Z01SS0402PC
SCREW SET
Z901-685-018
SPACER VALVE
ZC15FC-T01D-1025-0LINER 10.25" DIA. #435
Z600-229-001
LINER COMPRESSOR
ZC15FC-T03A-1025-0ALUMINUM PISTON / CFT RINGS
Z620-177-002
PISTON END
Z620-190-003
CARRIER RING
Z903-108-108
RIDER RING
Z939-642
RING COMPR SEG
Z620-172-002
WASHER
Z620-173-001
WASHER
ZC15FC-T04A-0000-0PISTON ROD - STANDARD LENGTH
Z600-469-003
ROD COMPR PSTN
ZC15FC-T10A-0000-0CYL.ROD PACKING (STD)
Z600-249-001
PACKING COMPR ROD
Z908-822-009
Gskt-wire
Z600-089-001
Ring double acting type"BT"
Z600-087-002
Ring double acting type"BD"
Z900-838-050
O-Ring-Viton
Z600-088-001
Oil Scraper type "3RWS"
Z900-838-015
Seal O Ring
1
4
2
2
9
1
1
1
1
1
1
2
1
1
1
1
1
1
2
6
4
4
4
4
1
1
1
2
1
1
2
1
1
1
1
1
1
1
3
1
1
1
4
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
SUPERIOR COMPRESSORS
ENGINEERING STANDARD
Superior Compressor Start-Up Checklist and Report Control Procedures
1.0 PURPOSE
The purpose of this Engineering Standard is to identify procedures for distribution and control of the
Superior Start-Up Checklist and Report. This checklist provides packagers, service representatives,
and users with a clear and concise checklist to follow during initial starting of Superior compressors.
It is also the official notification to Superior that the compressor has been placed in service.
2.0 SCOPE
The Superior Start-Up Checklist and Report is to be used by all Cooper Energy Services service
personnel, as well as packagers, and customers. It is not intended to include all safety precautions
and procedures and the checklist is to be used in conjunction with the equipment.
3.0 REQUIREMENTS
Instruction Manual, customers regulations/procedures and any applicable safety regulations. The
Superior Start-Up Checklist and Report should be used as a minimum. More detailed locally
developed start-up checklists may be used if they report all of the data and checks covered in the
Superior Start-Up Checklist and Report. If the locally developed start-up checklist does not cover all
items listed on the Superior checklist please complete the Superior list as well as the locally
developed list.
4.0 RESPONSIBILITY
The attached start-up checklist and report must be filled out for each start-up of new or OEM
remanufactured compressors/cylinders. It is the responsibility of the customer to make sure the
checklist/report is completely filled out and returned to Superior in a timely manner. If the packager
is doing the start-up the customer must make sure the packager completes the checklist and gives
it to the customer so that the customer can mail a copy of the completed list to Superior.
5.0 PROCESS
5.1 A Master (Controlled) Copy of the Superior Start-Up Checklist and Report will be maintained
on the Intranet computer system under Superior Products. The Technical Publications
Department as needed will modify this file.
5.2 A copy of the checklist will be included with every set of Instruction Manuals.
5.3
After all applicable sections of the checklist have been completed; the
originator will forward to the Field Engineering Department at the following
address:
Cooper Energy Services
Attention: Compressor Field Engineering
20110 GH Circle
Waller, Texas 77484
5.4 The checklist will be reviewed and filed in the Field Engineering job file. Compressor
warranty coverage is based on the completion and the return to Superior of this Superior
start-up checklist.
Manager, Design
and Development
Technical
Publications
Quality
Assurance
Issued By:
Date:
07/25/02
Supersedes
2/2/93
Aaron Merritt
Patricia Delaney
Doug Paulsen
Tom Stout
ES 30
Distribution
Level A, B, E
Page 1 of 7
SUPERIOR COMPRESSORS
ENGINEERING STANDARD
Superior Start-Up Report and Checklist
NOTE
The Equipment Operation and Maintenance Manuals should be reviewed in detail before
performing any procedures and inspections. All Warnings, Cautions, and Notes should be
thoroughly understood and observed.
Cylinder Throw #1
Cylinder Throw #2
Cylinder Throw #3
Cylinder Throw #4
Cylinder Throw #5
Cylinder Throw #6
Cylinder Special:
SITE INFORMATION:
Manager, Design
and Development
Technical
Publications
Quality
Assurance
Issued By:
Date:
07/25/02
Supersedes
2/2/93
Aaron Merritt
Patricia Delaney
Doug Paulsen
Tom Stout
ES 30
Distribution
Level A, B, E
Page 2 of 7
SUPERIOR COMPRESSORS
ENGINEERING STANDARD
COMPRESSOR APPLICATION: ____________________GAS COMPRESSED: ____________________
(Gathering, Booster, Injection, etc.)
(Natural Gas, Air, CO2, N2, etc.)
SPECIFIC GRAVITY: __________ , H2S: ______%, CO2: ______%, N2: ______%, N VALUE:
_______ CAPACITY: __________MMSCFD, NON-LUBED CYLINDERS: YES ______, NO _______
AMBIENT TEMPERATURE ______F, SITE ELEVATION _______FEET
PRE-GROUT AND/OR PRE-ALIGNMENT CHECK LIST
TYPE OF FOUNDATION ___________________ TYPE OF CYLINDER SUPPORTS _________________
TYPE GROUT USED: SAND/CEMENT___ EPOXY ___ ;
___ ___
___ HAVE BOTTLES AND SCRUBBERS BEEN CLEANED TO REMOVE INTERNAL DEBRIS?
2.
___ ___
3.
___ ___
___ HAS ALL PACKAGE AND FIELD PIPING BEEN PROPERLY DESCALED AND CLEANED?
4.
___ ___
5.
___ ___
6.
___ ___
ALINGMENT?
7.
___ ___
___ CHECKED COMPRESSOR FOR SOFT FOOT (IF SHIMMED) AND CRANKSHAFT WEB
___ ___
___ NO ELBOWS ON VENTS DISCHARGE ENDS. VENTS PIPES ARE WELL SUPPORTED TO
PREVENT THE VENT PIPES FROM WHIPPING BACK AND FORTH WHEN VENTING
OCCURS.
9.
___ ___
___ ALL FILL AND DRAIN CONNECTIONS LOCATED AT PIPINGS LOW POINTS?__________.
___ PRELUBE PUMP SERVICED? IF PNEUMATIC: AIR OR GAS ____, VENTED: YES __ NO ___
14. ___ ___ ___ ALL SAFETY SHEILDS/GUARDS AND PROTECTIVE DEVICES INSTALLED?
Manager, Design
and Development
Technical
Publications
Quality
Assurance
Issued By:
Date:
07/25/02
Supersedes
2/2/93
Aaron Merritt
Patricia Delaney
Doug Paulsen
Tom Stout
ES 30
Distribution
Level A, B, E
Page 3 of 7
SUPERIOR COMPRESSORS
ENGINEERING STANDARD
15. ___ ___
___ HAVE ALL PIPING AND INSTRUMENT LINES BEEN BLOWN CLEAN TO REMOVE
INSTALLATION?
17. ___ ___ ___ LOOSENED PIPING TO AND FROM COMPRESSOR TO MAKE SURE NO MISALIGMENT
BETWEEN PIPING AND COMPRESSOR/CYLINDER IS PRESENT.
18. ___ ___ ___ DOES DRIVER ROTATION MATCH THE COMPRESSOR ROTOR DIRECTION
N/A
___
___ START-UP SPARES, INSTRUCTION MANUALS AND SPECIAL TOOLS BEEN RECEIVED?
3. ___
___
4. ___
___
5. ___
___
___ PISTON END CLEARANCE CHECKED, 1/3 CRANK END, 2/3 HEAD END OR STANDARD?
THROW #1
THROW #2
THROW #3
THROW #4
THROW #5
THROW #6
HE _____
HE ______
HE ______
HE ______
HE ______
HE ______
CE _____
CE ______
CE ______
CE ______
CE ______
C E ______
6. ___
___
7. ___
___
8. ___
___
___ ALL COMPRESSOR VENTS AND DRAINS LINES PLUMBED CORRECTLY AND OPEN?
9. ___
___
___ PACKING AND CROSSHEAD GUIDE VENT LINES VENTED TO SAFE LOCATION AND
10. ___
___
___ FRAME CLEANED (NO DIRT, RUST OR WATER) AND FILLED WITH LUBE OIL?
11. ___
___
___ LUBE OIL HIGH TEMPERATURE SHUTDOWN INSTALLED AND SET TO MANUALS
12. ___
___
___ LUBE OIL LOW PRESSURE SHUTDOWN INSTALLED AND SET TO MANUALS SPEC?
13. ___
___
___ CRANKCASE OIL LEVEL CONTROLLER SET AND SUPPLY ISOLATION VALVE
OPEN?
SPEC?
OPENED?
14. ___
___
15. ___
___
___ ALL SAFETY RELIEF VALVES INSTALLED, OF CORRECT PRESSURE RATING FOR CYL.
/PIPING REQUIREMENTS FOR EACH STAGE, OPERATIONAL AND VENTED TO SAFE LOCATION?
16. ___ ___ ___ 40 MESH SUCTION SCREEN INSTALLED AT SUCTION SCRUBBER INLET?
17. ___
___
___ REMOTE MOUNTED LUBE OIL FILTER VENTED TO REMOVE AIR FROM FILTER?
18. ___ ___ ___ FRAME LUBRICATING OIL MEETS OEM SPECIFICATION? MAKE/GRADE ____________
19. ___ ___ ___ CYLINDER AND PACKING OIL MEETS OEM SPECIFICATION? MAKE/GRADE __________
20. ___
___
WORKING?
Manager, Design
and Development
Technical
Publications
Quality
Assurance
Issued By:
Date:
07/25/02
Supersedes
2/2/93
Aaron Merritt
Patricia Delaney
Doug Paulsen
Tom Stout
ES 30
Distribution
Level A, B, E
Page 4 of 7
SUPERIOR COMPRESSORS
ENGINEERING STANDARD
21. ___
___
___ HAS THE FF SYSTEM BLOWOUT (RUPTURE DISC) ASSEMBLY BEEN INSTALLED AND
___
23. ___
___
___ FF LUBRICATOR 90-DEGREE GEAR DRIVE FILLED WITH GEAR OIL? TYPE ___________
24. ___
___
25. ___
___
___ HAVE THE FF LUBE PUMPS FEED RATES BEEN SET FOR MAXIMUM RATE?
26. ___
___
___ CROSSHEAD GUIDES SHIMMED TO PREVENT PULL DOWN OF GUIDE? REF. TO SB #257
27. ___
___
28. ___
___
29. ___
___
30. ___
___
31. ___
___
32. ___
___
33. ___
___
34. ___ ___ ___ ARE TEMPERATURE AND PRESSURE GAUGES PROPERLY INSTALLED TO INDICATE
SYSTEM CONDITIONS? (OIL COOLING & COOLIANT, PROCESS GAS)
35. ___
___
___ DO ALL WATER COOLED PACKINGS HAVE SEPARATE WATER LINES USING COOLEST
36. ___
___
___ CHECKED ALL GAS AND AIR UTILITIES FOR CORRECT PRESSURE AND LEAKS?
37. ___
___
38. ___
___
___ HAVE ALL COMPRESSOR UNLOADERS BEEN TESTED FOR PROPER OPERATION?
39. ___
___
___ IS COMPRESSOR LUBE OIL PRESSURE BEING SENSED AT THE DRIVE END OF THE
POSSIBLE WATER?
FRAMES LUBE OIL HEADER? MH62, WH62, WG72, AND WG62 FRAMES OIL SENSED DOWN STREAM OF
FILTER.
40. ___
___
41. ___
___
CALIBRATED?
42. ___
___
43. ___
___
___ HAVE ALL LINES TO THE COMPRESSOR BEEN BLOWN OUT TO REMOVE DIRT/TRASH
FROM LINE?
START-UP CHECK LIST
YES
NO
N/A
1. ___
___
2. ___
___
3. ___
___
4. ___
___
5. ___
___
Technical
Publications
Quality
Assurance
Issued By:
Date:
07/25/02
Supersedes
2/2/93
Aaron Merritt
Patricia Delaney
Doug Paulsen
Tom Stout
ES 30
Distribution
Level A, B, E
Page 5 of 7
SUPERIOR COMPRESSORS
ENGINEERING STANDARD
6. ___
___
8. ___ ___
___ IS LUBE OIL PRESSURE PRESENT? PRESSURE: ________ PSIG (REFER TO MANUAL
___
___
___ CHECK MADE FOR LUBRICANT, COOLANT, AND GAS LEAKS? CORRECT ANY
LEAKS
11. ___
___
12. ___
___
___ ARE THE SCRUBBERS HIGH LEVEL SHUTDOWNS AND DUMPS FUNCTIONING?
13. ___
___
15. ___
___
16. ___
___
NECESSARY.
17. ___
___
___
___ FF LUBE PUMPS FEED RATES SET FOR BREAKIN RATE? CHECK MANUAL FOR RATE?
19. ___
___
___ COMPRESSOR LOAD CURVES MATCHING ENGINE LOAD CURVE AND FLOW METER?
20. ___
___
___ HAS CUSTOMER/OPERATOR BEEN SHOWN HOW TO LOAD AND OPERATE THE
COMPRESSOR?
21. ___
___
___ HAS START-UP INSTRUCTION FOR THE OTHER PACKAGE EQUIPMENT BEEN
FOLLOWED?
22. ___
___
23. ___
___
___ HAVE THE DISCHARGE GAS TEMPERATURE ALARMS BEEN SET AT 15 DEGREE F
___
___ HAS THE OVERSPEED SHUTDOWN BEEN SET? SPEED SETTING: ____________ RPM.
25. ___
___
Manager, Design
and Development
Technical
Publications
Quality
Assurance
Issued By:
Date:
07/25/02
Supersedes
2/2/93
Aaron Merritt
Patricia Delaney
Doug Paulsen
Tom Stout
ES 30
Distribution
Level A, B, E
Page 6 of 7
SUPERIOR COMPRESSORS
ENGINEERING STANDARD
WHEN UNIT IS LOADED
LOAD CONDITIONS:
1ST STG.
2ND STG.
3RD STG.
4TH STG.
5TH STG.
SUCTION PSIG
_________
__________
__________
_________
_________
DISCHARGE PSIG
_________
__________
__________
_________
_________
SUCTION TEMP F
_________
__________
__________
_________
_________
DISCHARGE TEMP F
_________
__________
__________
_________
_________
VV POCKET SETTING (inches)
_________
__________
__________
_________
_________
UNLOADERS HE/CE
_________
__________
__________
_________
_________
CYL. INACTIVE END
_________
__________
__________
_________
_________
COMMENTS: ________________________________________________________________________________________
____________________________________________________________________________________________________
____________________________________________________________________________________________________
____________________________________________________________________________________________________
COUPLING
COLD ALIGNMENT: FACE
(INCHES)
_____
_____
RIM
_____
_____
_____
HOT/FINAL
ALIGNMENT:
(INCHES)
_____
_____
_____
_____
FACE
_____
RIM
_____
_____
_____
_____
READINGS IN INCHES
_____
_____
THROW 1
THROW 2
THROW 3
THROW 4
THROW 5
THROW 6
CROSSHEAD CLEARANCE:
CRANK WEB DEFLECTION:
ROD RUN OUT (TOP/SIDE):
SOFT FOOT READINGS:
(IF SHIMMED)
Manager, Design
and Development
Technical
Publications
Quality
Assurance
Issued By:
Date:
07/25/02
Supersedes
2/2/93
Aaron Merritt
Patricia Delaney
Doug Paulsen
Tom Stout
ES 30
Distribution
Level A, B, E
Page 7 of 7