The contents of this document are proprietary and confidential.

They are the

property of Ariel Corporation and may not be disclosed, reproduced, or used for
ENGINEERING REFERENCE manufacture in part or in whole without written permission from Ariel Corporation.

Recommended Maintenance Intervals for

Continuous Duty Reciprocating Compressors
Ariel compressors, like all industrial equipment, require maintenance. The severity of compressor ser-
vice directly influences the frequency and amount of maintenance needed. Below are recommended
intervals for inspections and replacements to help determine appropriate intervals for a given com-
pressor application. Careful documentation of inspection results is critical to establish whether
recommended intervals are adequate or require more or less frequency.
NOTE: For intermittent duty service, see ER-8.2.2.
As part of your maintenance program, Ariel recommends:
Consistent adherence to safety policies, procedures, and equipment warning labels.
Daily operational checks.
Routine trending and review of operational parameters.
Routine oil analysis and trending.
Detailed records of all maintenance.
To avoid contamination, keep all covers in place where access is not required. Use lint free cloths or
paper towels during internal maintenance.

CAUTION: Gas compressors are complicated and dangerous pieces of equipment. Only
trained operators and mechanics familiar with unit operation should attempt any main-
tenance. Read and thoroughly understand the appropriate manual and always wear
appropriate personal protection equipment during maintenance. Never adjust any
fastener torques while the unit is operating or pressurized.
To reduce the risk of serious personal injury or death, verify driver or compressor cyl-
inder gas pressure cannot turn compressor crankshaft during maintenance. Before any
maintenance or component removal, relieve all pressure from compressor cylinders. See
packager information to completely vent the system or call the packager for assistance.
After maintenance, purge the entire system with gas prior to operation to avoid a poten-
tially explosive air/gas mixture.

For the most recent edition of this document, visit www.arielcorp.com.

21 020430 10-22-15
ER-74 was archived and superseded by ER-96.5.12. 20 020394 7-9-15
23 "One-Year (8,000-Hour) Maintenance", page 6, #16: "ER-96.5.12" was "ER-74".
19
18
019567
018938
3-16-15
11-13-14 23 201600170 7-25-16
17 019351 4-28-14 22 201600239 6-14-16
VER. DESCRIPTION VER. ECN DATE VER. ECN DATE

Page 1 of 7 VER. 23 ER-8.2

 The contents of this document are proprietary and confidential. They are the
property of Ariel Corporation and may not be disclosed, reproduced, or used for
ENGINEERING REFERENCE manufacture in part or in whole without written permission from Ariel Corporation.

Initial Maintenance
Comply with Ariel Packager Standards and the com-
pressor Start Up Check List. Adhere to all items before
and after start-up.
For cold alignment, account for the difference in thermal
growth height be-tween the compressor and driver.
TABLE 1 lists compressor centerline height change
based on 6.5 x 10-6/F (11.7 x 10-6/C).
NOTE: Thermal growth numbers were calculated using
170F (77C) as the frame operating temperature. Ini-
tial frame temperature is the temperature of the frame
during cold alignment. Obtain driver thermal growth pre-
dictions from the driver manufacturer.
Center the coupling between the driver and com-
pressor so it does not thrust or force the crankshaft FIGURE 1 Thermal Growth
against either thrust face.
To ensure parallel and concentric drive train
alignment, position connected equipment so
misalignment is as close to zero as possible.
Maximum rim (outside diameter) mis-
alignment is 0.005 inches (0.13 mm) for total
indicator reading (TIR) or 0.0025 inches
(0.064 mm) for laser alignment tool. Face
(angular) misalignment is to be within 0.005
inches (0.13 mm) for hub diameters up to 17
inches (430 mm). For hubs greater than 17
inches (430 mm), use the following formula:
Hub O.D. x 0.00029 = max angular mis-
alignment. See FIGURE 2
After running a new, relocated, reconfigured,
or overhauled compressor for 24 hours, shut
down, vent the gas system, and perform the FIGURE 2 Angular Coupling-Hub Face
following maintenance: Alignment Limits
1. At hot alignment check, adjust discharge
bottle supports and head end supports, if applicable.
NOTE: To avoid cylinder distortion, lift discharge bottles only 0.003 to 0.005 inch (0.08 to
0.13 mm) using the supports.
2. Check fastener torque on gas nozzle flanges, valve caps, cylinder heads, piston rod packing
flanges, crosshead guide hold down, crosshead guide to cylinder, and crosshead guide to frame bolt-
ing. See appropriate ER-96.2.x series document for correct torques.
3. Repeat torque check after 750 hours. If loosening persists, consult your packager. Recheck fasten-
ers found loose in any of these intervals after an additional 750 hours. If loosening continues, contact
your package supplier immediately.

Page 2 of 7 VER. 23 ER-8.2

 The contents of this document are proprietary and confidential. They are the
property of Ariel Corporation and may not be disclosed, reproduced, or used for
ENGINEERING REFERENCE manufacture in part or in whole without written permission from Ariel Corporation.

TABLE 1 Thermal Growth of Compressors

Initial THERMAL GROWTH, INCH (MM)

Frame
Temp.
F (C) JG:JGA JGM:P:N:Q JGJ:R JGH:E:K:T JGC:D:F JGZ:U/KBZ:U JGB:V KBB:V

0 (-18) 0.011 (0.29) 0.010 (0.26) 0.013 (0.34) 0.019 (0.48) 0.024 (0.62) 0.027 (0.68) 0.033 (0.85) 0.030 (0.76)
10 (-12) 0.011 (0.27) 0.010 (0.25) 0.012 (0.32) 0.018 (0.45) 0.023 (0.58) 0.025 (0.64) 0.031 (0.79) 0.028 (0.71)
20 (-7) 0.010 (0.26) 0.009 (0.23) 0.012 (0.30) 0.017 (0.42) 0.021 (0.55) 0.023 (0.60) 0.029 (0.75) 0.026 (0.67)
30 (-1) 0.009 (0.24) 0.008 (0.21) 0.011 (0.28) 0.015 (0.39) 0.020 (0.51) 0.022 (0.56) 0.027 (0.70) 0.025 (0.63)
40 (4) 0.009 (0.22) 0.008 (0.20) 0.010 (0.26) 0.014 (0.37) 0.019 (0.48) 0.020 (0.52) 0.025 (0.65) 0.023 (0.59)
50 (10) 0.008 (0.20) 0.007 (0.18) 0.009 (0.24) 0.013 (0.34) 0.017 (0.44) 0.019 (0.48) 0.023 (0.60) 0.021 (0.54)
60 (16) 0.007 (0.19) 0.007 (0.17) 0.009 (0.22) 0.012 (0.31) 0.016 (0.40) 0.017 (0.44) 0.021 (0.54) 0.019 (0.49)
70 (21) 0.007 (0.17) 0.006 (0.15) 0.008 (0.20) 0.011 (0.28) 0.014 (0.37) 0.016 (0.40) 0.020 (0.50) 0.018 (0.45)
80 (27) 0.006 (0.15) 0.005 (0.14) 0.007 (0.18) 0.010 (0.25) 0.013 (0.33) 0.014 (0.36) 0.018 (0.45) 0.016 (0.40)
90 (32) 0.005 (0.14) 0.005 (0.12) 0.006 (0.16) 0.009 (0.23) 0.011 (0.29) 0.012 (0.32) 0.016 (0.40) 0.014 (0.36)
100 (38) 0.005 (0.12) 0.004 (0.11) 0.005 (0.14) 0.008 (0.20) 0.010 (0.26) 0.011 (0.28) 0.014 (0.35) 0.012 (0.31)
110 (43) 0.004 (0.10) 0.004 (0.09) 0.005 (0.12) 0.007 (0.17) 0.009 (0.22) 0.009 (0.24) 0.012 (0.30) 0.011 (0.27)
120 (49) 0.003 (0.09) 0.003 (0.08) 0.004 (0.10) 0.006 (0.14) 0.007 (0.18) 0.008 (0.20) 0.010 (0.25) 0.009 (0.23)
130 (54) 0.003 (0.07) 0.002 (0.06) 0.003 (0.08) 0.004 (0.12) 0.006 (0.15) 0.006 (0.16) 0.008 (0.21) 0.007 (0.19)

Daily Maintenance
1. Log and trend the following:
Operating RPM, gas pressure and temperatures - determine if the unit is operating within design
parameters and expectations.
NOTE: Verify high and low pressure shutdowns are set as close as practical to normal
operating conditions. Set points must protect the machine from exceeding compressor
limits.
Bearing temperatures - if the unit is equipped with main bearing temperature sensors.
Compressor frame oil pressure - at operating temperature (190F (88C) max. inlet oil tem-
perature), it should be 50 to 60 psig (3.5 to 4.2 barg) at the filter gauges. If pressure falls below 50
psig (3.5 barg), shut down the compressor then determine and correct the cause.
Compressor frame inlet oil temperature.
Compressor frame oil filter differential pressure - differential pressure exceeding the filter change
value indicates a need for a filter change. See filter information plate on top cover or Maintenance
and Repair Manual for procedure.
2. Check compressor frame oil level. It should be about mid-level in the sight glass and free of foam
when running. If not, determine and correct the cause. Do not overfill. Check oil makeup tank for suf-
ficient oil supply. For dry sump frames, check the package sump oil level. Do not add oil to the
crankcase through the breather hole while the unit runs. This causes oil foaming and unnecessary
no-flow shutdowns in the force feed lubrication system.
3. Check force feed lubricator box oil level. It should be full to the overflow line.

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 The contents of this document are proprietary and confidential. They are the
property of Ariel Corporation and may not be disclosed, reproduced, or used for
ENGINEERING REFERENCE manufacture in part or in whole without written permission from Ariel Corporation.

4. Log and trend piston rod packing vent/drain temperature and check distance piece vents for leak-
age. If the piston rod packing vent/drain temperature is trending high, then verify leak rate before
performing maintenance.
5. If applicable, check suction valve unloader actuator vents for leakage.
6. If applicable, check head end clearance pocket vents for leakage.
7. Verify all cylinder high discharge gas temperature shutdowns are set to within 10% or as close as
practical above the normal operating discharge temperature. Do not exceed the maximum dis-
charge temperature shutdown setting for the application.
8. Log and trend cylinder valve cap temperatures.
9. Check lubricator block cycle time. See lubricator box data plate for correct cycle time. Changes in
gas composition may require a review of cycle time. Check lube sheet for units not running at rated
speed.
10. Check for gas, oil, and coolant leaks.

CAUTION: Do not attempt to repair leaks while the unit is operating or pressurized.

11. Check for unusual noises or vibrations.

12. See packager documentation for additional recommended checks, i.e. scrubber liquid levels, dump
valve operation, cooler louver positions, etc.

Monthly Maintenance
1. Perform all Daily maintenance.
2. Verify safety shutdown functionality.
3. Sample compressor frame oil and send it to a reputable lubricant lab for analysis. See ER-56.06 for
a list of what an oil analysis should provide. If analysis results indicate increasing levels of lead, tin, or
copper particles in the oil, shut down unit. Remove frame top cover and crosshead guide side cov-
ers. Visually inspect for debris. Do not disassemble further without good reason. If debris indicates,
replace affected parts, then change oil, oil filter, and clean the strainer with a suitable solvent.
4. Check and log cylinder clearance devices in use and their settings.

Six-Month (4,000-Hour) Maintenance

1. Perform all Daily and Monthly maintenance.
2. Shut down unit and allow sufficient time for components to cool.
3. Drain and replace force feed lubricator box oil.
4. Where applicable, clean sintered element in the small oil filter on the force feed lubrication system
now or at every main oil filter change. Use a suitable solvent. Where applicable, replace force feed
lubricator inlet filter in independent supply system.
5. Change compressor oil filter. See top cover filter information plate or Maintenance and Repair
Manual for procedure.
NOTE: For replaceable element style filters, drain the canister completely before remov-
ing the element. Inspect elements for cleanliness and damage. Do not install dirty or
damaged elements.
6. Change compressor oil. Extremely dirty environments, oil supplier recommendations, or oil analysis
results may dictate a different oil change interval. Follow these steps:

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property of Ariel Corporation and may not be disclosed, reproduced, or used for
ENGINEERING REFERENCE manufacture in part or in whole without written permission from Ariel Corporation.

Drain oil from frame, associated piping, and oil cooler.

Clean oil strainer with a suitable solvent. In dry sump applications, the strainer is located at the oil
reservoir.
Remove frame top cover and crosshead guide side covers. Visually inspect for debris. Do not dis-
assemble further without good reason. If debris indicates, replace affected parts, then change the
oil filter and clean the strainer with a suitable solvent.
Refill compressor frame with fresh, clean oil.
7. Check cylinder lubrication. See Maintenance and Repair Manual for procedure.
8. Re-tighten hold down fasteners to proper torque (compressor frame feet and crosshead guide/dis-
tance piece support feet). Inspect for frame twist or bending to verify main bearing bore alignment.
See Ariel document ER-82 for flatness and soft foot requirements.
9. Perform a coupling alignment (see "Initial Maintenance" above).
10. Remove and inspect inlet screens on each stage; clean if clogged with debris or replace if damaged.
Clean inlet screens regularly to avoid increased pressure that may collapse them. More debris in the
screen may dictate more frequent inspections. Inlet screens may be removed if they catch little or no
debris and the gas stream is clean (optional).

One-Year (8,000-Hour) Maintenance

1. Perform all Daily, Monthly, and Six-Month maintenance.
2. Grease VVCP stem threads at grease fitting, with 2 to 3 pumps of cylinder lube compatible grease
using a standard hand pump grease gun. Turn VVCP adjustment handle all the way in and all the
way out to lubricate the threads. Measure or count turns to return the handle to its original position.
3. Open force feed lubricator box and visually inspect pump followers, cams, and gears for wear.
4. Pressure test distribution blocks. See Maintenance and Repair Manual for procedure.
5. Measure, log, and trend the following:
Main bearing, connecting rod bearing, and crankshaft jack and thrust clearances.
NOTE: Clearance trends along with oil analysis and crankcase visual inspection can indic-
ate the need for bearing replacement. Contact Ariel for original assembly clearances.
Crosshead to guide clearances.
Piston rod runout.
See procedures in Maintenance and Repair Manual. If any of the above items are outside limits lis-
ted in the Maintenance and Repair Manual, find the cause and correct it. It may require part
replacement.
6. Remove valves and valve gaskets:
a. Visually inspect valve pockets for damage. Verify all old valve seat gaskets are removed.
b. Have a qualified valve repair shop disassemble, visually inspect, and refurbish the valves where
needed. Provide the valve repair shop an Ariel torque chart and valve service guide.
c. Visually inspect cylinder gas passages and clean them of all debris.
7. If applicable, visually inspect suction valve unloader actuator stems for damage or wear. Visually
inspect stem seals for damage or wear and confirm that the actuator moves freely.
8. If applicable, visually inspect pneumatic clearance pockets for damage or wear (seating surface and
stems/stem seals). Confirm that actuator moves freely.

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property of Ariel Corporation and may not be disclosed, reproduced, or used for
ENGINEERING REFERENCE manufacture in part or in whole without written permission from Ariel Corporation.

9. Inspect cylinder bores for damage or wear. Replace the cylinder body or restore the bore if any of
the following conditions exist:
Bore surface blemishes or gouges.
Bore out of round more than 0.001 inch per inch of bore diameter (0.001 mm/mm) or tapered.
Main bore is worn to counterbore diameter or larger.
10. Inspect piston rings and wearband:
a. Measure and log piston ring condition, end gap, and side clearance.
b. Replace rings that are damaged or outside limits listed in the Maintenance and Repair Manual.
c. When replacing rings, re-measure and log ring side clearance to check for groove wear.
d. Measure and log radial projection of wear band.
11. Inspect piston rods for damage and excessive wear. Replace rod if any of these conditions exist:
Gouges or scratches on the rod.
Under size more than 0.005 inch (0.13 mm).
Out of round more than 0.001 inch (0.03 mm) per inch of rod diameter.
Tapered more than 0.002 inch (0.05 mm) for JG:A:M:P:N:Q:R:J:H:E:K:T or 0.005 inch (0.1 mm)
for Z:U:B:V per inch of rod diameter.
12. Rebuild piston rod pressure packing cases. See the Maintenance and Repair Manual for procedure.
13. Re-install valves, retainers, and valve caps using new valve seat gaskets and valve cap O-ring-
s/seals. See ER-96.5.2. Use proper installation techniques and torque procedures for valve caps.
14. Check and re-calibrate all required instrumentation.
15. Clean crankcase breather filter with suitable solvent.
16. Check and, if needed, adjust drive chains. See ER-96.5.12 for procedure.
17. If the compressor is equipped with crankcase over-pressure relief valves, visually inspect and exer-
cise valves to manufacturer recommendations.
18. Check fastener torques of gas nozzle flanges, head end head or unloader, valve caps, piston rod
packings, crosshead pin thru- bolts, crosshead guide to frame, crosshead guide to cylinder, cylinder
mounting flange to forged steel cylinder, distance piece to cylinder, distance piece to crosshead
guide, and tandem cylinder to cylinder.

Two-Year (16,000-Hour) Maintenance

1. Perform all Daily, Monthly, Six-Month, and One-Year maintenance.
2. Rebuild oil wiper cases.
3. If applicable, use new piston and stem seals to rebuild actuators on suction valve unloaders and
fixed volume pneumatic pockets. Replace piston stem assemblies where stem is damaged or worn.
4. Check auxiliary end chain drive for undercut sprocket teeth and chain for excessive stretching.
Replace as required.

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 The contents of this document are proprietary and confidential. They are the
property of Ariel Corporation and may not be disclosed, reproduced, or used for
ENGINEERING REFERENCE manufacture in part or in whole without written permission from Ariel Corporation.

Three-Year (24,000-Hour) Maintenance

1. Perform all Daily, Monthly, Six-Month, and One-Year maintenance.
2. Replace non-ELP connecting rod bearings for JGE:T:C:D:U:Z:B:V and KBB:V models. See Main-
tenance and Repair Manual for procedures.
NOTE: Main and connecting rod bearing wear and replacement intervals are heavily
dependent on many factors including speed, load, oil temperature, oil cleanliness, and oil
quality. Depending on the severity of service, the bearing maintenance interval may be
longer or shorter.

Four-Year (32,000-Hour) Maintenance

1. Perform all Daily, Monthly, Six-Month, One-Year, and Two-Year maintenance.
2. Remove crosshead pins. Measure and log crosshead pin to crosshead pin bore and connecting rod
bushing bore clearances. Check crosshead pin end caps and thru-bolt for wear. Replace if needed.
3. Check for bushing wear in the auxiliary end drive chain tightener.
4. Check for ring groove wear in pistons.

Six-Year (48,000-Hour) Maintenance

1. Perform all Daily, Monthly, Six-Month, One-Year, Two-Year, and Three-Year maintenance.
2. Replace lubricator distribution blocks.
3. Replace crosshead bushings and connecting rod bushings. See Maintenance and Repair Manual
for procedures.
4. Replace connecting rod bearings. See Maintenance and Repair Manual for procedure.
5. Replace main bearings. See Maintenance and Repair Manual for procedure.

Page 7 of 7 VER. 23 ER-8.2