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information to facilitate use and maintenance of WG series compressor frames purchased from Cooper Energy Services. By 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.
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maintenance and dependable service. The balance-opposed design, with two crank throws separated by a crank cheek, is a modern standard for reciprocating compressor frames. This manual describes the WG series compressor frame. These compressor frames are designed for oil and gas production, gas transmission, process, cogeneration and power generation applications. Precision designed main and connecting rod bearings are thick walled, steel backed and split. The crankshaft is removed through the top of the base without disturbing the cylinders. The lube oil pump and the force feed lubricator are gear or shaft driven and mounted on the auxiliary end cover. Either may be maintained independently. Lube Oil is drawn from the sump through a strainer that protects the lube oil pump. A 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 to the stroke and model, all cylinders will fit interchangeably on the standard crosshead guide. Careful attention is given to the cooling of cylinders designed for a 1.5:1 to 5:1 pressure ratio. V t Figure 1-4 WG Cylinder Head Options a r i a Typical Variable Pocket Cylinder Head Plug b l e
V o l u m 00748 00749 e Pockets are furnished as standard equipment on all cylinder classes, except the model #602 through #605 forged steel cylinders. On these cylinders, other methods of adding clearance, such as fixed heads, fixed volume heads, or valves spacers can be furnished when required.
Crankshaft Rotation
When facing the oil pump end of the frame, the crankshaft rotates in a counterclockwise direction.
Section 1: Introduction to Servicing the WG Series Compressor Cooper Energy Services n Superior Compressor Product Group WG-4/3/03
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Figure 1-5
WG Stroke Options
Figures 1-6 and 1-7 show the general configuration of the WG compressor
Connecting Rod
Crankshaft Frame
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Section 1: Introduction to Servicing the WG Series Compressor Cooper Energy Services n Superior Compressor Product Group
WG-4/3/03
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Discharge Valve
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I CAUTION
Balancing of the unit is accomplished by using both an appropriate weight crosshead assembly and piston rod jam nut (balance nut) The maximum allowable variation is two pounds (0.90 kg) on the reciprocating weights and one pound (0.45 kg) on the connecting rod weights, but not to exceed one pound net, for each pair of opposing throws.
Since the goal is to produce a balanced opposed compressor, it is necessary to make the reciprocating weight on each pair of opposing throws approximately the same.This is quite a task, in view of the large number of cylinder sizes and throw location combinations that are possible, and because each piston and rod assembly (piston, rings, piston rod and cap screws) has a certain combined weight which will probably be different from the weight of the piston assembly that it will oppose.
N 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.
I CAUTION
Also available are balance nuts in 2.5 and 5-pound increments. Consult an Authorized Unit Distributor for details concerning the use of the special weight nuts. In addition to the above mentioned balance parts, the connecting rod weight is also involved in the balance. Connecting rods vary in weight and when the units are assembled at the factory, care is taken to select the connecting rods so that the weight variation for opposing throws does not exceed 1 pound (0.45 kg).Every effort should be made to achieve as near equal balance between opposite throws as possible.This does not apply to adjacent throw pairs, which sometimes vary by 100 pounds (45 kg) or more, depending on cylinder sizes.
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.
The crosshead assembly consists of a pair of shoes, the bolts and nuts to attach the shoes, and the crosshead. There are two different weight crossheads available.
00752
The estimated balance for the original assembly of a compressor is recorded on the Compressor Vent Fill Plug Torsional and Balance Data Sheet. A copy of the data sheet for each compressor is included in the Operation Manual, and should be referred to in Upper the event . a change which would affect the balPlug ance is contemplated.The actual weight of parts . from the estimated weights. Also, when can vary replacing crossheads, connecting rods, pistons, or changing piston ring material, the new parts Drain Plugshould be weighed, in order to reaffirm the actual unit balance.
WG-4/3/03
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Section 1: Introduction to Servicing the WG Series Compressor Cooper Energy Services n Superior Compressor Product Group
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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: Frame, crosshead guide, and lubrication systems Compressor details including: rings, rider bands, pressure packings, valves, and unloaders Support systems to include: Coolers, water pumps, and control systems Description of installation, inspection, and set up procedures for rod run out, web deflection, coupling alignment Description of recommended operational procedures include: startup, normal & emergency shutdown and compressor performance control Description and application of recommended maintenance: maintenance, critical repairs, and troubleshooting If training is needed, contact the CES Learning Center by calling (713) 354-4062.
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Section 5: Installation. This section provides an in-depth functional description guidelines for the foundation, coupling installation, crankshaft web deflection, cylinder mounting, setting piston end clearance, piston rod run out. Section 6: Operation Start-up. This section provides procedure for startup, recommended operating conditions, and form to request for performance curves. Section 7: Maintenance. This section contain precautions, tolerance limits, and recommended torque values. Section 8: Frame "as built" Bills of Materials unique to your compressor. Included are exploded views of the assemblies. Section 9: Cylinder "as built" Bills of Materials unique to your compressor. Included are exploded views of the assemblies.
Related Publications
The following related publications contain more information about the Superior WG Series Compressor: Superior MH, WH, W7, & WG Compressor Frame Technical Data Book. Superior Compressor Cylinders Technical Data Book
Standards
Cooper Energy Services has developed several standards for our compressor addressing cooling water quality, lubrication, and packaging. CES recommends that users of Superior compressor understand and follow these standards to get the best performance possible from the equipment. CES also recommends that oil and gas production service packagers follow the guidelines for prime movers described in the American Petroleum Institutes Specification for Packaged Reciprocating Compressors for Oil and Gas Production Services (API Specification 11P). American Petroleum Institute http://www.api.org will default you to http://www.global.ihs.com 1-800-854-7179 ext. 7969 for a copy of API 11P.
Warranty
The Seller warrants to the Buyer that the equipment to be delivered hereunder will be free from defects in material, workmanship and title and will be of the kind described in the contract. THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES
Section 1: Introduction to Servicing the WG Series Compressor Cooper Energy Services n Superior Compressor Product Group WG-4/3/03
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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.
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Section 2: Safety Precations and Guidelines Cooper Energy Services n Superior Compressor Product Group
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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: The CAUTION symbol indicates that if the specified precaution is not heeded, damage to equipment and/or personal injury may result. The following is an example of a CAUTION: The DANGER symbol indicates that if the specified warning is not heeded, there is a substantial risk of serious equipment damage, personal injury or even death. The following is an example of a DANGER:
When changing the frame lubricating oil, change the oil filter.
I CAUTION
NDANGER
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.
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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.
NDANGER
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.
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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.
NDANGER
If Poisonous or suffocating gases are being compressed, follow all plant safety procedures prior to and during maintenance on any gas equipment or piping to avoid injury or death due to inhalation of such substances.
It is in the best interest of everyone involved in operation and maintenance of the equipment to observe these additional precautions: Always wear safety glasses or goggles, steel-toe safety shoes, hearing protection and protective head gear. Additional equipment may be required by the job conditions. Do not wear loose clothing, neckties, or jewelry that can catch on controls or other parts of the moving equipment. Keep long hair tied back. Make certain all protective guards and covers are secured in place. Use only non-flammable, non-toxic cleaning solvents. Never use gasoline or other flammable products for cleaning purposes. Use fans, blowers, etc. during maintenance and clean-up work in enclosed areas to remove fumes released by cleaning solvents and vented gases. Never put maintenance fluids into glass containers; since glass containers break. Report all needed repairs. When operating this equipment in an enclosed area, vent the exhaust to the outside. Keep the area around the unit clean and orderly with ample space to walk safely around the unit. Clean up spills and leaks quickly to prevent accidents caused by slipping and falling.
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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.
Section 2: Safety Precations and Guidelines Cooper Energy Services n Superior Compressor Product Group
WG-4/3/03
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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.
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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.
Section 2: Safety Precations and Guidelines Cooper Energy Services n Superior Compressor Product Group
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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.
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Section 3: Lubrication and Cooling Cooper Energy Services n Superior Compressor Product Group
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Table 3-1 & 3-2 ) will be suitable. In applications where the compressor cylinders are handling corrosive gases such as H2 S or CO2 , 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: Table 3-1 General Specifications
Specification Viscosity: cSt @ 100oC Viscosity: cSt @ 40 o C Viscosity Index Flash Point Pour Point Range 12.5 to 16.3 204 Maximum 70 Minimum 400 o F (204oC) Minimum 15oF (-9o C) Maximum Test Procedure ASTM D 445 ASTM D 445 ASTM D 2270 ASTM D 92 ASTM D 97
Table 3-2 Viscosity Information-this information is equivalent to the ranges above and provided for information only
Specification Viscosity: SUS @ 210oF Viscosity: SUS @ 100oF Range 75 to 85 1100 Maximum Test Procedure ASTM D 88 ASTM D 88
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.
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Compressor design, operating conditions, and the gases being handled all have a significant affect on how well a lubricant performs in the given application. Because of a variety of gases and operating conditions encountered by Superior compressor cylinders, the lubricant must be selected with the proper characteristics suitable for the application involved. In all applications, the oil used for compressor cylinders should have the following qualities: Good wetting ability High film strength Good chemical stability Clean and refined Unless the service uses Hydrogen Sulfide, oxidation and corrosion prohibitors are not required, but may be beneficial. Pour point must be equal to gas suction pressure minus15oF-20o F (8oC-11o C). Good resistance to carbon deposits and sludge formation. If any carbon is formed, it should be the soft, loose and flaky type. Minimum flash point is 400o F (204oC).
Figure 3-3 The compressor frame lubrication system consists of a gear driven pump, pressure relief valve, check valves, oil cooler and oil filter. This Figure illustrates the lubrication oil system flow .
Section 3: Lubrication and Cooling Cooper Energy Services n Superior Compressor Product Group
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Viscosity Requirements
The viscosity of the oil should be selected on the basis of operating pressure conditions of the cylinder. For multi-stage applications, the viscosity required for the highest pressure cylinder can also be used in lower pressure cylinders. The viscosities listed in Table 3-4 are the suggested minimum requirements. These values will be adequate for most oils. However, oils of the same viscosity may not necessarily have identical lubricating qualities. Periodic examination of the cylinder bores during the first few weeks of operation is recommended to assure that lubrication is adequate. Table 3-4 Minimum viscosity and specifications for Superior cylinder lubricants Table 3-4A Discharge Pressure
0-499 psi 500-1199 psi 1200-1999 psi 2000-3999 psi 4000-up psi
Remarks
Crank Case Oil Crank Case Oil External Oil External Oil External Oil
METHANE WITHOUT H2 S, METHANE CONTAINING ANY COMBINATION OF HEAVY HYDROCARBONS ( EXCLUDING ETHANE ),CO2 AND H 2 0 THAT TOTALS TO <5% (BY MOLE WT.) Note: (External Cylinder Lubrication Supply Required above 1200 psi
Remarks
External Oil External Oil External Oil External Oil External Oil
METHANE WITH H2S, METHANE CONTAINING ANY COMBINATION OF HEAVY HYDROCARBONS ( EXCLUDING ETHANE ), CO2 AND H2O THAT TOTAL TO 5-20% (BY MOLE WT.) Note: (External Cylinder Lubrication Supply Required)
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Table 3-4-C
Discharge Pressure
0-499 psi 500-1199 psi 1200-1999 psi 2000-3999 psi 4000-up psi
Remarks
External OIl External Oil External Oil External Oil External Oil
CO2, HEAVY HYDROCARBONS,METHANE CONTAINING ANY COMBINATION OF HEAVY HYDROCARBONS (EXCLUDING ETHANE), CO2 AND H2 O THAT TOTALS TO >20% BY MOLE WEIGHT. Note: (External Cylinder Lubrication Supply Required)
Application Requirements
Many applications require special attention in addition to that given to most natural gas and similar services. The process in which a gas is being utilized will often influence the lubricating oil selected. The following recommendations will provide basic guidelines in selecting the proper lubricant for these special applications. Final selection should be made only after consultation with an Authorized Unit Distributor and the desired oil supplier: Table 3-5 Minimum Qualities of a Compressor Cylinder Lubrication
Service Wet Air High Pressure (PSIG) High Discharge Temperatures(350 o -375o) Natural Gases, Methane, Ethane Natural Gases Saturated With Water and/or Wet With Higher Ended Hydrocarbons Butane, Propane, Ethylene, Carbon Dioxide Hydrogen, Nitrogen, Helium, Carbon Monoxide, Exhaust Gas, Ammonia Synthesis Ammonia Hydrogen Sulfide Recommendations Requires compounding with 3% to 5% acid less tallow or other suitable fatty oils. Increase supply over normal. Use minimum viscosity listed in Table 3-4, plus 3% to 5% compounding with tallow if gas is wet. Contact A CES Authorized Unit Distributor. Use viscosity data in Table 3-4 and 3% to 5% compounding with tallow if the gas is wet and/or saturated. Requires compounding with 3% to 5% acid less tallow or other suitable fatty oils. Increase supply over normal. These gases are dilutents of oil. Use the next higher viscosity over Table 3-4 recommendations. Increase supply quantities over normal. Lubricant must be dry. There are inert gases relative to lubricating oils. Use the recommendations in Table 3-4. Use a mixed base or napthentic straight mineral oil. Use dry, compounded, straight mineral oil. 3% to 8% compounding with acid less tallow and addition of corrosion and oxidation inhibitors is required. Viscosity as recommended in Table 3-4.
Section 3: Lubrication and Cooling Cooper Energy Services n Superior Compressor Product Group
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Lubrication Rate
IT IS IMPORTANT that during start up safe and ample lubrication The lubrication rate should be provided. This is accomplished by properly adjusting the for break-in should be force feed lubricator pump(s). Observe the detailed instructions, double that for norgiven in Section 6, when first starting up the compressor. With all mal operation. lubricator pumps set at full 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. Experience has shown that the quantity of the oil required to properly lubricate compressor cylinders is dependent upon bore diameter, stroke, and speed. For the Superior compressors 1/5 (0.2) pint per day for each inch of cylinder bore diameter has normally proven to be an adequate quantity. The piston rod and packing is considered as a separate cylinder but with double the lubrication rate required. Packings then require 2/5 (0.4) pints per day for each inch of rod diameter. Minimum should be 0.45 pints per day per packing. See Figure 3-6 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. The gas being compressed, its cleanliness and tendencies to act as an oil dilutent, and the type of the oil being used all influence the lubrication rate required. Many applications may require more or less than the calculated feed rates. To assure that adequate lubrication is being achieved, a periodic visual inspection of the cylinder bore and piston rod are recommended. Initial setting and adjustments to the feed rate should also be accomplished on a 24-hour basis since the drop size varies with the viscosity of the oil.
Figure 3-6 Force Feed Lubricator
I CAUTION
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Table 3-7 is an example of the calculations for determining the lubrication rate for a 2-throw compressor frame with one (1) 10 bore diameter cylinder and one (1) 20 bore diameter cylinder operating at 1200 RPMs: Over-lubrication can be just as harmful as under-lubrication. Excess lubrication can cause valve deposits, valve failures, contamination of the gas stream, and other down-stream equipment.
The regulator is not designed to make large quantities of oil in a short time period, such as refilling the crankcase after oil or filter changes.Its function is to compensate for small losses that occur during normal operation.
Figure 3-7 Example of Calculating Lubrication Rates for Cylinders and Packing
Lubrication Rate For the 10 Cylinder 1 packing X 2.75 X 0.4 pints/day = 1.1 pints/day or 11 drops/minute PLUS EQUALS 10 X 0.2 pints/day = 2 pints/day or 20 drops/minute 3.1 pints/day or 25 drop/minute
Lubrication Rate For the 20 Cylinder 1 packing X 2.75 X 0.4 pints/day = 1.1 pints/day or 11 drops/minute PLUS EQUALS 20 X 0.2 pints/day = 4 pints/day or 40 drops/minute 5.1 pints/day or 50 drop/minute
Total Lubrication Rate 3.1 pints/day or 25 drops/minute for the 10 bore diameter cylinder PLUS 5.1 pints/day or 50 drops/minute for the 20 bore diameter cylinder EQUALS 8.2 pints/day or 75 drops/minute
Synthetic Lubricants
Synthetic lubricants have higher flash points than conventional lubricants. This makes them highly desirable from a safety and fire reduction standpoint. However, synthetics impose problems which are usually not associated with natural mineral oils. They dissolve paints, are corrosive to common bearing materials such as lead and tin, and have low viscosity indexes. For these reasons, when synthetics are considered for use in compressor cylinders or frames, consult an Authorized Unit Distributor .
Multi-Grade Lubricants
Multi-grade oils provide the same protection as heavier single grade oils and do not put undue stresses on the compressor cylinder lubrication system. However, all multi-grade oils do not provide the same protection. For this reason, if a multi-grade oils is being considered for use a a cylinder lubricant, consult an Authorized Unit Distributor.
Section 3: Lubrication and Cooling Cooper Energy Services n Superior Compressor Product Group
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Additional Recommendations
For wet and saturated gas conditions and 0-1000 PSIG, use a minimum viscosity of 85 SUS at 210oF with 3% to 8% compounding with acid less tallow, or two grades heavier than normally used for the pressure conditions involved. For heavy hydrocarbon and sour gases, use the next higher viscosity as shown in Table 3-4 , with a minimum of 85 SUS at 210oF. For refrigeration service, use the highest possible viscosity that should be used and still retain the pour point 15 oF below gas suction temperature. For chemically active gases, consult an Authorized Unit Distributor. Whenever there is any question as to viscosity selection, always use the heavier oil. For oil viscosities over 100 SUS at 210oF, take measures to maintain lubrication pump inlet temperatures at or above 120 oF.
Operation
The cylinder lubrication system consists of a force-feed lubricator and distribution block system that provides lubrication for the cylinder walls and piston rod packing (see Fig 3-8 for a typical setup). The lubricator is directly driven off the compressor shaft through a right-angle-drive worm and spur gear set mounted on the lubricator box. Lubricator pump(s) fed directly from the
Page 3-8
crankcase lube system or from an external tank are used to provide oil to the cylinders. (Note that oil from the lubricator box is not used.) A packager-supplied external tank is used when the requirements of the cylinder oil are different from those of the crankcase. A shutoff valve is supplied to isolate the external tank and the lubricator box. The oil flows to the pumps and then pumped to a common manifold feeding the automatic divisioning system. The automatic divisioning system consists of a rupture indicator (set for the job), a 10-micron strainer, a digital no-flow and counter, divider blocks and optional pin indicators (shows which points are over-pressurized and sets accordingly). Each lubrication point (cylinder and packing case) has a double ball check valve. The lubricator box uses the same oil as in the frame or external tank to lubricate its cams and bearings. The right-angle-drive gear on the lubricator box requires a gear oil that meets ISO 680 AGMA-8 (Exxon TK-680 Cylesstic is acceptable). If a blockage or other anomaly occurs, and the system pressure continues to build up, the safety rupture relief in the collector manifold bursts , relieving pressure throughout the entire system and causing the no-flow shutdown to activate and stop the compressor. The protruding pin in the indicator on the distribution block gives a visual indication of the point where the blockage occurred. Before restarting, new rupture discs of the same color and thickness as originally installed must be replaced at the location where rupture occurred. It is the thickness of the color coded discs that determine the rupture pressure. Refer to rupture disc data sheet in Auxiliary Equipment section of this manual.
Figure 3-8 General Cylinder Lubrication Logic
Section 3: Lubrication and Cooling Cooper Energy Services n Superior Compressor Product Group
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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.
! 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.
I CAUTION
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)
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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.
00752
Section 3: Lubrication and Cooling Cooper Energy Services n Superior Compressor Product Group
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66,672 BTU/hr (70,339 kj/hr) 133,344 BTU/hr (140,678 kj/hr) 200,000 BTU/hr (211,000 kj/hr)
46,300 BTU/hr (48,847 kj/hr) 92,000 BTU/hr (97,693 kj/hr) 138,900 BTU/hr (146,540 kj/hr)
Page 3-12
point is at least 25 F (14C) less than the suction gas temperature (or ambient, whichever is lower). 3. The third form of cooling is by coolant circulation through the cylinder jackets. This form of cooling must be used on compressor cylinders having gas discharge temperatures greater than 250 F (121 C) or a gas temperature rise greater than 170F (77 C). For maximum performance, it is recommended that the cylinder coolant temperature be maintained 10oF to 15F (6o C to 8C) higher than the suction gas temperature. At lower coolant temperatures, condensation forms on the cylinder walls. This condensation must be avoided as it has a tendency to wash the oil film from the cylinder bore, promote corrosion (especially in non-lubricated cylinders), and cause internal damage by excessive wear on rods, rings, valves, and the cylinder bore due to lack of lubrication. Also, condensates are incompressible fluids which can cause damage to any cylinder part by creating forces well beyond the capability of the machine. To control condensates and still maintain optimum cylinder performance, the coolant must be monitored and regulated. This is accomplished by monitoring the coolant in and out temperatures for each cylinder with thermometers and sight flow indicators. From these readings, the operator may regulate the water flow to each cylinder by using a water regulating valve until a coolant temperature differential of 10 F (6C) (15 F (8 C) maximum) is obtained.
Applications that require low suction temperatures below 40o F (4 oC) must contact an Authorized Unit Distributor for assistance.
Packing Cooling
In the majority of applications, rod packings will perform satisfactorily without a coolant being circulated through the packing case and therefore dont have coolant passages. Some applications, however, do require that the packing cases be cooled in order to achieve adequate packing ring life. These applications usually involve high pressures and temperatures, marginal lubrication (characteristically encountered with wet and sour gases), and unclean gases. On these units, the packing cases are provided with internal coolant passages. (Figure 3-11 & 3-12 ). Adequate cooling flow through the packing cases at a satisfactory temperature is required to properly conduct the heat out of the packing. Inlet coolant temperatures should be as cool as possible, but no higher than 90 F (32C) is recommended to achieve optimal cooling. The coolant flow required is normally 1 GPM (4 lpm) for each inch of rod diameter with a minimum of 2 GPM (8 lpm). A pressure drop with water coolant of approximately 30 to 50 psig (207-345 kPag) should be expected across each packing case at the required flows.
Section 3: Lubrication and Cooling Cooper Energy Services n Superior Compressor Product Group
4/3/03
Page 3-13
Figure 3-11 Crosshead Guide and Distance Piece - Lube and Liquid Cooled Package
Figure 3-12 Crosshead Guide and Distance Piece - Lube and Non-Liquid Cooled
Coolant Requirements
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.
I CAUTION
Cleanliness is critical. protect cooling water from impurities and always use clean tools.
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.
Page 3-14
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.
Category
pH Level Total Hardness PPM Chlorides PPM Sulfates PPM Total Dissolved Solids PPM Silica PPM
Standard System
7.5 MIN / 9.5 MAX 100.0-170.0 MAX 25.0 MAX 20.0-100.0 MAX 300.0-400.0 MAX -----
Steam System
7.5 MIN / 9.5 MAX 5.0 MAX 25.0 MAx 20.0-100.0 MAX 300.0-400.0 MAX 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.
Section 3: Lubrication and Cooling Cooper Energy Services n Superior Compressor Product Group 4/3/03
Page 3-15
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. A clean system is a prerequisite for establishing protection of any cooling system. Adequately protected closed cooling systems seldom, if ever, present problems caused by scaling, corrosion, deposits or cavitation.
Cooling System
There are three types of cooling systems used for stationary equipment: open, closed and combination. Open systems involve cooling towers, spray ponds, etc., and cool the water by evaporation. Closed systems involve heat rejection through or shell and tube-type or radiator-type heat exchangers. Combination systems have the engine and compressor jacket water in a closed system using shell and tube-type heat exchangers to transfer the heat to an open system using cooling towers, etc, as above. Closed type systems are commonly used and approved cooling methods; however, because open-type systems involve not only large volumes of make-up water, but also the ease of airborne contamination, Cooper Energy Services do not recommend using these for this equipment.
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N 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 (H 2S). This chemical is dangerous and can cause harm to personnel. H2S is colorless and smells like rotten eggs. In higher concentrations it will kill your sense of smell and impede your ability to detect it. DO NOT relay on your sense of smell as a detection method. Table 4-1 gives some general information on the concentrations levels of H2 S and its effect on the body. This should be thoroughly read and understood before working in an H2S environment.
Section 4: Safety Precations and Guidelines Cooper Energy Services n Superior Compressor Product Group
WG-4/3/03
Page 4-1
Protective Equipment Is Recommended For Any Concentrations Over 10 ppm (0.001%) 100 ppm (0.01%) 200 ppm (0.02%) 500 ppm (0.05%) Kills sense of smell in 3 to 5 minutes. May burn eyes and throat. Kills sense of smell rapidly. Burns eyes and throat. 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. Immediate unconsciousness. Permanent brain damage may result if not rescued immediately.
The equipment specifications are based on three levels of sour gas plus additional National Association of Corrosion Engineers (NACE) requirements as defined by the following percentages of H2 S: Level I Level 1-11P Level 2-11P Enhanced Trim Less than 2% H2S (by volume) 2% to 5% H2S (by volume) Greater than 5% H2 S (by volume) Follow NACE MR0175 Guidelines
Trim Requirements
For Hydrogen Sulfide (H 2S) Concentrations Up To 2% By Volume: For any concentration of H2S up to 2% by volume in lubricated service, special trim will not be required. Standard material is acceptable and special lubrication practices are 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 (< 27 F (<-3 C) Neoprene (Spec. 479) can be specified as an option. Level 1-11P trim (H2 S 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.
Section 4: Safety Precations and Guidelines Cooper Energy Services n Superior Compressor Product Group
WG-4/3/03
Page 4-3
Level 2-11p Trim (H 2S Concentrations > 5%) All of the requirements for H2 S 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) H2 O. 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 H2 S trim in excess of API 11P requirements is needed to meet NACE. This enhanced level of trim can also be used for any concentration of H2S as required by the customer. 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) H2 O. 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) H2 O. 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 Cooper Energy Services n Superior Compressor Product Group WG-4/3/03
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.
Page 5-1
decrease the soil 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 Base Frame/Skid Mounting Block (Concrete) Mounting
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.
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t Figure 5-3
First, remove the template and chip off the top layer of pure cement and sand so that the grout will have a good solid surface for bonding. Then, clean the top surface of the foundation thoroughly. Soak the surface for several hours before pouring grout, but make sure there is no standing water. Remove the stuffing from around the foundation bolts, but place a dam around the top 00759 of the bolt and extending into the can, to avoid grout contact with any part of the bolt. Next, screw each jackscrew through the frame (Figure 5-3) in a manner which would support the frame approximately 1 to 1.5 inch (2.5 to 3.8 cm) above the foundation. This provides for leveling, aligning and grouting. (There should be a jackscrew at each holddown bolt.) With the compressor resting on the jackscrews, check to see that it is level. Place level on top side of frame as required to level in both directions all around. Bring frame to level by adjusting jackscrews. Keep all jackscrews snug. After levelling, foundation bolt nuts should be secure but NOT TIGHTENED. It is very important the unit is aligned as accurately as possible so that after grouting or shimming has been completed, the foundation bolts may be pulled down without any resulting stresses.
I 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.
When the grout has completely hardened, LOOSEN THE JACKSCREWS and tighten down all the foundation bolt nuts evenly. Make sure that no stresses are set up when pulling down the nuts by checking alignment with a dial indicator.
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The success of a compressor installation depends greatly upon the construction of the foundation and upon the care used to align the compressor with its driver. The standard flexible coupling used to drive the Superior compressor is shown in Figure 5-4. Installation is as follows dial indicator method: Figure 5-4 Flexible Coupling Assembly
a. Disassemble the flexible coupling. Note the arrangement of bolts, washer, and nuts. They must be replaced in their original position. Tie a string or wire through one bolt hole of the laminated rings (A) to retain the dialed position of individual discs. . b. Mount flange (B) on engine flywheel. Torque flange screws per Table 7-2 and lockwire together. Mount hub (C) on compressor crankshaft. (See instructions given in Drive Coupling Hub Page 7-9.)
c. With engine and compressor moved into position, as shown on the outline drawing, reassemble coupling. Dimension (D) must be maintained during the following alignment procedure. t Figure 5-5 Dial Indicator Method of Alignment
00761
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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.
n. Alignment should be checked periodically. Realign unit when parallel misalignment exceeds 0.014 inch (0.036 cm) T.I.R. and/or angular misalignment exceeds 0.020 inch (0.051 cm) T.I.R.
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Page 5-5
Table 5-6 Rexnord Flexible Coupling Torque Values Coupling Size Bolt Size Threads/Inch Torque -- Footin inches Lbs. (N-m)
500 550 600 700 750 800 850 925 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.
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Page 5-6
b. Bar over the compressor, at least one revolution in Figure 5-9 Measuring the Piston the normal operating direction, to insure all parts are End Clearance working freely. c. While barring the compressor over again, head end clearance is taken by inserting a 1-inch (2.5 cm) length of soft solder between the approaching piston and cylinder head. Pistons 10 inches (25 cm) and larger should use solder inserted from both sides to keep the piston from cocking and giving a false reading (Figure 5-8). Measure the crushed solder wire (Figure 5-9). The head end clearance should be 0.070 to 0.090 inch (1.78 to 2.29 mm) for a cold compressor. d. Check the crank end using the same method. For a cold compressor, the crank end clearance should be 0.030 to 0.050 inch (0.76 to 1.27 mm). e. If any adjustment is needed, loosen the balance nut and screw the piston and rod assembly in or out of the crosshead. The WG piston rods are threaded with 12 threads per inch. Thus one complete turn of the piston and rod assembly moves it 0.083 inch (2.11 mm).
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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.
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Page 5-8
I 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. f. Remove a valve from each end of every compressor cylinder. g. Check the piston end clearances on all cylinders, and then replace the valves. h. Add lubricating oil, which meets the proper specifications, to the base and to the lube oil filter.
NDANGER
Vent the compressor and the process system to the atmosphere before removing any gas-containing part of the compressor or its associated piping.
NDANGER
High pressure oil stream may puncture skin. Use proper wrench and keep hands away from the immediate point where connection is purging air.
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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.
Oil level in frame should be filled to the level in the Kenco level regulator NOT the level in the frame bulls-eye.
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.
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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).
I CAUTION
Running compressor at speeds less than 600 RPM for longer than 12 minutes may result in unusual wear of the piston rings.
2. Start up and operate the unit under no-load conditions at reduced speed where possible (600 RPM for engine driven units). Check the oil pressure. When the compressor is started, an oil pressure of 20 psi (138 kPa) must be experienced within 5 seconds or the compressor must be immediately shut down. Do not restart until adequate oil pressure can be assured. The oil level in the frame is normally at the center of the sight glass. 3. Run compressor for 2 to 5 minutes at 600 RPM. If driver is a constant speed electric motor run compressor for only 1 to 2 minutes. 4. Shut system down and check all bearings and packings for high temperatures. 5. Remove crosshead guide covers and check all lubricated surfaces for high temperatures. 6. Check piping for oil or water leaks. 7. Start system and compressor up again and run for approximately 20 to 30 minutes. Add oil to the crankcase to bring the oil level (while running) up to the middle of the sight glass. Shut down and recheck as above.
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8. Start unit. Bring unit up to full rated speed. Apply load to compressor by closing the bypass line between the first stage suction and last stage discharge lines. 9. During the initial period of operation, pay close attention to the machine for any unusual high temperature, pressure, or vibration. In the event of equipment malfunction where excessive vibration, noise, high temperature, or any other dangerous condition exists, the compressor should be stopped immediately.
NDANGER
Do
not immediately remove the equipment covers after the compressor has been stopped. Allow the unit to cool down to prevent possible explosion due to in rush of air or injury caused by contact with hot surfaces.
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. 7. Bring up to rated speed and apply load.
NDANGER
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.
WG-4/3/03
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4. Close suction and discharge block valves. 5. Turn off water supply. 6. Relieve pressure by venting compressor cylinders, suction piping, and discharge piping to remove any remaining gas.
Emergency Shutdown
In an emergency situation, the shutdown devices will shut down the system. In such as case, the cause of the shutdown must be identified and corrected before restarting the compressor. Refer to the Troubleshooting Page 7-23 thru 7-31 to troubleshoot compressor.
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.
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WG-4/3/03
Page 6-6
Cooper Energy Services 20110 GH Circle P.O. Box 947 Waller, Tx 77484 Fax:713-890-1399
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:
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WG-4/3/03
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Section 7 Maintenance
General
The diligent observation of the inspection and maintenance procedure, given in this section, will go a long way toward insuring satisfactory operation of the compressor. Superior recommends planned periodic inspections of equipment. Regardless of the gas compressors, malfunctions can occur. Faithful preventive maintenance and the use of genuine Superior parts will help prevent costly down time, repairs, and replacement costs. Planned shutdowns for doing preventive maintenance will result in minimum maintenance costs and maximum mechanical efficiency of your equipment. Good preventive maintenance practice includes a periodic check of critical bolt torques, such as compressor main and connecting rod bolts and drive coupling bolts.
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Page 7-1
SIZE
430 - 460 (583 - 624) 570 - 630 (773 - 854) 640 - 700 (868 - 949) 260 - 290 (353 - 393) 200 - 220 (271 - 298) 35 - 45 (47 - 61) 3090 - 3790 (4192 - 5140) 1180 - 1265 (1598 - 1713)
Torque Ft.-Lbs. (N-m)* 4-6 (5-8) 12-18 (16-24) 35-45 (47-61) 60-70 (81-95) 120-140 (163-190) 200-220 (271-298) 260-290 (353-393) 370-410 (502-556) 520-570 (705-773) 700-770 (949-1044) 930-1030 (1261-1397)
Cylinder Diameter in inches 6.00 6.25 6.75 5.75 6.25 6.75 7.25 7.00
Valve Cap Nut Torque Ft.-Lbs. (N-m)* 370 (502) 370 (502) 370 (502) 300 (407) 300 (407) 300 (407) 300 (407) 370 (502)
Page 7-2
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 Table 7-2. Additional information is given in Service Bulletins SB168 and SB175 . 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. Periodic calibration is essential to ensure accuracy.
I CAUTION
When tightening nuts and bolts on compressor valve caps, bottles, and flanges care must be taken to avoid excessive tightening. Overtightening can result in unnecessary stress in the cylinder body and, in the case of valve caps, can result in valve seat distortion.
Occasionally clean and lubricate the ratcheting head with light oil, NOT GREASE.
Precautions
Follow the precautions listed below when any maintenance is performed. Damage to the equipment, personal injury or death may result if these precautions are not followed. 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.
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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.
NDANGER
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.
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. 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.
Component Maintenance
Base (Crankcase)
The base is made of high strength alloy iron and is heavily ribbed and reinforced for maximum rigidity. Large spacer bars provide further stability and ease reassembly. The top and end covers are individually removable to provide easy access to moving parts. Our open-top design allows
Page 7-4
WG Series Compressor Frame Instruction Manual the crankshaft to be easily removed. An oil sump is provided in the lower portion of the base. The line-bored main bearing supports have caps which are match-marked and numbered and must be assembled accordingly.
I CAUTION
Only use a pencil for marking on the parting line faces or in the groove of the bearing shells.
After removing the main bearing cap and the upper bearing shell, the lower bearing shell can be rolled out from underneath the crankshaft with the help of the main bearing removal tool. This is done by inserting the neck of the tool into the oil passage hole in the crankshaft journal. When the compressor is barred over, the tool will push the bearing shell out from underneath the journal and around to the top where it can be removed. A new bearing shell can be installed using the same procedure. Carefully clean the crankshaft, bearing shells and saddles before attempting to replace the bearing shells. Under no circumstances should any filing, scraping, or other fitting be done on either bearing shells or saddles. The bearing cap nuts should be tightened uniformly (using a crisscross pattern) to the proper torque given in Table 7-2. The main bearing clearance (tolerance value) can be checked by using a dial indicator and a hydraulic jack. Proceed as follows: a. Remove the top cover to gain access to the crankshaft. b. Attach the dial indicator to the bearing cap via a magnetic base. Mount the indicator so the button comes in contact with the crankshaft at its highest point. Depress the button until the dial makes one complete revolution and set the pointer top to zero. c. Use a hydraulic jack that will fit between the crankshaft and frame bottom. Position it as close as possible to the bearing being checked.
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d. Support the jack with a piece of wood and jack the crankshaft up and down to get a clearance reading on the dial indicator. e. Compare the clearance reading with the tolerance value given in Table 7-1. If the clearance reading exceeds the maximum limit, the bearing needs to be replaced.
NDANGER
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.
The upper end of the connecting rod carries one pressed in bushing. When the bushing is replaced in the field, extreme care should be used in shrinking the new bushing in place. To change the connecting rod bearings (crankpin end), bar the compressor over until the connecting rod cap rises to its highest point. This will offer easy access to the cap bolts. Support the connecting rod so it will not drop after the cap has been removed. With the connecting rod supported, remove the rod cap and its bearing half. In order to get access to the other bearing half, bar the compressor over so the crankshaft moves slightly away from the connecting rod. Install a new bearing half against the back wall of the connecting rod. The tang recess within the rod should support the bearing until the crankshaft can be moved back into position. Complete the assembly process by putting the other bearing half and rod cap in position and tighten the bolts (using a crisscross pattern) per the torque values given in Table 7-2. The rod cap and crosshead pin must be removed to remove a connecting rod. The crosshead pin can only be removed when the crosshead is in the outermost position. Remove the crosshead pin assembly. Push the pin through the crosshead far enough to release the connecting rod. The connecting rod can be eased out of its position when the crankshaft throw is slightly below the innermost position. A connecting rod can be installed by reversing the above procedure.
NDANGER
Always support the connecting rod so it can not drop and damage equipment or cause injuries.
The caps and rods are numbered by throw and have their weights stamped on them. Always install rods with this information displayed up.
Page 7-6
Crosshead Guide
The fasteners holding the crosshead guide to the base must be torqued uniformly (using a crisscross pattern) to prevent cocking of the guide relative to the base and crankshaft. (See Table 7-2 for torque values). Large side covers on the crosshead guide allow easy access to the crosshead, connecting rod, and rod packing. The crosshead can be removed through these openings without disturbing the cylinder mounting.
Page 7-7
To install a crosshead, reverse the above sequence. 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 balance nut must be toward the crosshead. Check piston end clearances and then make sure that the balance nut is torqued properly ( Table 7-2) against the crosshead.
Crossheads and balance nuts are stamped with throw numbers and must be replaced accordingly.
This procedure applies to the old style cover part #620-093-001. The new cover is machined and does not contain the same number of components.
If it is desirable to remove the crankshaft from the base without removing the drive coupling hub, this can be done. First, remove the screws holding the drive end cover. Then support the drive end cover in place on the crankshaft, while lifting out the crank. Remove the screws holding the seal cover. The drive end cover can now be snaked off the crankshaft toward the auxiliary end - leaving the seal cover on the slinger hub. It must be supported to prevent it from moving. Lube Oil Supply (Sump) The oil circulating system is of the pressure, wet sump type, where the lubricating oil supply is carried in the compressor frame and circulated by means of a gear type pump - gear driven from the crankshaft. The pump takes oil from the frame sump, through a suction strainer and delivers it into the lubricating oil header, or manifold on the compressor - the oil first passing through an oil cooler and full flow filter.
Page 7-8
WG Series Compressor Frame Instruction Manual The precision built, gear type lube oil pump provides full pressure lubrication for all moving parts in the frame. The pump, with its drive gear, can be removed from the base end cover independent of the cover or other gear drives. When installing the pump, observe the following: a. Clean the pump mounting face thoroughly. b. Assemble key, drive gear and lock plate. Tighten screws holding the lock plate to the gear, and fasten with lock wire. Add a slotted nut to the rotor shaft and lock in place with a cotter pin. c. Add gasket for carrier assembly. Slide carrier assembly into place on the end cover, using the dowel to locate. d. Proper gear backlash is given in Table 7-1.
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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 inch (1.27 mm). e. Heat the coupling hub and slide it on the shaft until it engages the gage block (with the reduced amount of shims as defined in item d above). 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 7-10
WG Series Compressor Frame Instruction Manual of the coupling and are generally adequate for most installations. It should be kept in mind that there are definite advantages to be gained from aligning the equipment to more precise values than those shown. The primary advantage is that the reserve margin for accepting misalignment during the life of the machinery is thereby increased. Exceeding the Table 5-6 values for alignment will reduce the service life of the coupling. Another factor to be considered, and one of the most important to good performance is adherence to the bolt torquing recommendations Table 5-6. Loose bolts can induce fretting corrosion, hammering, and pounding which will eventually destroy the bolts and coupling discs.
00767
00768
00769
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Page 7-11
00770
t o r q u e
! Caution
Figure 7-10 Torque Overload If bulged or bowed condition only appears in one chordal section there may be a loose bolt on one side of the distortion. Loosen coupling locknuts and turn bolt slightly to remove friction. Bulge should flatten out. Re-torque locknuts. If distortion does not disappear, replace disc pack.
Page 7-12
WG Series Compressor Frame Instruction Manual sections will be very straight and tight. Check the driven equipment loading. If not correctable, contact the Cooper Energy Service facility immediately.
Cylinder Body
A wide range of cylinder sizes is available. Each cylinder is conservatively designed for very low stress at rated working pressures. Some cylinder bodies are provided with drilled water passages, top and bottom, which connect the water inlet and outlet with the cooling muff, which surrounds the ring travel area of the bore. Whenever the water jacket covers on the cylinder sides are removed to clean out deposits, the drilled passages should also be cleaned out. If the pipe plugs in the crank end of the drilled passages are removed, they should be coated with good waterproof sealer and replaced. This will prevent water seepage into the atmospheric vent space. Lube oil, from the force feed lubricator tubing system, passes through a check valve and into a fitting on the outside should be cleaned out and all steel tubing checked for soundness and tightness. This paragraph does not apply to non-lube operation. Plugs are provided, on all size of cylinders, which can be removed and indicator cocks inserted to take pressure readings, if desired.
Cylinder Head
I CAUTION
The cylinder head must be properly indexed on the mounting studs so that the valve cut-outs in the head align with valve locations in the cylinder body.
After removing a cylinder head, examine the o-ring which provides a seal between the cylinder head and the cylinder body for nicks, tears and compression set. Replace as required. The water seal grommets should also be checked. It is recommended that a complete set of o-rings and grommets, for all cylinder sizes used, be kept in stock at all times.
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Page 7-13
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 Superior Engineering Department for wear limits for your specific cylinder size and application.
Figure 7-11
Page 7-14
WG Series Compressor Frame Instruction Manual Ordinarily, packing cases t (cups and glands) are not severely worn. Therefore, it is possible to repair piston rod packings by replacing the packing rings only. It is good practice to keep a complete set of packing rings on hand for the packing assemblies of all your cylinders. In order to remove a packing case from a crosshead guide or cylinder, the piston rod must be pulled out through the assembly and cylinder. Before disassembling a packing case, note all identification marks to ensure components are reassembled properly. If components are not marked, identify each cups position relative to the adjacent cup or flange by numbering or marking them together. While disassembling a packing, record the position of each ring and the direction each ring faces for proper reassembly. Refer to Figure 7-13 for aid in identifying packing rings. Knowing your packing rings is very helpful when ordering new ones.
Figure 7-12
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Page 7-15
Figure 7-13
00776
Page 7-16
WG Series Compressor Frame Instruction Manual The packing cups and glands that are not being replaced by new ones must be soaked and thoroughly cleaned in a non-acid solvent. They should then be blown dry and examined closely for unusual nicks or burrs which might interfere with the rings free floating or contact with the rod. Particular care must be taken with rings made of soft metals and it is very important that wiper rings be handled and installed carefully to prevent damage to the scraping edges. Before installing new packing assemblies, it is important that the piston rod be carefully checked. If the rod is worn, rough, pitted or has a taper, it must be replaced. The bore for the pressure packing nose cup must be cleaned and examined for burrs. If found, burrs should be removed. Also, replace the o-ring in the outside diameter of the wiper packing flange with a new one. A new metallic gasket should be placed in the groove of the pressure packing nose cup. Remove the old metallic gasket with a sharp tool; take care not to damage the groove. Clean the groove thoroughly and install a new gasket. Tap the gasket into the groove with a hard rubber mallet. Do not use a steel hammer as this may damage the sealing surface of the new gasket.
I 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 Section 3.
The rings must be placed in the packing cups in the same position (facing original direction) as the original set.
After installing the packing cases and before connecting the oil tubing to the packing flange (for lubricated packing), hand pump the force feed lubricator (when supplied) until oil runs from one of the disconnected tubes. Connect this tube to the respective hole in the packing flange and continue to pump the lubricator 12 to 15 more strokes. After the piston and rod assembly has been reinstalled, the piston end clearance must be set and the piston rod runout must be checked per Section 5 .
Valves
Valve Installation Suction and discharge valves must be installed in the proper direction. This can be determined by first inspecting the valve to see which direction the valve plates move while opening or compressing the springs. Gas will flow in that same direction (Figure 7-14) .
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Page 7-17
Valve Replacement
Refer to Figure 7-14 . Proceed with valve removal in the following manner: 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 7-14
Valve Installation
c. Loosen set screw in valve retainer (bottom valves only). Insert threaded puller into valve retainer and remove. d. Using threaded valve puller, remove valve from seat in cylinder. e. Remove, inspect and replace gaskets as needed. f. Clean all gasket surfaces on valve and in valve pocket, and on valve retainer and on valve cap. g. Install new gasket in valve pocket. Place valve in pocket FACING PROPER DIRECTION . h. Install the retainer on top of the valve. Install new gasket in place on retainer, as applicable. i. Grease or oil the o-ring on the valve cap. Force the valve cap into place by torquing the nuts or screws evenly to the values listed in Table 7-2.
Before removing any gas containing part of the compressor or associated gas piping system, vent compressor and system to atmospheric pressure.
The valve cap flange must not contact the cylinder body. Clearance must exist at this point to insure that pressure is applied to the valve and retainer gaskets when the relief cap bolts or nuts are tightened.
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.
Page 7-18
WG Series Compressor Frame Instruction Manual k. Lift the valve, retainer, and gasket up into the bottom port, making sure that the valve seat enters first. l. Tighten the retainer lock screw just enough to hold retainer and other parts in place. t
Figure 7-15
Valve Replacement
00778
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Page 7-19
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 .
Special Tools
Refer to the section 9 and 10 of this manual for information on special tools.
Table 7-16
Alarm/Shutdown
Oil Pressure in Header Oil Temperature out of the Frame Vibration Gas Temperature Water Temperature
Alarm Point
25 psig (173 kPag) 185 F (85C) Out 1/4-3/8 turn from normal condition 20F (11 C) above TS or TD 20F (11 C) above Tout or Tin 5% below PS 5% above PD
Shutdown Point
20 psig (138 kPag) 190 F (88C) Out 3/8 - 1/2 turn from normal condition 25F (14 C) above TS or TD 25F (14 C) above Tout or Tin 10% below PS 10% above PD
Gas Pressure
Page 7-20
Perform safety shutdown system tests. Note and record panel gauge readings. Check calibration of all themometers and pressure gauges.
LUBRICATION SYSTEM
Check oil levels, oil level regulator, and oil sight level. Check lubricator line connections for leakage. Inspect frame, lubricator, and packing cases for leakage. Clean and/or replace crankcase breather(s). Check compressor force feed lubricator pump(s) for proper output rate. Collect a compressor oil sample for analysis.
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 X X X X X X X X
X X X X X X
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Page 7-21
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 7-18 through 7-22 list many typical symptoms, causes and corrective measures. It may be necessary to refer to more than one symptom to locate the entire difficulty. The suggested corrective actions are supposed to direct you to those areas most likely to be at fault. However, do not limit your analysis only to those areas found in the table. If symptoms persist, contact your nearest Cooper Energy Services Aftermarket office for possible field assistance. Table 7-18
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.
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. Total weight of crosshead, balance nuts, piston rods, connecting rods, and rings must be within 3 lbs. (1.4 kg) of same components on opposite throw. Replace balance nuts or crossheads to obtain this balance. Possible broken frame, Verify crankshaft alignment, piston rod runout, and connecting rods, crankshaft, or bearing clearances. Replace bearings as needed. piston rods. Reverify alignment and runout. Foundation damage, Realign the compressor per Section 5. foundation bolt failure, grout cracking, or broken frame and crankshaft. Excessive vibration causing Analyze compressor with a vibration or indicator analyzer. cracked welds, foundations, Install orifices at the cylinder flange, change piping, grout, and parts. Also possible change cylinder operating configuration, or change foundation bolt breakage. operating speed.
Page 7-22
Table7-19
Symptom No lube oil pressure Possible Cause Lack of oil
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. Scored bearings, crankshaft, pressure crosshead shoes, and pins. Seizure of compressor is possible. Clogged or dirty filters. Same as above. Air leak on suction side of pump. Sticking or maladjusted pressure relief valve. Excessive main and connecting rod bearing clearance. High lube oil Lube oil cooler clogged temperature or dirty. . Insufficient warm cooling water through cooler. Same as above. Same as above. Same as above.
Check all lubricated surfaces and replace parts as needed. Replace filter element and/or strainer. Find and stop leak. Free or adjust valve. Replace defective bearings.
Reduce viscosity resulting in Clean cooler. lower lubrication and filtration. Same as above. Correct water flow problem or temperature.
Table 7-20
Symptom Failure to deliver gas
Cylinder damage through broken valve parts in the cylinder bore. High or low discharge pressure between stages with insufficient rod reversal, resulting in pin failure Possible broken plate valves or springs.
Open or defective clearance pocket Defective piston High discharge temperatures rings Low compressor cylinder Worn piston Piston, ring, and bore overheating discharge pressure rings
Clean and replace any defective valve parts. Review type and quantity of lube oil used. Possible insufficiencies on rod load reversal If open, load compressor. If and head mechanism damage damaged, replace defective parts. Replace rings Replace with new rings
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Page 7-23
Table 7-20
Symptom
Possible Cause
Potential Damage
Corrective Measure
Low compressor cylinder Loose valve(s) discharge pressure (Continued) High compressor cylinder discharge pressure.
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.
NDANGER
Loose valves.
If all valves are reversed, excessive pressure can build up resulting in cylinder failure and injury.
Same as above. Possible damage to valve Remove valve and retainer. seat, valve bodies or retainers. Replace any broken parts. Dye check the cylinder valve seat.
Page 7-24
Table 7-20
High interstage pressure Improper settings of clearance pockets on the higher stage heads Missing or defective suction valve(s) on the higher stage. Worn piston rings in the higher stage cylinder Defective relief valve
Symptom
High gas discharge temperature
Possible Cause
Defective discharge valves High discharge pressure
Potential Damage
Damaged gaskets, damaged O-rings, and cylinder overheating Rod load exceeding design. Insufficient rod load reversal exceeding the M.W.P. of the cylinder. High discharge temperature
Corrective Measure
Replace defective parts
Increase setting of variable volume pocket(s) or open fixed 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. Insufficient rod load reversal which can lead Try corrective measures listed for to damage to the crankshaft from excessive Low Compressor Cylinder heating, seizure of the crosshead pin, as well Discharge symptom. as damage to the piston rods, crossheads, crosshead guides, and connecting rods. Leaking suction valves causing suction valve Replace springs or plates. damage. Overheating of compressor cylinder. Breakdown in cylinder lubrication causing Check pump for proper flow, heat overheating, cylinder scoring, and valve exchanger condition for proper damage. cooling, and water supply for proper level. Repair or clean cooling system, or add water as required.
Table 7-21
Symptom Growling in lube oil pump
Chatter in relief valve Air in oil lines. Knock in cylinder area Foreign material in cylinder (including water). Piston-to-cylinder end clearance set incorrectly. Improperly installed valve. Loose valve. Loose piston nut.
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Page 7-25
Table 7-21
Incorrect piston to head clearance. Scored piston or cylinder. Loose valve assembly. Loose packing assembly. Loose piston. Excess carbon deposits. Foreign object in cylinder
Symptom Possible Cause Knock in cylinder area Loose cylinder head. (continued) Loose variable volume pocket Damage to gasket seal surface. Tighten variable volume pocket. unloader. Whine in auxiliary end Worn, broken, or chipped gear Gear damage. Replace gear. gear teeth. Improper backlash setting. Gear damage. Reset gear lash.
Table 7-22
Symptom Vibration
General Troubleshooting
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. Piping strain. Loss of production. Apparent production loss. Failure of individual components. Causes abnormal cylinder capacity performance. Overload. Corrective Measure Install proper piping support to raise the frequency of the vibrations. Replace all damaged components. Tighten components properly. Tighten nuts. Tighten. Properly design piping system. Use correct measurement techniques. Restore to proper mechanical condition. Modify piping to eliminate pulsation. Determine cause and correct.
Possible Cause Piping system improperly supported. Loose piston or piston rod.
Low capacity
High load
Loose nuts on cylinder to frame mounting studs. Unit loose on foundation or rails. Excessive pressure drop in piping system. Gas measurement techniques are not correct. Poor mechanical condition of unit. Gas pulsation in vicinity of cylinders. Excessive capacity being delivered. Poor mechanical condition of unit. Gas pulsation in vicinity of cylinders.
Distortion of compression cycle Correct mechanical problems. resulting in excess load. Abnormal cylinder horsepower Modify piping to eliminate performance. pulsations.
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Table 7-22
Lubricator does not discharge oil
General Troubleshooting
Overheated and/or damaged packing. Scored cylinder walls. Same as above. Same as above. Same as above. Same as above. Same as above. Same as above. Damage to cooler. Prime lubricator pump to insure oil passage to the pump. Add oil to proper level. Unplug vent. Unkink or replace line. Replace oil check valve. Readjust pump stroke. Retighten fitting or replace line as needed. Replace faulty compressor valves.
Feeds not vented of air. Low oil level. Plugged vent in lubricator tank. Line leaking or kinked. Oil check valve on cylinder faulty. Incorrect adjustment of pump stroke. Leak in line or fitting.
High cooler pressure. Faulty suction valves in high stage cylinder. Defective gauge. High discharge temperature Faulty valves.
Scored piston or liner. Symptom High discharge temperature (continued) Possible Cause Insufficient lubrication (lubricated cylinder only). Packing too tight.
Improper operation of the Replace gauge. compressor. Cracked or broken cylinder, Replace valves. bent rod, or worn piston rings or packing. Same as above. Repair damage and replace damaged parts. Potential Damage Corrective Measure Same as above. Increase lubrication.
Same as above.
Same as above.
Condensate caused by cold Broken or bent rod. Cracked interstage piping. cylinder. Liquids in process are not Same as above. removed from the gas stream by separation equipment. Dirty gas or foreign matter in High gas temperatures. gas stream. Possible piston and cylinder damage. Liquid in cylinder. Same as above. Excessive lubrication. Same as above. Carbon deposits. Same as above. Improper assembly. Same as above. Insufficient control. Pressure Same as above. or leaking seal in variable volume pocket unloader.
Check rings for proper clearance and packing case for clearance around rod. Check valves, coolers, and process. Check valves and/or process condition. On multistage units check suction valves of next higher stage. Check proceeding stages of process. Raise cooling water temperature. Check process operating conditions. Check operation of separation equipment and dump valves. Clean up gas by proper separation and/or filtration. Find source of liquid and correct. Reduce lubrication. Reduce lubrication. Change to lubricant which forms less carbon. Reassemble properly. Check for possible control pressure leak.
4/3/03
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Table 7-22
General Troubleshooting
Trace line from designated rupture disk and fix malfunctions. Replace filter. Unblock line. Unblock line. Clean divider block interior.
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.
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