You are on page 1of 84

WG Series Compressor Frame Instruction Manual

Section 1 Introduction to the WG Series Compressor and Specifications
About This Manual
Thank you, for purchasing Cooper Energy Services equipment! This Instruction Manual contains safety, operating and basic maintenance instructions for the Superior® WG series compressor frames. Cooper Energy Services is committed to continuous improvements and design advancements. Because of this commitment, changes may occur in your compressor frame that may not appear in this instruction manual. Some photographs or illustrations in this manual show details or options that may not appear on your compressor frame. Guards, covers or other protective mechanisms may have been removed for demonstrative or illustrative purposes. Any time a question arises concerning your compressor or this instruction manual, please contact an authorized Cooper Energy Services Distributor for the latest available information. Figure 1-1 WG Compressor It is very important that perDurable Frame: sonnel associated with Enhanced structural strength, one-piece construction Up to 9000 operation maintenance of Horsepower the WG series compressor @ 1200 RPM read this manual and support documentation. Keep O’Ring Seals this manual with related litDigital erature and compressor No-Flow Meter information. Store it so it is easily found by maintenance or service personnel. Easy to service It is also important that Oil Supply users carefully study the System 48” cylinder Lower Center of Spacing safety information provided Gravity for less Vibration in Section 2. Always use 6” and 7” Extra Robust good safety practices at all Stroke Capability Support times to prevent injury to personnel or damage to equipment. This manual contains confidential and proprietary information from the Superior Compressor Products Group of Cooper Energy Services, a division of Cooper Cameron Corporation. This manual is given to users for the limited purpose of providing
Section 1: Introduction to Servicing the WG Series Compressor Cooper Energy Services n Superior Compressor Product Group WG-4/3/03

Page 1-1

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.

Identifying Your Compressor Frame and Cylinder

Figure 1-2 Frame Nameplate
Correspondence concerning your compressor frame must include the Cooper Energy Services compressor frame serial number. The compressor frame serial number applies to the frame and running gear parts. It is located on the frame nameplate which is attached to the top cover. Each compressor frame and cylinder has its own serial number.

Figure 1-3 Cylinder Nameplate
Correspondence concerning your cylinder must include the Cooper Energy Services cylinder serial number.

Compressor Frame Overview
All Cooper Energy Services compressor frames are engineered for reliable, continuous, heavy duty and trouble free operation. These ruggedly constructed, balanced-opposed type compressor frames are built with high speed, high precision, high quality and field proven standards of CES’s Superior ® compressors. Easy access to all wearing parts means simplified

Page 1-2

Cooper Energy Services n Superior Compressor Product Group

WG Series Compressor Frame Instruction Manual

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

Pneumatically Operated Pocket

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

Page 1-3

Figure 1-5

WG Stroke Options

Figures 1-6 and 1-7 show the general configuration of the WG compressor

Figure 1-6 WG Compressor Breather

Connecting Rod

Crankshaft Frame

Page 1-4

Cooper Energy Services n Superior Compressor Product Group

Alarm Point Lube Oil Filter Differential pressure .inches (mm) Crosshead Pin Diameter .Normal Lube Oil Filter Differential Pressure .Oiling Method Lube Oil Filter Differential Pressure .Shutdown Maximum Limit for Reciprocating Weights * Subject to change without notice.625 (117.WG Series Compressor Frame Instruction Manual t Figure 1-7 General WG Series Compressor Specifications Table 1-8 Compressor Specifications Specification Connecting Rod Length Center to Center-inches (mm) Crosshead Guide Bore Diameter . Type Of Unit WG6 WG7 17 (432) 17 (432) 13.inches (mm) Crosshead Shoe .75 (349) 13.625 (117.5) 4.5) External Internal >5 psi -15 psi -25 psi -539 lbs 539 lbs Section 1: Introduction to Servicing the WG Series Compressor Cooper Energy Services n Superior Compressor Product Group WG-4/3/03 Page 1-5 .75 (349) 4.

Compressor System Vibration Due to the nature of the horizontal compressor design. Operators and maintenance personnel should be alert for excessive system vibration that can cause damage to equipment. Normally. valves. the reciprocating weights generate some vibrational forces. piping. Compressor systems (including skids. and other components) are subject to vibration. This is the preferred method of attachment. if necessary. t Figure 1-9 Suction Valve Piston Piston Rod Crosshead WG Transverse Cross Section Variable Volume Pocket Packing Discharge Valve Connecting Rod Location Page 1-6 Cooper Energy Services n Superior Compressor Product Group . Most cylinders now have a machined boss with drilled and tapped holes for attaching an outboard cylinder vibration suppression device. Proper balance of reciprocating weights on the opposing throws will minimize this effect. clamping or adding additional support to a vibrating component will raise natural frequency and eliminate the vibration problem. bottles. by attaching additional supports directly to the cylinder from the skid or foundation. Compressor cylinder mounting can be stiffened. The design goal is to have a system free of vibrations in a normal operating speed range.

Figure 1-10 Balance Sheet Example 00752 The estimated balance for the original assembly of a compressor is recorded on the Compressor Vent Fill Plug Torsional and Balance Data Sheet. or changing piston ring material.WG Series Compressor Frame Instruction Manual Balancing Compressor Frames Cooper Energy Services manufactures balanced opposed reciprocating compressor having one to six cylinders. WG-4/3/03 t Section 1: Introduction to Servicing the WG Series Compressor Cooper Energy Services n Superior Compressor Product Group Page 1-7 . There are two different weight crossheads available. When replacing crossheads. 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. connecting rods. piping vibration. connecting rods. when can vary replacing crossheads. depending on cylinder sizes. rings. Connecting rods vary in weight and when the units are assembled at the factory. foundation cracking and other damage to the compressor.This is quite a task. the new parts Drain Plugshould be weighed.45 kg) on the connecting rod weights. the connecting rod weight is also involved in the balance. care is taken to select the connecting rods so that the weight variation for opposing throws does not exceed 1 pound (0. In addition to the above mentioned balance parts. the new parts should be weighed. N DANGER Failure to verify and correct compressor balance can result in excessive mechanical vibration. pistons. It also creates a potentially unsafe operating condition for the operator. Since the goal is to produce a balanced opposed compressor. in order to reaffirm the actual unit balance. and the crosshead. Also. in order to reaffirm the actual unit balance.90 kg) on the reciprocating weights and one pound (0.5 inches (76 mm to 673 mm) in diameter and may be mounted on the frames in various combinations.Every effort should be made to achieve as near equal balance between opposite throws as possible. I CAUTION Also available are balance nuts in 2. from the estimated weights. The cylinders range in size from 3 to 26. and should be referred to in Upper the event .This does not apply to adjacent throw pairs. or changing piston ring material. frame cracking.45 kg). for each pair of opposing throws. A copy of the data sheet for each compressor is included in the Operation Manual. but not to exceed one pound net. pistons. 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. and because each piston and rod assembly (piston. the bolts and nuts to attach the shoes. which sometimes vary by 100 pounds (45 kg) or more. Consult an Authorized Unit Distributor for details concerning the use of the special weight nuts.5 and 5-pound increments. a change which would affect the balPlug ance is contemplated. it is necessary to make the reciprocating weight on each pair of opposing throws approximately the same. in view of the large number of cylinder sizes and throw location combinations that are possible. The crosshead assembly consists of a pair of shoes.The actual weight of parts .

net Prerequisites Personnel using this guide should be familiar with compressor systems. Page 1-8 Cooper Energy Services n Superior Compressor Product Group . rider bands.cooperenergy. and unloaders Support systems to include: Coolers. You must have Adobe® Acrobat® Reader version 3. Training includes the following: • • • • Frame. and set up procedures for rod run out. and lubrication systems Compressor details including: rings. This section describes the purpose of the manual and prerequisites. It includes information on how to use the manual. crosshead guide. critical repairs. • Section 3: Lubrication and Cooling Specifications. • Section 4: Specifications for sour gas applications. water pumps. and control systems Description of installation. contact the CES Learning Center by calling (713) 354-4062. This section is a comprehensive reference regarding. web deflection. related publications and important product information.0 or later in order to view the bulletins: http://www. coupling alignment • Description of recommended operational procedures include: startup. the Superior WG Instruction Manual is organized into the following sections: • Table of Content. lubricating and cooling the WG series compressor frame. standard mechanical service tools. This section explains basic equipment maintenance safety policies and practices. and troubleshooting If training is needed. Cooper Energy Services recommends that all personnel using this manual should complete CES Superior Reciprocating Compressor Training.com Unrestricted copies of Service Bulletins are available at the Cooper Energy Services web site. normal & emergency shutdown and compressor performance control • Description and application of recommended maintenance: maintenance. Service personnel should have adequate experience in good maintenance and troubleshooting techniques. regarding compressor frame operation and maintenance. pressure packings.cooperenergy. valves.Additional Information Please visit the Cooper Energy Services web site: http://www. and compressor terminology. • Section 1: Introduction To WG series compressor and frame specifications. inspection. • Section 2: Safety Precautions and Guidelines. How to Use This Manual Manual Organization To make finding information as easy as possible.

Related Publications The following related publications contain more information about the Superior WG Series Compressor: •Superior MH. and recommended torque values. coupling installation. CES also recommends that oil and gas production service packagers follow the guidelines for prime movers described in the American Petroleum Institute’s Specification for Packaged Reciprocating Compressors for Oil and Gas Production Services (API Specification 11P). W7. Warranty The Seller warrants to the Buyer that the equipment to be delivered hereunder will be free from defects in material. services and communications with ever-increasing quality and value for our customers is a continuous business process in our company. Providing goods. •Superior Compressor Cylinders Technical Data Book Standards Cooper Energy Services has developed several standards for our compressor addressing cooling water quality. This section provides procedure for startup. & WG Compressor Frame Technical Data Book. This section provides an in-depth functional description guidelines for the foundation. Included are exploded views of the assemblies.global. lubrication. • Section 7: Maintenance. workmanship and title and will be of the kind described in the contract. Customers include purchasers of goods and services. co-workers.org will default you to http://www. 7969 for a copy of API 11P. setting piston end clearance. and form to request for performance curves. tolerance limits. • Section 9: Cylinder "as built" Bills of Materials unique to your compressor.WG Series Compressor Frame Instruction Manual • Section 5: Installation. Included are exploded views of the assemblies. • Section 8: Frame "as built" Bills of Materials unique to your compressor.api. • Section 6: Operation Start-up.ihs. This section contain precautions. Our Quality Policy All Cooper Energy Services employees will work to understand and to meet or exceed our customer's expectations. CES recommends that users of Superior compressor understand and follow these standards to get the best performance possible from the equipment. and packaging. and identify needed changes. WH. All employees will correctly and efficiently perform their respective functions in accordance with established requirements. American Petroleum Institute http://www. cylinder mounting. 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 Page 1-9 . recommended operating conditions.com 1-800-854-7179 ext. piston rod run out. other departments and suppliers. crankshaft web deflection.

is hereby assigned without recourse by the Seller to the Buyer. either by repairing any defective part or parts or by making available. 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. AS TO THIS SPECIAL EQUIPMENT. The liability of the Seller to the Buyer (except as to title) arising out of the supplying of the equipment. whichever first occurs. that the equipment does not meet the warranty specified above and the Buyer notifies the Seller promptly. All rights reserved. including but not limited to generators. at the Seller's option. (c) overloading or overspeeding. ORAL OR IMPLIED (INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR PURPOSE). The warranty given to the Seller by its supplier of special equipment.WHETHER WRITTEN. The foregoing shall constitute the sole remedy of the Buyer and the sole liability of the Seller. whether on warranty. Page 1-10 Cooper Energy Services n Superior Compressor Product Group . or its use. contract or negligence. a repaired or replacement part. All rights reserved. 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. at the Seller's factory. WHICH GENERALLY BEARS THE NAMEPLATE OF THE SELLERS SUPPLIER. 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. Copyright© 2002 Adobe Systems Incorporated. WHETHER WRITTEN. (b) failure to maintain the equipment properly. the Seller shall correct any defect. ORAL OR IMPLIED (INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR PURPOSE). or (d) use of repair parts not approved by Seller. THE SELLER ASSUMES NO LIABILITY WHATSOEVER FOR BREACH OF WARRANTY. Copyright© 2002 Cooper Cameron Corporation.

Note. maintenance and repair are caused by failure to observe basic safety rules or precautions. Most accidents involving equipment operation. maintenance or repair of this equipment can be dangerous and could result in injury or death. work. Safety precautions and warnings are provided in this manual and on the equipment. lubrication. skills and tools to perform these functions properly. Equipment operators should also have the necessary training. and Danger Symbols These safety instructions and procedures are intended to prevent injury in the operation and maintenance of Cooper Energy Services compressors and auxiliary equipment. lubrication. FOR TRAINING INFORMATION. If these hazard warnings are not heeded. maintenance and repair instructions and warnings in this Operations Manual. A person must always be alert to potential hazards.WG Series Compressor Frame Instruction Manual Section 2 Safety Precautions and Guidelines Important Safety Information DO NOT OPERATE OR ATTEMPT TO REPAIR THIS EQUIPMENT UNLESS YOU HAVE HAD THE PROPER TRAINING APPROVED BY SUPERIOR. Contact your authorized Cooper Energy Services Distributor for replacement manuals. Proper care is your responsibility. TEXAS. Good judgement and careful safety practices should always be used. Caution and Danger Symbols portion of this section. Do not operate. maintenance or repair on this equipment unless you have read and understand the operation. Failure to follow the instructions or heed the warnings could result in injury or death. Caution. PHONE (713) 354-4062. Improper operation. or perform any lubrication. bodily injury or death could occur to you or other persons. These safety procedures should not be considered as the only precautions to be taken. CONTACT THE COOPER ENERGY SERVICES TRAINING DEPARTMENT IN HOUSTON. The hazards are identified by a safety alert symbol and followed by a signal word such as "DANGER!" as shown in the Note. Section 2: Safety Precations and Guidelines Cooper Energy Services n Superior Compressor Product Group WG-4/3/03 Page 2-1 . An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

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. to clean safety signs. Make sure that you can read all safety signs. change the oil filter. missing or cannot be read. etc. Warning Signs and Labels There may be several specific safety signs on your equipment. If a tool. Page 2-2 Cooper Energy Services n Superior Compressor Product Group . The use of solvents. Authorized Cooper Energy Services Distributors have the most current information available. etc. When cleaning the labels use a cloth. pressures. water and soap. 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. See your Authorized Cooper Energy Services Distributor for new labels. Do not use solvents. gasoline. If a label is attached to a part.. The information. Please take the time to familiarize yourself with the safety signs. Clean or replace these if you cannot read the words or see the pictures. adjustments. personal injury or even death. torques. The warnings in this publication and on the equipment are therefore not all inclusive. and other items can change at any time. I CAUTION NDANGER Cooper Energy Services cannot anticipate every possible circumstance that might involve a potential hazard. and maintenance or repair procedures you choose. and illustrations in this publication are presented on the basis of information available at the time it was written. gasoline. you must satisfy yourself that it is safe for you and others. work method or operating technique not specifically recommended by Cooper Energy Services is used. could loosen the sign's adhesive and cause the sign to fall off. illustrations. procedure. You should also ensure that the equipment will not be damaged or made unsafe by the operation. These changes can affect the service given to the equipment. The following is an example of a CAUTION: The DANGER symbol indicates that if the specified warning is not heeded. make sure a new label is installed on the replaced part. damage to equipment and/or personal injury may result. lubrication. measurements. and that part is replaced.. Obtain the complete and most current information before starting any job. The specifications. there is a substantial risk of serious equipment damage. specifications. The following is an example of a DANGER: i When changing the frame lubricating oil. You must replace a label if it is damaged.

1. A threaded plastic pipe that all temporary plastic plugs are replaced before plug may occasionally be found on older compressor cylinders. If any plug is in question. using the compressor equipPainted threaded plastic pipe plugs may look like painted steel pipe ment. It must never be directed toward an area where the vented gases could come into contact with operators or other personnel. Pressurizing the compressor equipment while temporary plugs are in place may result in serious injury or death and may damage the equipment. If the existing plugs are painted. cooling water connection. etc. The Bicera valve has a 120 o exhaust port opening through which pressure is vented. replace it. even when painted. Always verify can be easily identified.Per CES Engineering Service Bulletin SB282 2. Any Plastic plugs found must be replaced.) and insure each port is properly connected to its specific application or plugged. scrape off enough paint to verify that the plug is made of steel and not plastic. All of the precautions that follow are interpreted as having a CAUTION or DANGER status.Per CES Engineering Service Bulletin SB290 Section 2: Safety Precations and Guidelines Cooper Energy Services n Superior Compressor Product Group WG-4/3/03 Page 2-3 . The type of plug used is usually a “push-in” insert that ommended. NDANGER Ports that are not used must be filled with a properly installed steel plug. These temporary plugs protect the equipment from dirt. Compressor Frame Crankcase Rapid Pressure Relief Valves2 Cooper Energy Services recommends the installation of Bicera crankcase rapid pressure relief valve. The equipment installer must determine the purpose of all empty ports (i. cylinders are components are often sealed at the factory with temporary plastic plugs. proper orientation of the exhaust port is critical for a safe operating environment.e. Vented gas could be dangerous to both operator and equipment. water and other contaminants during shipping Stainless steel plugs are recand storage. Due to the content and high temperature of the vented gas. plugs. lubricator oil connection.WG Series Compressor Frame Instruction Manual Specified Precautions It is important that these precautions be read and clearly understood. vent. These valves protect the compressor frame from excessive pressure. Temporary Shipping Plugs in Compressor Equipment 1 Small diameter threaded connections located on compressor frames. The 120o exhaust port must always be directed towards the drive end of the compressor frame.

vent the exhaust to the outside. if equipment must be started to make adjustments Page 2-4 Cooper Energy Services n Superior Compressor Product Group . perform all maintenance as follows: •Follow all safety and operating procedures put in place by the company that owns and operates the equipment. blowers. When appropriate. Use caution when removing cover plates. or jewelry that can catch on controls or other parts of the moving equipment. General Maintenance Precautions Unless instructed differently. steel-toe safety shoes. •STOP the equipment. non-toxic cleaning solvents. neckties. •Make certain all protective guards and covers are secured in place. •Do not wear loose clothing.General Precautions Attach a DO NOT OPERATE or similar warning tag to the start button or controls before performing maintenance or repairing the equipment. Ensure the protective locks or controls are in the applied position. •Use fans. Additional equipment may be required by the job conditions. Do not attempt any repairs or adjustments to the equipment while it is running. •Never put maintenance fluids into glass containers. Pry cover loose to relieve any spring or other pressure. 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. NDANGER If Poisonous or suffocating gases are being compressed. since glass containers break. Gradually loosen (do not remove) the last two bolts or nuts located at opposite ends of the cover or device. etc. •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. Keep long hair tied back. during maintenance and clean-up work in enclosed areas to remove fumes released by cleaning solvents and vented gases. •Use only non-flammable. before removing the last bolts or nuts. Make sure all protective guards and covers are installed. attach tags at the equipment and at each operator's position and disconnect starting controls. Never use gasoline or other flammable products for cleaning purposes. •Report all needed repairs. Be absolutely sure the remote starting system is disabled and/or disconnect the starting system on the equipment being serviced. •When operating this equipment in an enclosed area. 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. hearing protection and protective head gear.

They are provided to prevent personal injury and equipment damage. Cooper Energy Services recommends that the maximum air pressure applied in this type of application must be below 200 kPa (30 psi) for cleaning purposes. •Unloader control pressure is typically not shown on gauges. valve caps. •Remove manual barring devices if used during maintenance before starting the equipment. Fluid Precautions Always use a board or cardboard when checking for a leak. measure the stud's height from the machined surface and install the replacement stud to the identical height. •Vent all gas pressure from the compressor system and know the piping system associated with the compressor. • Do not disable or bypass automatic alarm/shutoff circuits. Carefully vent unloader control pressure lines by loosening the control line tubing fitting. •Before replacing any studs. a doctor familiar with this type of injury must treat it immediately. •Lock out starting devices and controls Pressurized Air and Water Precautions Pressurized air and water can cause debris and/or hot water to be blown and could result in personal injury. •Be sure to allow the compressor system to cool for at least 15 minutes before opening suction or interstage vents . or cylinder heads. work carefully around them. Air may be drawn into the system if a vacuum exists. •Check local or panel pressure gauges for a zero reading before removing any gas pressure components such as valves. Escaping fluid under pressure (even a pinhole size leak) can penetrate body tissue. When using pressurized air or water for cleaning. •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. This can create an explosive mixture. causing serious injury or possible death. Section 2: Safety Precations and Guidelines Cooper Energy Services n Superior Compressor Product Group WG-4/3/03 Page 2-5 . Open discharge blowdown and/or bypass valves to vent into the atmosphere. Compressor System Maintenance Precautions •Suction and discharge block valves must be closed to prevent gas from flowing into the compressor system during maintenance. To help prevent an accident caused by parts in rotation. always wear eye/face protection and protective clothing and shoes.WG Series Compressor Frame Instruction Manual or checks. If fluid is injected into your skin.

fittings. Check for the following: •End fittings damaged. connectors. Pipes. leaking or displaced. it can be hazardous to your health. fittings.Asbestos Precautions Cooper Energy Services equipment and replacement parts shipped from the factory are asbestos free. there are several common sense guidelines that should be followed. use wet methods or a vacuum equipped with a high efficiency particulate air (HEPA) filter. •Use exhaust ventilation on permanent machining jobs. •Outer covering ballooning locally.A. •Avoid brushing or grinding of asbestos containing materials. tubes or hoses. •Never use compressed air for cleaning. which may contain asbestos. The asbestos used in components is usually bound in a resin or sealed in some way. •For clean up. Lines. Caution should be used to avoid breathing dust when handling components containing asbestos fibers. connectors. Leaks can cause fires. tubes or hoses. (i. •Wear an approved respirator. connectors. Fittings. If any replacement parts containing asbestos are used. OSHA requirements 29 CFR 1910. the following guidelines should be used in handling these parts and asbestos debris. Normal handling is not hazardous as long as airborne asbestos dust is not generated. U. •Outer coverings chafed or cut and wire reinforcing exposed.S.e.e. Cooper Energy Services recommends the use of ONLY genuine Superior® parts. tubes and hoses carefully. Avoid areas where airborne asbestos particles may be present. Tubes and Hoses Do not bend or strike any high-pressure connection (i. Repair any loose or damaged fuel and oil pipes. Do not install bent or damaged pipes. Tighten all connections to the recommended torque (Section 5). connectors.1001). pipes. lines. If this dust is inhaled. Page 2-6 Cooper Energy Services n Superior Compressor Product Group . If dust. •Follow environmental rules and regulations for disposal of asbestos. lines. •Comply with applicable rules and regulations for the work place. Do not use your bare hands to check for leaks. Connectors. is present. fittings. lines. tubes or hoses). lines. Inspect all pipes.

Coolant Precautions Remove the cooling system filler cap slowly to relieve pressure.) Oil Precautions Hot oil and components can cause personal injury. Any contact with hot water or steam can cause severe burns. avoid contact with the skin and eyes and do not drink. oil. Allow cooling system components to cool before draining. are flammable. Hold a cloth over the cap or plug to prevent being sprayed or splashed by liquids under pressure. this hot water can turn into steam. (Remember: Antifreeze/glycol solutions. as well as most lubricants. When pressure is relieved rapidly. 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 WG-4/3/03 Page 2-7 . breathers or drain plugs. Cooling system additive (conditioner) contains alkali. To prevent personal injury. Burn Precautions Do not touch any part of operating equipment. The cooling system and all lines to heaters or the equipment contain hot water. Use caution when removing vent release valve. •Armoring embedded in the outer cover. the equipment coolant is hot and under pressure. fuel or cooling systems before any lines. grease fittings. At operating conditions. guards and heat shields are installed correctly to prevent vibration. Allow the equipment to cool before any repair or maintenance is performed on the equipment. rubbing against other parts and excessive heat during operation. Check the coolant level only after the equipment has been stopped and the filler cap is cool enough to remove with your bare hand.WG Series Compressor Frame Instruction Manual •Evidence of kinking or crushing. Relieve all pressure in air. Make sure that all clamps. Fire and Explosion Precautions A flash fire may result in personal injury if crankcase covers are removed within 15 minutes after an emergency shutdown. fittings or related items are disconnected or removed. pressure taps.

Chips or other debris can fly off objects when struck.Fire may result from lubricating oil or fuel sprayed on hot surfaces causing personal injury and property damage. supported or clamped securely. Clean steps. Always wear protective head gear when working on the compressor package. the equipment or stand on components that cannot support your weight. Inspect all lines and tubes for wear or deterioration. When possible use platform steps and hand holds (if equipped) when mounting and dismounting. or jump off. Leaks can cause fires. hand holds and platform areas of the equipment you will be working on or around. Tighten all connections to the recommended torque (Section 7). Crushing or Cutting Precautions Wear protective glasses when striking objects to avoid injury to your eyes. They must be routed. Page 2-8 Cooper Energy Services n Superior Compressor Product Group . Take care to insure no one can be injured by flying debris before striking any object. Mounting and Dismounting Precautions Do not climb on.

) The system that provides lubrication for the cylinders and packing. and the gases being handled all have a significant effect on how well a lubricant performs in the given application. Using known and reputed products will provide the best assurance for achieving effective lubrication. connecting rods and the crosshead guides. An oil level sight gage with low oil indicator is installed on the frame. To assure oil suitably. Compressor design. Do not permit your compressor to be used as an experimental unit for trying out new or questionable lubricants. Other features include a connection port for low oil pressure shutdown switch. always use a reliable and known brand. The following will assist users in selecting the proper lubricant for each application. Cooper Energy Services does not endorse particular brands of oils and does not guarantee the quality or performance of lubricating oils. Use only products with field proven reliability and merit. Use of such products should always follow the manufacturer’s recommendation. which provides resistance to oxidation. An off-mounted shell and tube type oil cooler is provided with connections for water inlet and outlet. a lubricating oil with the minimum quantities specified in ES1002 (see Section 3: Lubrication and Cooling Cooper Energy Services n Superior Compressor Product Group 4/3/03 Page 3-1 . blender or re-brander. 2. (This is especially done when the oil for cylinder and packing system is different type compared to the frame oil). An adjustable pressure relief valve is installed in the delivery cavity of the frame for cold start protection. Compressor Frame Lubrication: A gear driven lubricating pump is mounted on the auxiliary end of the frame. the frame lubricant must be capable of operating with the type of gas being handled by the compressor cylinders. The lubrication of Superior® Compressors requires the use of premium quality. Frame Lubrication Specifications: A good mineral oil of recommended viscosity.) The system that provides lubrication to the frame running parts ( see the compressor Frame Technical Data Book). the cylinder system may use oil from an external tank. In addition to the above requirement. The pump delivers the oil from the frame sump to the bearings. and corrosion is generally suitable for frame lubrication. operating conditions. if required. of equal importance: 1. The responsibility for selecting the proper lubricant falls on the user. Satisfactory oil quality is the responsibility of the refiner.WG Series Compressor Frame Instruction Manual Section 3 Lubrication And Cooling The complete lubrication system of the compressor is divided into two parts. A detergent oil if readily available may also be used. Both systems can use oil from the frame sump. For most sweet natural gases and allied gas services. However. lubricating oils designed for heavy duty compressor service.

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 . Page 3-2 Cooper Energy Services n Superior Compressor Product Group .5 to 16. Oil condition and trace metal element trends can be effective diagnostic and preventive maintenance tools. Regular monitoring of the crankcase oil condition can help establish oil change out periods for a specific unit. reputable lab should be used and results should be carefully analyzed and trended. 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 Lubrication System Maintenance The compressor oil and filters should be changed after the first 500 hours on a new or overhauled compressor. In applications where the compressor cylinders are handling corrosive gases such as H2 S or CO2 .Table 3-1 & 3-2 ) will be suitable. recommended location is at driver end of lube oil header when possible. 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. Cooper Energy Services strongly recommends that customers use a laboratory analysis program to ensure proper lubricant performance. After the first oil change. An experienced. a lubricant with a higher TBN or method for adequate retention of the original TBN is recommended for service in the frame. the oil and filters should be changed every 2000 hours. I CAUTION Low lube oil pressure alarm and shut down device(s) must monitor compressor frame’s lube oil pressure down stream of the compressor frame’s lube oil filter.

WG Series Compressor Frame Instruction Manual Compressor Cylinder and Packing Lubrication: The cylinder lubrication system consists of a forced-feed lubricator and distribution block system that provides lubrication for cylinder walls and piston rod packing. Section 3: Lubrication and Cooling Cooper Energy Services n Superior Compressor Product Group 4/3/03 Page 3-3 . check valves. t Figure 3-3 The compressor frame lubrication system consists of a gear driven pump. pressure relief valve. the lubricant must be selected with the proper characteristics suitable for the application involved. •Pour point must be equal to gas suction pressure minus15oF-20o F (8oC-11o C). •Good resistance to carbon deposits and sludge formation. loose and flaky type. oil cooler and oil filter. This Figure illustrates the lubrication oil system flow . oxidation and corrosion prohibitors are not required. operating conditions. it should be the soft. but may be beneficial. and the gases being handled all have a significant affect on how well a lubricant performs in the given application. If any carbon is formed. 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. Compressor design. •Minimum flash point is 400o F (204oC). Because of a variety of gases and operating conditions encountered by Superior compressor cylinders. In all applications.

METHANE CONTAINING ANY COMBINATION OF HEAVY HYDROCARBONS ( EXCLUDING ETHANE ).) Note: (External Cylinder Lubrication Supply Required above 1200 psi Table 3-4-B Discharge Pressure 0-499 psi 500-1199 psi 1200-1999 psi 2000-3999 psi 4000-up psi Oil Viscosity Viscosity Specification SUS @ 210 F ISO 220 (SAE 50) ISO 220 (SAE 50) ISO 220 (SAE 50) ISO 320 (SAE 60) ISO 460 (SAE 70) 85-110 85-110 85-110 105-125 125-150 Remarks External Oil External Oil External Oil External Oil External Oil METHANE WITH H2S. the viscosity required for the highest pressure cylinder can also be used in lower pressure cylinders.CO2 AND H 2 0 THAT TOTALS TO <5% (BY MOLE WT. CO2 AND H2O THAT TOTAL TO 5-20% (BY MOLE WT. 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 Oil Viscosity Viscosity SUS Specification @ 210 F ISO 100 (SAE 30) ISO 150 (SAE 40) ISO 220 (SAE 50) ISO 320 (SAE 60) ISO 460 (SAE 70) 55-70 70-85 85-110 105-125 125-150 Remarks Crank Case Oil Crank Case Oil External Oil External Oil External Oil METHANE WITHOUT H2 S. The viscosities listed in Table 3-4 are the suggested minimum requirements.Viscosity Requirements The viscosity of the oil should be selected on the basis of operating pressure conditions of the cylinder. METHANE CONTAINING ANY COMBINATION OF HEAVY HYDROCARBONS ( EXCLUDING ETHANE ). These values will be adequate for most oils. oils of the same viscosity may not necessarily have identical lubricating qualities. For multi-stage applications.) Note: (External Cylinder Lubrication Supply Required) Page 3-4 Cooper Energy Services n Superior Compressor Product Group . However. Periodic examination of the cylinder bores during the first few weeks of operation is recommended to assure that lubrication is adequate.

Use viscosity data in Table 3-4 and 3% to 5% compounding with tallow if the gas is “wet” and/or saturated. 3% to 8% compounding with acid less tallow and addition of corrosion and oxidation inhibitors is required. Increase supply over normal. Use a mixed base or napthentic straight mineral oil. Viscosity as recommended in Table 3-4. Use the recommendations in Table 3-4. Requires compounding with 3% to 5% acid less tallow or other suitable fatty oils.METHANE CONTAINING ANY COMBINATION OF HEAVY HYDROCARBONS (EXCLUDING ETHANE). Lubricant must be dry. Nitrogen. Ethylene. There are inert gases relative to lubricating oils. straight mineral oil. Helium.WG Series Compressor Frame Instruction Manual Table 3-4-C Discharge Pressure 0-499 psi 500-1199 psi 1200-1999 psi 2000-3999 psi 4000-up psi Oil Viscosity Viscosity Specification SUS @ 210 F ISO 220 (SAE 50) ISO 220 (SAE 50) ISO 320 (SAE 60) ISO 460 (SAE 70) ISO 680 (SAE 80) 85-110 85-110 105-125 125-150 140-200 Remarks External OIl External Oil External Oil External Oil External Oil CO2. Use minimum viscosity listed in Table 3-4. Use dry. compounded. HEAVY HYDROCARBONS. Methane. Increase supply over normal. Use the next higher viscosity over Table 3-4 recommendations. CO2 AND H2 O THAT TOTALS TO >20% BY MOLE WEIGHT. plus 3% to 5% compounding with tallow if gas is “wet”. 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. Carbon Dioxide Hydrogen. Section 3: Lubrication and Cooling Cooper Energy Services n Superior Compressor Product Group 4/3/03 Page 3-5 . Ethane Natural Gases Saturated With Water and/or “Wet” With Higher Ended Hydrocarbons Butane. These gases are dilutents of oil. Propane. Contact A CES Authorized Unit Distributor. Increase supply quantities over normal. 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. Exhaust Gas. Ammonia Synthesis Ammonia Hydrogen Sulfide Recommendations Requires compounding with 3% to 5% acid less tallow or other suitable fatty oils. Carbon Monoxide. The process in which a gas is being utilized will often influence the lubricating oil selected.

Figure 3-6 Force Feed Lubricator I CAUTION Page 3-6 Cooper Energy Services n Superior Compressor Product Group . This is accomplished by properly adjusting the for break-in should be force feed lubricator pump(s). Packings then require 2/5 (0. when first starting up the compressor. stroke. Observe the detailed instructions. See Figure 3-6 for an example of a force feed lubricator. A quantity of 1/5 (0. With all mal operation.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. double that for norgiven in Section 6.45 pints per day per packing. Experience has shown that the quantity of the oil required to properly lubricate compressor cylinders is dependent upon bore diameter. Watch for any signs of malfunction. a little each day. a periodic visual inspection of the cylinder bore and piston rod are recommended. See section 6-2 thru 6-3 for information on the sight glass oil level. and should take several days to accomplish. bring the cylinder pressure up slowly until the unit is running at full rated speed and load. and speed.Lubrication Rate IT IS IMPORTANT that during start up safe and ample lubrication The lubrication rate should be provided. Adjustment should be made slowly. Minimum should be 0. Many applications may require more or less than the calculated feed rates. The gas being compressed. For the Superior® compressors 1/5 (0. its cleanliness and tendencies to act as an oil dilutent. To assure that adequate lubrication is being achieved.4) pints per day for each inch of rod diameter. lubricator pumps set at full stroke. 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. and the type of the oil being used all influence the lubrication rate required. The piston rod and packing is considered as a separate cylinder but with double the lubrication rate required. the lubrication rate should be gradually reduced to the amount necessary for correct lubrication.2) pint per day for each inch of cylinder bore diameter has normally proven to be an adequate quantity. After the first 48 hours at full load.

1 pints/day or 11 drops/minute PLUS EQUALS 10” X 0. They dissolve paints. if a multi-grade oils is being considered for use a a cylinder lubricant.4 pints/day = 1. such as refilling the crankcase after oil or filter changes.1 pints/day or 11 drops/minute PLUS EQUALS 20” X 0. Figure 3-7 Example of Calculating Lubrication Rates for Cylinders and Packing Lubrication Rate For the 10” Cylinder… 1 packing X 2.4 pints/day = 1. Excess lubrication can cause valve deposits. However. i The regulator is not designed to make large quantities of oil in a short time period. all multi-grade oils do not provide the same protection. and other down-stream equipment.2 pints/day or 75 drops/minute Synthetic Lubricants Synthetic lubricants have higher flash points than conventional lubricants.75” X 0.1 pints/day or 50 drops/minute for the 20” bore diameter cylinder EQUALS 8. when synthetics are considered for use in compressor cylinders or frames.75” X 0. and have low viscosity indexes. 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. synthetics impose problems which are usually not associated with natural mineral oils.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. are corrosive to common bearing materials such as lead and tin.1 pints/day or 25 drop/minute Lubrication Rate For the 20” Cylinder… 1 packing X 2. For this reason.WG Series Compressor Frame Instruction Manual 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.2 pints/day = 4 pints/day or 40 drops/minute 5. consult an Authorized Unit Distributor.Its function is to compensate for small losses that occur during normal operation. valve failures. This makes them highly desirable from a safety and fire reduction standpoint. consult an Authorized Unit Distributor . However. Section 3: Lubrication and Cooling Cooper Energy Services n Superior Compressor Product Group 4/3/03 Page 3-7 . contamination of the gas stream.2 pints/day = 2 pints/day or 20 drops/minute 3. For these reasons.

This is done by removing a valve at each end of the cylinder after 48 hours of continuous operation at the final lubrication settings. Whenever there is any question as to viscosity selection. Pump Per Point System If a cylinder has more than one feed point. Lubricator pump(s) fed directly from the Page 3-8 Cooper Energy Services n Superior Compressor Product Group . To validate the lubrication rate. A visual inspection of the lubrication rate is required for this type of system. and more than one pump. with a minimum of 85 SUS at 210oF. or two grades heavier than normally used for the pressure conditions involved. The lubricator is directly driven off the compressor shaft through a right-angle-drive worm and spur gear set mounted on the lubricator box. the proper proportioning of oil to cylinders and packings should. take measures to maintain lubrication pump inlet temperatures at or above 120 oF. consult an Authorized Unit Distributor. For oil viscosities over 100 SUS at 210oF. For chemically active gases. For refrigeration service.Additional Recommendations For wet and saturated gas conditions and 0-1000 PSIG. use the highest possible viscosity that should be used and still retain the pour point 15 oF below gas suction temperature. use the next higher viscosity as shown in Table 3-4 . On a normal force feed lubricator (Figure 3-6). the requirements for lubrication must be split evenly. it must be measured using actual oil consumption for a 24 hour period. as a first approximation. always use the heavier oil. use a minimum viscosity of 85 SUS at 210oF with 3% to 8% compounding with acid less tallow. There should be a film of oil over the entire circumference of the ring travel section of the cylinder bore. be adjusted by the drops per minute method. individual pumps may be adjusted “up” or “down” in the same proportion as the size of the cylinders being fed to improve the lubrication rate. As a result of the inspection. For heavy hydrocarbon and sour gases. 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).

Refer to rupture disc data sheet in Auxiliary Equipment section of this manual. The lubricator box uses the same oil as in the frame or external tank to lubricate its cams and bearings. The oil flows to the pumps and then pumped to a common manifold feeding the automatic divisioning system. a 10-micron strainer. (Note that oil from the lubricator box is not used. 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.) A packager-supplied external tank is used when the requirements of the cylinder oil are different from those of the crankcase. Each lubrication point (cylinder and packing case) has a double ball check valve. a digital no-flow and counter. new rupture discs of the same color and thickness as originally installed must be replaced at the location where rupture occurred. A shutoff valve is supplied to isolate the external tank and the lubricator box. If a blockage or other anomaly occurs. Before restarting. divider blocks and optional pin indicators (shows which points are over-pressurized and sets accordingly). 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). The automatic divisioning system consists of a rupture indicator (set for the job).WG Series Compressor Frame Instruction Manual crankcase lube system or from an external tank are used to provide oil to the cylinders. Figure 3-8 General Cylinder Lubrication Logic Section 3: Lubrication and Cooling Cooper Energy Services n Superior Compressor Product Group 4/3/03 Page 3-9 . and the system pressure continues to build up. the safety rupture relief in the collector manifold bursts . It is the thickness of the “color coded” discs that determine the rupture pressure.

Replace defective parts. tighten the nuts on the tubing lines.each piston is match-honed to its cylinder. the pin indicators. e. The nut at the entry to the distribution block.clean with compressed air. Pistons are not interchangeable . Pistons are removed by hand-punching with a brass rod (either way). I CAUTION If the distribution block is disassembled. Avoid vise marks. air-free oil appears at either of the two loosened vent screws. and only then. lbs. (27-34Nm) •Check Valves = 15-20 ft. f. Then. Continue to operate the pump manually until air-free oil has emerged from tubing nuts at every injection point. BUT NOT REMOVING the nuts of the lube lines at the point of injection to permit purging of oil and air. and NEVER grip the ground mating surfaces in a vise. retighten second vent screw. Use proper wrench and keep hands away from the immediate point where the system is purging air. Retighten this vent screw and continue pumping until air-free oil emerges at the other vent screw. (20-27 Nm) •Alternate Outlets and Pin indicators = 10-15 ft.. the lubrication system must be completely purged of air. Do not disassemble check valves . carefully observe the torque used when reassembling manifolds: •Distribution Block Tie Rod Nuts = 20-25ft. ! Caution High pressure oil streams may puncture skin. Loosen the vent screws in the top section of the distribution block. Have a clean work area. d. observe the following: a. Continue to operate the lubricator pump manually until clear. b. Use all new gaskets when reassembling manifolds. as required. Note If distribution block must be disassembled for cleaning. g. This is done by LOOSENING. c. h.Maintenance In order to operate properly. for the same reason.lbs. (14-20Nm) Page 3-10 Cooper Energy Services n Superior Compressor Product Group . protect ground surfaces. Record order of manifold sections and outlet positions in order to facilitate reassembly.. When this occurs. all pin indicators and 1/8-inch pipe plugs in the face of the block must be loosened also. Clean all sections with an approved solvent. and pipe plugs. lbs. lbs. (20-27 Nm) •End Plugs = 15-20 ft.

3. and should not need filling. and precise proportioning to meet different or equal oil requirements. 4. Lubricator Worm And Gear Drive When starting a compressor for the first time. a pneumatic or electric shutdown switch in the event of lubricant flow failures. t Vent Fill Plug Upper Plug Drain Plug 4/3/03 Figure 3-9 Gear Box Filling Filling Instructions 1. It is advisable to check periodically to be certain that the supply of gear oil is maintained. or after servicing. . New units are filled with oil at the factory. positive. displacement method of lubricating the compressor cylinders and packing. Loosen upper plug. The force feed lubricator pumps oil into a single main line leading to a proportional distribution block. and a rupture disk in the lubricator collector manifold. Tighten upper plug. Install vent/fill plug. 2. Remove vent/fill plug. central warning equipment can sense trouble anywhere in the system. Oil flow rates given in percent of lubricator pump stroke accompany each compressor. 00752 Section 3: Lubrication and Cooling Cooper Energy Services n Superior Compressor Product Group Page 3-11 . Selection and make-up of the distribution block allows for accurately measured “shot” sizes. (ISO680 Agma-8) until it begins to leak at upper plug. Since the system operates on a proportional basis. Hydraulically balanced pistons in the block divide the oil into accurate metered amounts for each lubrication point it serves. See Figure 3-9. Safety equipment includes pin fault indicators. Because of the positive. Fill with Exxon TK-680 Cylessic oil . metered operation. These settings must be followed and checked to provide adequate lubrication for both “break-in” and normal operation. in each outlet from the distribution block.WG Series Compressor Frame Instruction Manual Proportional Lubrication System The distribution block type lubrication system is a metered. be sure that the gear box is filled with Exxon TK-680 Cylesstic Worm Gear Oil (ISO680 AGMA-8). a single adjustment at the force feed lubricator pump increases or decreases the flow to every lubrication point.

344 BTU/hr (140.000 BTU/hr (211. the air present inside the cylinder water jacket is the medium which transfers heat out of the cylinder.300 BTU/hr (48. (2) standpipe. The maximum recommended oil temperature for oil returning to the frame is 175 oF (79o C).339 kj/hr) 133. and the rise between gas suction and discharge temperature is less than 170° F (77°C). Table 3-10 WG Compressor Frame Heat Rejection Data Compressor Model WG6 Heat Rejection WG7 2-throw 4-throw 6-throw 66. 1.Compressor Frame Lubrication Oil Cooling The compressor frame is lubricated by the pressurized lubrication system. Oil should be circulated through the shell side and coolant through the tube side of the cooler.900 BTU/hr (146. In this form of cooling. This form of cooling may be used when the gas discharge temperature is less than 250° F (121° C). In standpipe cooling. a coolant must be chosen whose boiling point is at least 25 °F (14 °C) greater than the mean temperature and whose freezing Page 3-12 Cooper Energy Services n Superior Compressor Product Group . The temperature of the liquid coolant will reach a mean temperature somewhere between the suction and discharge gas temperatures. The vent (or standpipe) should be a 6-inch (15 cm) long vertical section of pipe which will contain the coolant when it expands.693 kj/hr) 138. 2. Dry jacket cooling is generally used where the gas discharge temperature is less than 140 oF (60o C) and gas inlet temperature is greater than 60o F (16oC). The cylinder jackets must be vented when this form of cooling is used. a water with corrosion inhibitor and/or antifreeze solution is used as the medium for heat transfer.847 kj/hr) 92. These cylinder jackets can be cooled by one of three ways: (1) dry jacket. The cylinder jackets are filled with the coolant and then vented to the atmosphere at their highest point.678 kj/hr) 200.672 BTU/hr (70.000 BTU/hr (97.000 kj/hr) 46. Accordingly. or (3) circulated water cooling. To insure this oil temperature. coolant temperature and flow must be selected to remove heat according to Table 3-10. The oil must be cooled by the shell and tube cooler provided with the compressor (shipped separate for mounting by the packager). The pipe must be topped with a vented cap to prevent dirt from entering the coolant.540 kj/hr) Compressor Cylinder Cooling Some Superior compressor cylinders are built with cooling water jackets.

From these readings. 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. This is accomplished by monitoring the coolant in and out temperatures for each cylinder with thermometers and sight flow indicators. To control condensates and still maintain optimum cylinder performance. On these units. Section 3: Lubrication and Cooling Cooper Energy Services n Superior Compressor Product Group 4/3/03 Page 3-13 . and cause internal damage by excessive wear on rods. do require that the packing cases be cooled in order to achieve adequate packing ring life. the packing cases are provided with internal coolant passages. and unclean gases. Inlet coolant temperatures should be as cool as possible. whichever is lower). valves. This form of cooling must be used on compressor cylinders having gas discharge temperatures greater than 250 °F (121° C) or a gas temperature rise greater than 170°F (77° C). rod packings will perform satisfactorily without a coolant being circulated through the packing case and therefore don’t have coolant passages. (Figure 3-11 & 3-12 ). marginal lubrication (characteristically encountered with wet and sour gases). Some applications. and the cylinder bore due to lack of lubrication. condensates are incompressible fluids which can cause damage to any cylinder part by creating forces well beyond the capability of the machine. promote corrosion (especially in non-lubricated cylinders). At lower coolant temperatures.WG Series Compressor Frame Instruction Manual point is at least 25° F (14°C) less than the suction gas temperature (or ambient. the operator may regulate the water flow to each cylinder by using a water regulating valve until a coolant temperature differential of 10° F (6°C) (15 °F (8° C) maximum) is obtained. it is recommended that the cylinder coolant temperature be maintained 10oF to 15°F (6o C to 8°C) higher than the suction gas temperature. The coolant flow required is normally 1 GPM (4 lpm) for each inch of rod diameter with a minimum of 2 GPM (8 lpm). These applications usually involve high pressures and temperatures. condensation forms on the cylinder walls. the coolant must be monitored and regulated. Also. but no higher than 90° F (32°C) is recommended to achieve optimal cooling. i Applications that require low suction temperatures below 40o F (4 oC) must contact an Authorized Unit Distributor for assistance. The third form of cooling is by coolant circulation through the cylinder jackets. however. For maximum performance. Packing Cooling In the majority of applications. Adequate cooling flow through the packing cases at a satisfactory temperature is required to properly conduct the heat out of the packing. rings. 3. This condensation must be avoided as it has a tendency to wash the oil film from the cylinder bore.

corrosion. 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.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. scale and sludge formation and other water treatment related problems. or sludge deposits that would reduce the transfer of heat to the coolant. Page 3-14 Cooper Energy Services n Superior Compressor Product Group . corrosion. I CAUTION Cleanliness is critical. protect cooling water from impurities and always use clean tools.Lube and Liquid Cooled Package t Figure 3-12 Crosshead Guide and Distance Piece .t Figure 3-11 Crosshead Guide and Distance Piece . scaling.

0 MAX 25.0 MAx 20. The most important consideration for the cooling system is good water quality. The job of the inhibitor is to recoat these areas. The dissolved minerals tend to come out of solution when the water is heated. If raw water is tested and is found to have higher concentrations than those shown on the chart.5 MIN / 9. surface temperature.0 MAX 50.0 MAX 25. These protective films can be of anti foam or coating nature. metals in the cooling system.5 MIN / 9. The anti foam nature reduces the formation of air bubbles in the coolant.0 MAX 300. As the depth of the corrosion increases iron oxide particles will flake off.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.WG Series Compressor Frame Instruction Manual 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. During cavitation. its concentration levels must be maintained to continue adequate protection. the water is suitable for use with inhibitors added. fretting or galvanic.0-170.5 MAX 100. The types of corrosion commonly found in cooling systems can be crevice. Therefore. cavitation and erosion. Because the inhibitor is recoating the metal surfaces.0 MAX 20. the coolant inhibitor concentration must be checked periodically. Scales and Sludge Minerals dissolved in water form scales and sludge. exposing more new surface material to attack. Section 3: Lubrication and Cooling Cooper Energy Services n Superior Compressor Product Group 4/3/03 Page 3-15 .0 MAX 300. In doing so.0-100. Where it will occur in the cooling system and to what degree it will progress depend on factors such as quality of water.0-400.0-400. The coating effect gives a protective layer between the metal surfaces and the coolant. the violent collapse of the vapor bubble literally blasts small holes in the film. and mechanical conditions of surfaces.0-100.0 MAX ----- Steam System 7. The scales and sludge also interfere with the ability of corrosion inhibitors to form their protective films. Table 3-13 Raw Cooling Water Specifications Category pH Level Total Hardness PPM Chlorides PPM Sulfates PPM Total Dissolved Solids PPM Silica PPM Standard System 7. Table 3-13 shows the range of maximum limits for raw cooling water quality. especially iron to iron oxide (rust). the water will require treatment or deionizing.5 MAX 5. and added when needed. the scale is formed on the hot metal surfaces and impedes good heat transfer. If concentrations are below those shown.

This characteristic requires periodic adjustments to maintain the corrosion protective qualities of the coolant. but also the ease of airborne contamination.Good industrial grade antifreeze should be used in all closed-type cooling systems. minimum compound additions place a minimum burden on the user for materials and maintenance. Page 3-16 Cooper Energy Services n Superior Compressor Product Group . therefore. The equipment user must obtain the specific instructions for the use and testing requirements of the inhibitor compounds from the supplier or manufacturer. When exposed to heat. Adequately protected closed cooling systems seldom. Cooper Energy Services do not recommend using these for this equipment. Closed systems involve heat rejection through or shell and tube-type or radiator-type heat exchangers. Open systems involve cooling towers. etc. closed and combination. 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. if ever. A clean system is a prerequisite for establishing protection of any cooling system.. The key to adequate cooling water is to begin with clean water and use a reliable water treatment specialist. etc. Periodic testing of the coolant. deposits or cavitation. Most of the products will do an adequate job when quality water (deionized and demineralized) is used. Closed type systems are commonly used and approved cooling methods. Corrosion inhibitors vary in the chemical make-up and concentrations depending upon the manufacturer. these inhibitors break down. as above. corrosion. because open-type systems involve not only large volumes of make-up water. The low make-up water requirements of closed systems and. Chemical treatment of a closed water system is simplified by the use of proprietary inhibitor compounds. whether by the user or the vendor of the treatment system. All industrial grade antifreezes have some corrosive inhibitors. and cool the water by evaporation. however. present problems caused by scaling. is absolutely necessary in order to assure that a proper level of protection is maintained. Corrosion inhibitors are ineffective in hard or sub-quality water. spray ponds. Cooling System There are three types of cooling systems used for stationary equipment: open.

Table 4-1 gives some general information on the concentrations levels of H2 S and its effect on the body.com 1-800-854-7179 ext. Hazards of Hydrogen Sulfide or “Sour Gas” Caution should be taken when working in or around hydrogen sulfide (H 2S). The requirements listed are based on American Petroleum Institute (API) Production Equipment Standard 11P.146 App D).nace. and Cooper Energy Services experience.WG Series Compressor Frame Instruction Manual Section 4 Sour Gas Compressor Applications This section defines additional compressor hardware and special materials for use when the compressor is applied in sour gas or corrosive gas service.osha-slcgov. Sour gas is poisonous and attacks the nervous system and can cause paralysis.1000) and the Confined Space Pre-Entry Check List (standard 1910. These specifications apply to equipment only! Follow safe operating and maintenance procedures associated with personnel around sour gas machinery as dictated by your company procedures. National Association of Corrosion Engineers -A copy of specification MR0175 can be purchased online at www. 7969 for a copy of API 11P.org or by calling (281) 228-6200.api.org will default you to http://www.global. This chemical is dangerous and can cause harm to personnel. Section 4: Safety Precations and Guidelines Cooper Energy Services n Superior Compressor Product Group WG-4/3/03 Page 4-1 . 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. Copies of API 11P and NACE MR0175 can be purchased on line: American Petroleum Institute http://www. Additional specifications may apply to pulsation dampers.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. These regulations are available online at the OSHA website:www. This should be thoroughly read and understood before working in an H2S environment. H2S is colorless and smells like rotten eggs. Every precaution reguarding life and equipment must be taken in a hydrogen sulfide application. piping and other equipment used in conjunction with this compressor.ihs. Read and understand the United States Department of Labor’s Occupational Safety and Health Administration (OSHA) regulations for Air Contaminants (standard 1915. National Association of Corrosion Engineers’ (NACE) Standard MR0175. permanent injury or death! N DANGER Sour gas or hydrogen sulfide (H2S) is a highly corrosive and extremely toxic gas.

May burn eyes and throat.Table 4-1 Effects of H 2S on the Human Body at Various Concentrations H2 S Concentration 1 ppm (0. Effects Protective Equipment Is Recommended For Any Concentrations Over 10 ppm (0. Death will result if not removed quickly.000 ppm (0.001%) 100 ppm (0. 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. special trim will not be required. Burns eyes and throat. Permanent brain damage may result if not rescued immediately. Page 4-2 Cooper Energy Services n Superior Compressor Product Group . Loss of reasoning ability and sense of balance.05%) Kills sense of smell in 3 to 5 minutes.0001%) Detectable “rotten eggs” odor. Requires prompt artificial respiration. Supplement No1.01%) 200 ppm (0. Respiratory disturbances will occur within 12 to 15 minutes of exposure. Immediate unconsciousness. •The frame lubricant must meet or exceed the requirements of MIL-L-2104B. 700 ppm (0.10%) 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.02%) 500 ppm (0. Rapid loss of consciousness and breathing. •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. Standard material is acceptable and special lubrication practices are recommended. Immediate artificial respiration is required.07%) 1. Kills sense of smell rapidly.

•All carbon steel.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.33 HRC (Heat Treat Spec ZA). alloy steel. Section 4: Safety Precations and Guidelines Cooper Energy Services n Superior Compressor Product Group WG-4/3/03 Page 4-3 . bronze. It also helps to better form a barrier to corrosion by coating all the valve surfaces with an oil film.V. •The piston rods are 17-4 pH stainless steel with a hardness of 28 . •Soft iron or aluminum gaskets are to be used between the valve and valve seat. pocket screws as a minimum. Level 1-11P trim (H2 S Concentrations of 2% . 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. •All brass. •The distance piece is to be properly vented in accordance with local safety standards to provide maximum safety to personnel. 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 in addition to the regular cylinder lubrication. •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. 473) and this is also accept able for H2S service. This is to include all internal fasteners and V. 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. This helps to resist the natural solvent action of the sour gas and insures a thorough distribution of oil for better lubrication. •The compressor cylinder lubricant rate is to be double the normal rate for equivalent non-sour gas applications. but excludes valve fasteners. •The O-ring material used for standard equipment is Viton (Spec. •Cylinders are to be equipped with a suction flushing system (injection of cylinder lubricating oil into the suction nozzle of each cylinder). copper and other copper alloys are to be avoided on hardware for all gas wetted parts. •Compressor cylinder lubricants must adhere to the requirements of Superior Engineering Standard ES1002. •Forged steel cylinder bodies made of AISI 4142 are to have a maximum hardness of 235 HB.WG Series Compressor Frame Instruction Manual •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 valves will be standard construction and hardness. 479) can be specified as an option. •Packing and piston ring material shall either be non-metallic or contain no copper bearing metals. For lower temperature operations (< 27° F (<-3° C) Neoprene (Spec.

6 to 12.7 cm) H2 O. H2S). •The distance piece shall be purged with inert gas. vacuum systems or sweet natural gas purge). relief valves. Engineering will evaluate these on an individual basis and select appropriate alternative designs to meet the application requirements. Packing cases will not be purged unless required by the customers. The outer compartment must be purged with inert gas to a pressure of 3 to 5 inches (7. studs. etc. 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. That standard specifies more rigid H2S trim levels than required for standard API 11P trim. Page 4-4 Cooper Energy Services n Superior Compressor Product Group .. •Two compartment configuration of distance pieces is required. •All compressor cylinder and distance piece critical bolting. •Compressor valve components may also be made of AISI 416 stainless steel with a maximum hardness of 22 HRC. Enhanced H2S Trim Requirements Enhanced H2S Trim Requirements are based on guidelines established by NACE MR0175. process valving. bourdon tubes. •Nimonic 90 valve spring material will be used. The packager is responsible for purging per these requirements.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. 410 stainless steel with a hardness of 17 to 22 HRC will be used. 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).) shall meet the full requirements of NACE MRO175 except stainless steel tubing fittings. shutdowns. This requirement is the packager’s responsibility. This reduces the pressure differential capability of any specific valve design and thus the pressure differential capability of the cylinders. •This reduced hardness requirement also includes steel valve cages (retainers) when they are used. If other venting or purging systems are desired the details are to be negotiated between the purchaser and the packager (i.e. •All instrumentation that comes into contact with the process stream (liquid level controls. •When metallic plates are required. capscrew. •Valve plates wherever possible are to be plastic to better prevent seat wear against the softer valves seats.

•All steel gas wetted parts are to have a maximum hardness of 22 HRC. Engineering will evaluate these applications on an individual basis as some cylinder pressure ratings may have to be reduced. The outer compartment must be purged with inert gas to a pressure of 3 to 5 inches (7. •Compressor valve springs are to be Nimonic 90. Compressor valve components may also be made of AISI 416 stainless steel with a maximum hardness of 22 HRC. This is to include all internal fasteners and V.6 to 12. •Packing garter springs are to be Inconel. Section 4: Safety Precations and Guidelines Cooper Energy Services n Superior Compressor Product Group WG-4/3/03 Page 4-5 . pocket screws as a minimum. 410 stainless steel with a hardness of 17 to 22 HRC shall be used.6 to 12. •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. •The piston rods are stainless steel with a hardness of 28 . Engineering will evaluate these on an individual basis and select appropriate alternative valve designs to meet the application requirements. •Tungsten carbide coating is required in the packing travel area of the piston rods. •This reduced hardness requirement also includes steel valve cages (retainers) when they are used. 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). •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). ZA). •Two compartment distance pieces are required. This reduces the pressure differential capability of any specific valve design and thus the pressure differential capability of the cylinders. This enhanced level of trim can also be used for any concentration of H2S as required by the customer. capscrews. The inner compartment can either be separately vented as described previously or purged with inert gas to a pressure of 3 to 5 inches (7.7 cm) H2 O. The requirements are as follows: •A suitable corrosion inhibitor should be added to the cylinder lubricating oil.V.7 cm) H2 O. •Forged steel cylinder bodies are to be made of AISI 4142 with a maximum hardness of 235 HB. •All compressor cylinder and distance piece critical bolting. •Valve plates wherever possible are to be plastic to better prevent seat wear against the softer valve seats.33 HRC (Heat Treat Spec. •The cylinders are to be equipped with a suction flushing system (injection of cylinder lubricating oil into the suction nozzle of each cylinder). •When metal plates are required.WG Series Compressor Frame Instruction Manual The following requirements should be followed when H2 S trim in excess of API 11P requirements is needed to meet NACE. studs.

Page 4-6 Cooper Energy Services n Superior Compressor Product Group .

There are two basic compressor mountings: the baseframe or skid mount and the direct to block mount. CES will gladly furnish data on weights and unbalanced forces required for calculations by a foundation engineer.) The baseframe/skid mount is most commonly used whereby the fabricator sets up the complete installation as a package. See that provisions can be made for an overhead hoist.WG Series Compressor Frame Instruction Manual Section 5 Installation General Installation of the compressor will be determined by the fabricator and the end customer. but on surrounding machinery. Adequate ventilation is essential to safety and the welfare of the operating personnel. a neighboring installation on similar soil will serve as a clue to the soil conditions. In any case where increasing the size of the standard minimum foundation is necessary. If you have a choice as to the location of the compressor. unconfined sand and gravel. Since the method employed will vary due to application. unless the nature of the ground is well known. the following is offered as a guide to aid in the installation. Be sure that sufficient space is available for necessary maintenance. or that a portable crane can be moved into position as necessary for removal or installation of major parts or assemblies. it is advisable to dig several test pits at the proposed site. Preparing the Foundation The responsibility for an adequate foundation is that of the customer. (See Figures 5-1 and 5-2. Filled ground. lighting and cleanliness are other important factors. or similar soils provide poor support. select a site where the ground under and around the unit will be firm and dry at all times. These instructions are based on previous installations that have proven satisfactory. or personnel. thus the compressor is mounted direct to the foundation (block). buildings. there should be ample space to permit removing the piston and rod assembly out the outboard end of the cylinder. However. Often times. Electrical outlets. Thus. This package is then moved to location and placed on a foundation. it is suggested that a foundation engineer be called in where soil conditions are questionable or where the location of the compressor is such that transmitted vibration would have detrimental effects not only to the compressor installation. With the block mounting. there is no intermediate (baseframe) between the compressor and foundation. This type installation is of a more permanent nature. the area of the base should be increased to Section 5: Installation Cooper Energy Services n Superior Compressors 4/3/03 Page 5-1 . wet clay. For instance.

Figure 5-2 Figure 5-1 Base Frame/Skid Mounting Block (Concrete) Mounting 00757 00758 Foundation Bolts To locate the foundation bolts. etc. allowing space for the grout as indicated.decrease the soil loading and the possibility of rocking. 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. There are two important items which should be considered at this point: a. ( Figure 5-3). WG-4/3/03 Page 5-2 Cooper Energy Services n Superior Compressor Product Group . When freezing temperatures are likely to occur. frame. nut. the foundation must be carried well below the lowest expected frostline as determined by the foundation engineer. Fasten the template firmly in position. b. Provide allowance for misalignment. Make sure the bolts project far enough through the frame hole to allow two full threads beyond the nut. The next step is to attach the bolts to the template so that they will extend into the foundation. 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. Allow for thickness of grout. Set up the template in the exact position to be occupied by the compressor. make a wooden template to temporarily position the bolts according to the dimensions given on the foundation plan.

When the grout has completely hardened. Failure to comply with this warning may result in damage to your unit. Soak the surface for several hours before pouring grout. clean the top surface of the foundation thoroughly. but place a dam around the top 00759 of the bolt and extending into the can. screw each jackscrew through the frame (Figure 5-3) in a manner which would support the frame approximately 1 to 1. (There should be a jackscrew at each holddown bolt. LOOSEN THE JACKSCREWS and tighten down all the foundation bolt nuts evenly. aligning and grouting. Bring frame to level by adjusting jackscrews.5 to 3. Section 5: Installation Cooper Energy Services n Superior Compressors 4/3/03 Page 5-3 . Make sure that no stresses are set up when pulling down the nuts by checking alignment with a dial indicator.WG Series Compressor Frame Instruction Manual Placement and Leveling After the foundation has been completed and the concrete has had ample time to thoroughly set.8 cm) above the foundation. check to see that it is level.5 inch (2. Next. After levelling. Then. Grouting material instructions should be carefully followed. 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.) With the compressor resting on the jackscrews. It is very important the unit is aligned as accurately as possible so that after grouting or shimming has been completed. to avoid grout contact with any part of the bolt. t Figure 5-3 Foundation Bolt Positioning First. Keep all jackscrews snug. but make sure there is no standing water. I CAUTION Responsibility for the grout belongs with the customer or their contractor. foundation bolt nuts should be secure but NOT TIGHTENED. the unit is ready to be placed upon the foundation. Remove the stuffing from around the foundation bolts. the foundation bolts may be pulled down without any resulting stresses. Place level on top side of frame as required to level in both directions all around. This provides for leveling.

a. Torque flange screws per Table 7-2 and lockwire together. Note the arrangement of bolts. The standard flexible coupling used to drive the Superior compressor is shown in Figure 5-4. washer.Coupling Installation and Alignment i 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. and nuts. reassemble coupling.) c. Mount flange (B) on engine flywheel. Installation is as follows dial indicator method: Figure 5-4 Flexible Coupling Assembly Laminated rings must be re-assembled in the coupling exactly as received. Dimension (D) must be maintained during the following alignment procedure. They must be replaced in their original position. (See instructions given in Drive Coupling Hub Page 7-9. With engine and compressor moved into position. . as shown on the outline drawing. Disassemble the flexible coupling. Mount hub (C) on compressor crankshaft. b. t Figure 5-5 Dial Indicator Method of Alignment 00761 WG-4/3/03 Page 5-4 Cooper Energy Services n Superior Compressor Product Group . Tie a string or wire through one bolt hole of the laminated rings (A) to retain the dialed position of individual discs.

” Proper lining up may take a little time. See Table 7-2 for recommended torque values.051 cm) T. Move engine or compressor. This corrects angular misalignment. j. k. i Bolt heads should be held and locknuts only turned. but it is absolutely essential.R. Realign unit when parallel misalignment exceeds 0. the engine or compressor is moved during aligning trials. g. If any additional lubricant is used or if the threads are wiped dry. When installing coupling. The coupling should be turned several revolutions to make sure no “end-wise creep” in the crankshaft is measured. Rotate coupling 360 degrees. and/or angular misalignment exceeds 0. and (f) . or both. e. Rotate coupling 360 degrees.020 inch (0. When proper alignment is attained within the previously specified limits. d. the below values apply to bolts and locknuts as they are received from the factory. This is approximately 0. the greater the capacity of the coupling to take care of subsequent operational misalignment.R. if either. l. Section 5: Installation Cooper Energy Services n Superior Compressors 4/3/03 Page 5-5 . Set indicator stem on outer diameter surface of flange B and adjust to zero.036 cm) T.006 inch (0. recheck both alignment and bolt torque. adjust indicator to zero. Rotate coupling 360 degrees to locate point of minimum reading on dial. Reset indicator to zero and repeat steps (d) . h. Observe misalignment reading.014 inch (0.010 cm). until dial indicator reading does not exceed 0. The closer the initial alignment. Torque all bolts. There must be no end thrust due to poor initial assembly of the coupling.I. (e) . the laminated rings A must appear vertical and undistorted. these values must be modified. when tightening coupling bolts.015 cm) at outside diameter of flange B.004 inch (0.0003 cm per each cm of diameter at indicator stem). Alignment should be checked periodically.I. n.0003 inch for each inch of diameter at indicator stem (0. f.WG Series Compressor Frame Instruction Manual The recommended procedure for establishing final alignment is called the “indicator method. i Coupling bolts are tightened at the factory for shipping purposes only. Mount dial indicator (Figure 5-5 (view C)) to check for parallel misalignment. Attach dial indicator as shown in Figure 5-5 (view B). After several hours of operation. Move and/or shim the units until the indicator reading comes within the maximum allowable variation of 0. i. Flexible couplings should not be required to compensate for any misalignment that can be eliminated.

Note: The deflection can be measured with #1 connecting rod removed. WG-4/3/03 Page 5-6 Cooper Energy Services n Superior Compressor Product Group .001 inch (0. The deflection should be periodically checked and should not exceed 0.Footin inches Lbs. burrs. or other irregularities at the mounting surfaces. the cylinder head and the piston and rod assembly maybe installed prior to shipment. If a cylinder cannot be aligned.051 mm). ( Figure 5-7) The deflection should not be greater than 0. When reassembling the cylinder to the crosshead guide. the crankshaft web deflection should be measured on the number one throw. Sometimes. are intended to support the weight of the cylinder only. Outer end cylinder supports. cylinders may be shipped separately. Do not use them to force the cylinder into alignment. If that is your case.025 mm). use a criss-cross pattern nut tightening sequence.002 inch (0.Table 5-6 Rexnord Flexible Coupling Torque Values Coupling Size Bolt Size Threads/Inch Torque -. check for dirt. Figure 5-7 Crankshaft Web Deflection Measurement Cylinder Mounting Cylinders are normally mounted on the compressor frame when shipped to a location. because of shipping and packaging restrictions. (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) Dimension D-inches (mm) *on Fig 5-4 8-3/4 (222) 9-7/8 (2480 10-7/8 (2760 12-7/16 (316) 13-1/2 (343) 14-3/4 (375) 15-3/4 (400) 17-1/4 (438) Crankshaft Web Deflection The compressor should be aligned to the driver according to the instructions given above. See Table 7-2 for recommended torque values. if supplied. During the alignment procedure.

WG Series Compressor Frame Instruction Manual

Sliding Rod Through Packings
Obtain a piston rod starter tool before attempting to slide the rod through packing. This tool consists of a split sleeve cone and capscrew. The piston rod should be coated with grease before and after installing it on the rod. This tool is designed to protect the packing rings from damage during removal and installation of the rod from the cylinder.

Setting Piston End Clearance
Piston end clearance is set by screwing the piston and rod assembly further into or out of the crosshead. With a cold compressor, the total clearance should be distributed with two-thirds on the head end and onethird on the crank end of the cylinder. This allows for thermal growth of the reciprocating assemblies during normal operation. Measure end clearance as follows: a. Remove a valve from each end of the cylinder.

Figure 5-8 Piston End Clearance Check

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).

Section 5: Installation Cooper Energy Services n Superior Compressors

4/3/03

Page 5-7

f. After adjusting the piston and rod assembly, recheck the head end and crank end clearances. g. After setting the piston end clearance, re-torque ( Table 7-2 torque values) the balance nut.

Piston Rod Runout
Once the piston and rod assembly and cylinder head are assembled, and the piston end clearances are set, a check can be made for the piston rod runout. Proceed as follows: a. Bar over the compressor until reaching the crank end dead center position. b. Place two dial indicators as Figure 5-10 Dial Indicators close to the packing as possible. Zero the two dial indicators. (Figure 5-10). c. Bar over the compressor until reaching the head end dead center position. Record indicator movement. d. The horizontal runout must not exceed +/- 0.0010 inch (0.025 mm) for 6" stroke, or +/- 0.0012 inch (0.029 mm) for 7" stroke. Allowable vertical runout tolerances are in Table 5-11. e. If the horizontal run out exceeds acceptable limits, loosen the packing and re-torque. If the crisscross pattern of torquing is not followed, this may cause the packing case to seat at an angle, causing the rod to deflect to one side. A second technique would be to loosen the rodto-crosshead nut, and rotate the piston one quarter turn before re-torquing. If the runout still exceeds limitations, contact your Cooper Energy Services Aftermarket facility for assistance. f. If the vertical runout exceeds acceptable limits, check the packing case as explained for horizontal runout. Also, check the piping and bottles attached to the cylinder to see if they are distorting the cylinders. If runout still exceeds limits, loosen the cylinder to crosshead guide nuts and re-tighten them. If the runout is still beyond acceptable limits, contact your Cooper Energy Services Aftermarket facility for assistance.

WG-4/3/03

Page 5-8

Cooper Energy Services n Superior Compressor Product Group

WG Series Compressor Frame Instruction Manual

Section 6 Operation Start-up
Complete Superior® Compressor Start-Up Checklist and Report Control Procedures Engineering Standard ES30 and forward to the address included in procedure. Preparation For Initial Startup
Prior to startup, the frame lubrication system should be primed by using the lube oil hand priming pump or automatic priming pump. Use of this pump will prevent oil starvation in the bearings during startup, prolonging compressor life. Compressor design, operating conditions, and the gases being handled all have a significant effect on how well a lubricant performs in the given application.

I CAUTION
Read this manual and familiarize yourself with the compressor, auxiliary equipment, and your company’s 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.

Section 6: Installation Cooper Energy Services n Superior Compressor Product Group

WG-4/3/03

Page 6-1

i. Check the force feed lubricator for cleanliness and fill to the proper level with oil. j. Adjust all force feed lubricator pumps to full stroke for cylinder and packing break-in. k. Disconnect ends of force feed lubricator lines as close as possible to cylinders and crosshead guides. Hand pump the lubricators to fill lines and eliminate air. l. Connect the force feed lubricator lines and operate pumps ten more strokes to force oil into cylinders and rod packing. m. Prime the frame oil system with the lube oil priming pump. Operate the pump a minimum of 100 strokes or run automatic pre-lube pump. This should fill all empty oil lines. n. Hand lubricate the piston rod next to the packing. (This does not apply to non-lubricated applications.) o. Replace all covers with their respective gaskets and tighten screws according to Table 7-2. Distance piece covers may be left off to check for packing leaks on start up if not using sour gas. For sour gas applications, see warnings in sour gas trim Section 4.

i

Oil level in frame should be filled to the level in the Kenco level regulator NOT the level in the frame bull’s-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.

WG-4/3/03

Page 6-2

Cooper Energy Services n Superior Compressor Product Group

verify a lube oil header pressure of 20 psi (138Kpa) or greater occurs within 5 seconds of compressor startup. Start system and compressor up again and run for approximately 20 to 30 minutes. 7. When the compressor is started. Oil may be manually added through the breather cap hole in the top cover. 6.5 cm) from normal level. A shutdown should occur if the oil level rises an additional 1. an oil pressure of 20 psi (138 kPa) must be experienced within 5 seconds or the compressor must be immediately shut down. all compressors are equipped with low oil pressure shutdowns. To prevent damage to the crankshaft and other lubricated parts. 4. Remove crosshead guide covers and check all lubricated surfaces for high temperatures. Section 6: Installation Cooper Energy Services n Superior Compressor Product Group WG-4/3/03 Page 6-3 . Open the valves supplying water to the compressor cooling system (when required). The oil level in the frame is normally at the center of the sight glass. 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. Run compressor for 2 to 5 minutes at 600 RPM.5 inch (3. Check piping for oil or water leaks. this will submerge the gaskets on the bottom of the front and rear covers. If driver is a constant speed electric motor run compressor for only 1 to 2 minutes. The oil level in the frame is normally at the center of the sight glass. Start up and operate the unit under no-load conditions at reduced speed where possible (600 RPM for engine driven units). Shut system down and check all bearings and packings for high temperatures. Check the oil pressure. Do not restart until adequate oil pressure can be assured. Add oil to the crankcase to bring the oil level (while running) up to the middle of the sight glass. 3. 2. 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. Initial Startup 1. An alarm should sound if the oil level rises 1 inch during compressor operation. I CAUTION Running compressor at speeds less than 600 RPM for longer than 12 minutes may result in unusual wear of the piston rings. The oil level in the frame sump should be checked while the compressor is running. frame mounted oil level controller connected to an oil supply tank. 5. This is triggered when the oil pressure falls below 20 psi (138 kPa). Shut down and recheck as above.8 cm) or if the oil level falls 1 inch (2.WG Series Compressor Frame Instruction Manual When starting the compressor.

and high temperatures. for ten strokes. 5. Start unit. Check frame lube oil pressure. 6. (Be sure the lubricator tank is kept full. Turn on cooling water supply. Operate at low speed (600 RPM where possible) and no load for several minutes. Allow the unit to cool down to prevent possible explosion due to in rush of air or injury caused by contact with hot surfaces. Shutdown the compressor driver. 2. Decrease speed to 600 RPM (engine driven units only). fixed volume pockets. Start the unit. In the event of equipment malfunction where excessive vibration. NDANGER Do not immediately remove the equipment covers after the compressor has been stopped. 2. valve unloaders.) 3. NDANGER Improper setting of variable volume pockets. Check lube oil for proper level. or other unloading devices can result in damage and/or injury to equipment and/or personnel. Apply load to compressor by closing the bypass line between the first stage suction and last stage discharge lines. WG-4/3/03 Page 6-4 Cooper Energy Services n Superior Compressor Product Group . excessive rod loads. at sight gauge. 7. pay close attention to the machine for any unusual high temperature. Normal Shutdown 1. 3. or any other dangerous condition exists. Unload the compressor by opening the bypass line between the first stage suction and the last stage discharge lines. 4.Operating the system without clearance and loading information can result in equipment failure due to overload. During the initial period of operation. noise. Unload the fixed volume pockets or suction valve unloaders. Bring unit up to full rated speed. by hand. The following notes comprise the normal starting procedure: 1. Operate the force feed lubricator pumps. 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). Normal Startup Not all of the instructions provided for initial startups are required for routine starting. high temperature. Set all clearance devices at positions suited for the planned operating conditions. Bring up to rated speed and apply load. 9. or vibration. pressure. Check force feed lubricator sight glasses for feed ( Figure 3-6).8. the compressor should be stopped immediately.

WG Series Compressor Frame Instruction Manual 4. Refer to the Troubleshooting Page 7-23 thru 7-31 to troubleshoot compressor. the shutdown devices will shut down the system. contact your Cooper Energy Services Aftermarket Sales Office. The unit should never be operated at conditions other than those specified on the data sheets without contacting the manufacture. Relieve pressure by venting compressor cylinders. and discharge piping to remove any remaining gas. If compressor operating conditions change. Emergency Shutdown In an emergency situation. 6. pressures. Note Superior attempts to furnish performance curves and/or computer printouts to assist you with compressor operation. Recommended Operating Conditions The compressor should only be operated at speeds. 5. the cause of the shutdown must be identified and corrected before restarting the compressor. and temperatures listed on the data sheets or performance curves. In such as case. suction piping. Section 6: Installation Cooper Energy Services n Superior Compressor Product Group WG-4/3/03 Page 6-5 . Close suction and discharge block valves. Turn off water supply. If they have been omitted please fill out the following form and new curves will be provided to you.

WG-4/3/03 Page 6-6 Cooper Energy Services n Superior Compressor Product Group .

Tx 77484 Fax:713-890-1399 Unit Serial Number 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. Box 947 Waller. Send Performance Curves To: Section 6: Installation Cooper Energy Services n Superior Compressor Product Group WG-4/3/03 Page 6-7 .WG Series Compressor Frame Instruction Manual Fill Out and Return To: Cooper Energy Services 20110 GH Circle P.O.

WG-4/3/03 Page 6-8 Cooper Energy Services n Superior Compressor Product Group .

Faithful preventive maintenance and the use of genuine Superior® parts will help prevent costly down time.012 . the clearance should be within the range shown in Table 7-1.0.102 .003 . Good preventive maintenance practice includes a periodic check of critical bolt torques.0.0. Superior® recommends planned periodic inspections of equipment. such as compressor main and connecting rod bolts and drive coupling bolts.000 .031 (0. malfunctions can occur.41 .003-0.010 .239) 0.08 . If not.0.018 (0.0.0. and replacement costs.18) 0.Main Bearing Connecting Rod Bearing Crosshead Pin to Connecting Rod Bushing Crankshaft End Play . Regardless of the gas compressors.0.0.0094 (0.017 (0. During inspections.31 .15) 0.0.0. repairs.79) 0.43) 0.239) 0.016 .007 (0.0.0.45) 0.0. Acceptable Clearance Values Table 7-1 shows clearance values for some critical components when new.014 (0. will go a long way toward insuring satisfactory operation of the compressor.0.25 . When a part is first installed.0040 .0040 .000 .001 (0.102 . Planned shutdowns for doing preventive maintenance will result in minimum maintenance costs and maximum mechanical efficiency of your equipment. Table 7-1 Acceptable Tolerance Clearance Values Assemblies Crankshaft . clearances found exceeding the clearance range indicate worn parts that should be replaced. given in this section.006 (0.WG Series Compressor Frame Instruction Manual Section 7 Maintenance General The diligent observation of the inspection and maintenance procedure.010 .25 .025) 0.08 .0.Thrust Bearing Crankshaft Web Deflection Connecting Rod Thrust Gear Backlash-Aux End Lube Oil Pump (WG) Crosshead To Guide Lube Oil Pump Drive Gear Backlash Clearance range in inches (mm) 0. the part is defective or has been incorrectly installed.0.0.36) Section 7: Maintenance Cooper Energy Services n Superior Compressors 4/3/03 Page 7-1 .0094 (0.

25 7.12 UNF 1-1/4" .12 UNF 1" .630 (773 .949) 260 .854) 640 .9 UNC 1/2" .20 UNF 2-3/4" . (N-m)* 430 .290 (353 .-Lbs.00 Valve Cap Nut Torque Ft.75 5.700 (868 .25 6.61) 3090 .393) 200 .5140) 1180 .220 (271 .298) 35 .00 6.A.) Grade 5 or Better) SPECIFIC TORQUE VALUES Main Bearing Cap Connecting Rod Cap Base Spacer Bar Crosshead Guide to Frame Cylinder to Crosshead Guide Shoe to Crosshead Balance Nut Piston to Piston Rod Nut GENERAL TORQUE VALUES All Fasteners Size in Inches 1/4 3/8 1/2 5/8 3/4 7/8 1 1-1/8 1-1/4 1-3/8 1-3/4 SPECIAL TORQUE VALUES Cylinder Number 615 616 617 618 619 620 621 683 1-1/8" .1265 (1598 .E.460 (583 .-Lbs.Table 7-2 Recommended Torques Fastener (S.8 UNC 7/8" . (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 6.25 6.75 7.624) 570 .-Lbs.3790 (4192 .8 UNF (for through rod) * American measurement (metric measurements) SIZE TORQUE Ft.75 6. (N-m)* 370 (502) 370 (502) 370 (502) 300 (407) 300 (407) 300 (407) 300 (407) 370 (502) Page 7-2 Cooper Energy Services n Superior Compressors .12 UNR 2" .1713) Torque Ft.45 (47 .12 UNF 1-1/8" .

in the case of valve caps. •Every twelve months thereafter. Repeat this schedule when the compressor is rebuilt. or has major repairs.WG Series Compressor Frame Instruction Manual Torque Recommendations To insure satisfactory compressor performance and to minimize costly failures. •Occasionally clean and lubricate the ratcheting head with light oil. DO NOT USE any compounds containing molybdenum disulfide as a thread lubricant. Use an appropriate wrench or breaker bar. Precautions Follow the precautions listed below when any maintenance is performed. I CAUTION When tightening nuts and bolts on compressor valve caps. Overtightening can result in unnecessary stress in the cylinder body and. overhauled. Only pull from the hand hold to assure accuracy. Remove all gas by unloading. personal injury or death may result if these precautions are not followed. b. can result in valve seat distortion. Blinding means to shut off all block valves so there can be no process gas flow to the compressor. •Torque wrenches should not be used to “break loose” fasteners. Check all critical bolt torques on components as follows: •One month after unit is placed in service. Follow the following general recommendations . etc. Block the flywheel to prevent rotation of the compressor and driver. a. bottles. •Periodic calibration is essential to ensure accuracy. excessive stresses will result if used with the torque values given in Table 7-2. •Hand position is critical. •Six months after unit is placed in service. All torque values shown in Table 7-2 are based on threads which are clean. it is extremely important to tighten all nuts and bolts to the recommended torque values specified in Table 7-2. and flanges care must be taken to avoid excessive tightening. Unless specified. and lubricated with engine oil or similar petroleum base lubricants. Section 7: Maintenance Cooper Energy Services n Superior Compressors 4/3/03 Page 7-3 . Critical Bolt Torques It is critical that the following preventative maintenance schedule be followed to prevent major damage to your compressor. Additional information is given in Service Bulletins SB168 and SB175 . free of burrs. venting. paint. Damage to the equipment. Due to its high lubricity. NOT GREASE. and then “blinding” the compressor.

After completing maintenance. Component Maintenance Base (Crankcase) The base is made of high strength alloy iron and is heavily ribbed and reinforced for maximum rigidity. The top and end covers are individually removable to provide easy access to moving parts. dust or grit. i. NDANGER When work is being done on the compressor. k. remove any locking or blocking devices before attempting to rotate the equipment. n. l. f. Our open-top design allows Page 7-4 Cooper Energy Services n Superior Compressors . the rod could break. Rods that are bent or have burrs will damage the packing or prevent it from sealing. replace all worn or damaged gaskets and seals. In severe cases. Never distort or mark the piston rod with any tool or device. Eliminate all internal pressures by removing cylinder indicator plugs or vent through indicator cocks. j. if provided. Precaution must be taken to prevent the opening of any valve which would release pressure against a piston. 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. o. 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. After a long period of shutdown or a major overhaul. Do not refinish worn valve plates. Never file. Always install new cotter pins or lock wire. g.e. Check and clean all lubricating oil passages when the unit is down for repair or normal maintenance. Prevent clogged oil lines or filters by using only lint free cloths. h. grind or scrape any lubricated parts (i. dirt. e. d. m. When reassembling parts during maintenance. Air or gas must be bled off from the cylinders. Large spacer bars provide further stability and ease reassembly. Ensure all tools and work areas are clean and free of oil. causing it to rotate the unit at a critical moment.c. bearing shells or saddles). Genuine Superior® parts must replace any components which are changed. water. Never torque or tighten any nut. frequently check the unit during the first 300 hours of operation.

or other fitting be done on either bearing shells or saddles. The upper and lower main bearing shells are interchangeable. it is preferable that the shells be placed back in their original position. It fits into a groove machined in the main bearing saddle and is held captive by the crankshaft. Depress the button until the dial makes one complete revolution and set the pointer top to zero. Section 7: Maintenance Cooper Energy Services n Superior Compressors 4/3/03 Page 7-5 . c. The thrust bearing is a “half washer” type. Use a hydraulic jack that will fit between the crankshaft and frame bottom. This is done by inserting the neck of the tool into the oil passage hole in the crankshaft journal. Position it as close as possible to the bearing being checked. Under no circumstances should any filing. The crankshaft is drilled to carry lubrication from the main bearings to the connecting rod bearings. Proceed as follows: a. scraping. they should be so marked. Remove the top cover to gain access to the crankshaft. Mount the indicator so the button comes in contact with the crankshaft at its highest point. Both of these are shrunk onto the crankshaft. After the compressor has been run.WG Series Compressor Frame Instruction Manual the crankshaft to be easily removed. eliminating the need for keyways and keys. I CAUTION Only use a pencil for marking on the parting line faces or in the groove of the bearing shells. the tool will push the bearing shell out from underneath the journal and around to the top where it can be removed. b. Carefully clean the crankshaft. Thrust And Main Bearings The complete crankshaft assembly includes the drive end oil slinger and the auxiliary end drive gear. The main bearing clearance (tolerance value) can be checked by using a dial indicator and a hydraulic jack. the lower bearing shell can be rolled out from underneath the crankshaft with the help of the main bearing removal tool. Crankshaft. the main bearing saddle and the main bearing cap. When the compressor is barred over. Attach the dial indicator to the bearing cap via a magnetic base. An oil sump is provided in the lower portion of the base. The bearing cap nuts should be tightened uniformly (using a crisscross pattern) to the proper torque given in Table 7-2. The line-bored main bearing supports have caps which are match-marked and numbered and must be assembled accordingly. A new bearing shell can be installed using the same procedure. After removing the main bearing cap and the upper bearing shell. upon removal of the bearing shells. bearing shells and saddles before attempting to replace the bearing shells. Therefore.

if replacement is necessary. The upper end of the connecting rod carries one pressed in bushing. e. bar the compressor over so the crankshaft moves slightly away from the connecting rod. Push the pin through the crosshead far enough to release the connecting rod. The rod cap and crosshead pin must be removed to remove a connecting rod. If care is not taken during the bearing removal process. NDANGER Take extreme caution to adequately support the rod. personal injury and equipment damage could result. i The caps and rods are numbered by throw and have their weights stamped on them. This will offer easy access to the cap bolts. 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. remove the rod cap and its bearing half. If the clearance reading exceeds the maximum limit. To change the connecting rod bearings (crankpin end). Support the connecting rod so it will not drop after the cap has been removed. rifle-drilled to provide lubrication to the crosshead pin bushings. Compare the clearance reading with the tolerance value given in Table 7-1. The crankpin end of the rod is split and retains the precision type bearing shells by means of four alloy steel bolts and nuts clamping the cap and rod together. The crosshead pin can only be removed when the crosshead is in the outermost position. Install a new bearing half against the back wall of the connecting rod. the bearing needs to be replaced. Support the jack with a piece of wood and jack the crankshaft up and down to get a clearance reading on the dial indicator. Connecting Rod And Bearings The connecting rod is a steel forging. Always install rods with this information displayed up.d. In order to get access to the other bearing half. NDANGER Always support the connecting rod so it can not drop and damage equipment or cause injuries. The tang recess within the rod should support the bearing until the crankshaft can be moved back into position. The connecting rod can be eased out of its position when the crankshaft throw is slightly below the innermost position. When the bushing is replaced in the field. With the connecting rod supported. Remove the crosshead pin assembly. extreme care should be used in shrinking the new bushing in place. A connecting rod can be installed by reversing the above procedure. Page 7-6 Cooper Energy Services n Superior Compressors . bar the compressor over until the connecting rod cap rises to its highest point. The cap is aligned to the rod by dowels and both parts are precision machined as an assembly. A complete assembly must be ordered.

Loosen the balance nut with the crosshead nut wrench. j. e. h. nut. After the piston rod is free of the crosshead. and retainer plates. switching them from end to end. slowly bar over the compressor to innermost position. The crosshead can be removed through these openings without disturbing the cylinder mounting. Vent compressor clearance bottles. Remove the cylinder head and crosshead guide covers.WG Series Compressor Frame Instruction Manual 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. (Section 6. connecting rod. k. unloaders and all associated gas piping to atmospheric pressure. With the pin removed. Crosshead Removal And Installation The crosshead is made of ductile iron and has removable top and bottom shoes which have durable bearing material on the sliding surface. (See Table 7-2 for torque values). Large side covers on the crosshead guide allow easy access to the crosshead. Like all bearing maintenance. Section 7: Maintenance Cooper Energy Services n Superior Compressors 4/3/03 Page 7-7 . f. i. b. Screws and locknuts hold the shoes firmly in place. Bar over the compressor so piston is in the outer most position. and torquing the nut to pull the pin free. remove the balance nut from the rod. Care should be used to prevent damage to the shoes or slides. d. c. and rod packing. Support the crosshead weight. cleanliness is an important factor during the assembly of shoes to the crosshead and placing the crosshead in to the guide. These must be torqued uniformly to the figure specified in Table 7-2 . Remove the crosshead pin assembly by loosening the center bolt. roll the crosshead the rest of the way over and lift it out. Use the piston puller to turn the piston and rod assembly out of the crosshead. Prepare the piston rod for moving through the packing. Do not use directly on the piston rod. g. To remove a crosshead proceed as follows: a. Support the connecting rod and carefully remove the crosshead pin. Be careful to support the small end of the connecting rod so it cannot score or dent the bottom slide.) Pull the piston and rod assembly out far enough to allow the crosshead to be removed.

remove the screws holding the drive end cover. When using the crosshead installation handles. i This procedure applies to the old style cover part #620-093-001. Drive End Cover The drive end cover is aligned with the base by two dowel pins. i Crossheads and balance nuts are stamped with throw numbers and must be replaced accordingly. During the reassembly procedure. From the proper position. The pump takes oil from the frame sump. this can be done. It must be supported to prevent it from moving.gear driven from the crankshaft. where the lubricating oil supply is carried in the compressor frame and circulated by means of a gear type pump . The new cover is machined and does not contain the same number of components.the oil first passing through an oil cooler and full flow filter. (The oil drain hole must be down. If it is desirable to remove the crankshaft from the base without removing the drive coupling hub. DO NOT USE FORCE as this is the first indication that the job is being done incorrectly and damaged crosshead shoes may result. An additional dowel pin is used in the end cover to locate the seal cover. Then support the drive end cover in place on the crankshaft.To install a crosshead. or manifold on the compressor . Additional dowels in the auxiliary end cover provide proper location for attaching the lube oil pump drive carrier and the force feed lubricator drive carrier. Remove the screws holding the seal cover. through a suction strainer and delivers it into the lubricating oil header. Lube Oil Supply (Sump) The oil circulating system is of the pressure. First. while lifting out the crank.) The seal cover has a close pilot fit in the end cover. The drive end cover can now be snaked off the crankshaft toward the auxiliary end . Check piston end clearances and then make sure that the balance nut is torqued properly ( Table 7-2) against the crosshead. attempting to roll it in at short intervals. wet sump type.leaving the seal cover on the slinger hub. reverse the above sequence. The correct procedure is to stand to one side of the crosshead guide and feed the crosshead across. the crosshead will roll in easily without damage to the shoes. Page 7-8 Cooper Energy Services n Superior Compressors . Auxiliary End Cover The auxiliary end cover is aligned to the base and located by a dowel. the machined face of the balance nut must be toward the crosshead. more care and feel is required.

Tighten nuts on cap screws (H) per torque values given in Table 7-2. The pump. the hub is held in place by a round locknut which threads onto the end of the crankshaft and is locked in place by “Nylock” setscrews. Mount steel bar (G) in the manner illustrated. Tighten screws holding the lock plate to the gear. c. c. Figure 7-3 Removing Crankshaft Coupling Hub Section 7: Maintenance Cooper Energy Services n Superior Compressors 4/3/03 Page 7-9 .WG Series Compressor Frame Instruction Manual The precision built. Additionally. Proper gear backlash is given in Table 7-1. b. Assemble key. Clean the pump mounting face thoroughly. gear type lube oil pump provides full pressure lubrication for all moving parts in the frame. The coupling hub is removed as follows (Figure 7-3): a.000 psi hand hydraulic pump to the 3/8-inch pipe tap (F) in the hub. When installing the pump. b. Slide carrier assembly into place on the end cover. Putting a 1-1/2-6 UNC tapped hole at its midpoint will permit a standard 1-1/2 UNC cap screw to be used as a jackscrew. Loosen lock nut (E). e. Add gasket for carrier assembly. d. until there is 1/8 inch (3mm) of space at dimension (X). and fasten with lock wire. with its drive gear. can be removed from the base end cover independent of the cover or other gear drives. using the dowel to locate. Connect a 10. Drive Coupling Hub The main drive coupling hub has a shrink taper fit on the compressor crankshaft. after first unlocking its setscrews. Add a slotted nut to the rotor shaft and lock in place with a cotter pin. observe the following: a. drive gear and lock plate. Torque jackscrew (J) up against the crankshaft per torque values given in Table 7-2 . d.

the larger the reserve margin that will exist for accomplishing the intended purpose of the coupling. Heat the coupling hub and slide it on the shaft until it engages the gage block (with the reduced amount of shims as defined in item d above). g. e. push the hub on the crankshaft taper as far as possible. Use gage blocks and shims to fill the space between the coupling and the compressor end cover. See page 5-4 to 5-5 for the recommended limits. Hold hub in position until it is cool enough to engage the crankshaft. The flexible drive coupling will give you relatively trouble-free service and long life if installed and maintained properly. d. foundation settling. the hub can then be lifted off by crane or by hand. Operate the hand pump until the hub becomes loose and slides against the lock nut (E). the most practical method of removing the coupling hub from the crankshaft is by first removing the crankshaft from the base. Remove the amount of shims needed to provide an advance of the hub on shaft of 0. The more attention paid to initial alignment. Remove the jackscrew and bar arrangement. Install the coupling hub onto the crankshaft as follows: a. Initial alignment is one of the most critical factors affecting coupling performance. Flexible Drive Coupling Obtain the most recent version of Service Bulletin SB149 for detailed information on flexible drive couplings.050 inch (1.f. The coupling was selected based on known loads and operating conditions of the driver and driven equipment. h. f. When hub has cooled to room temperature.27 mm). These limits represent about one-third of the total misalignment capacity Page 7-10 Cooper Energy Services n Superior Compressors . c. It should be remembered that the couplings are basically in-line devices which are intended to compensate for small amounts of shaft misalignment caused by bearing wear. b. The crankshaft and drive end cover plate may now be taken to a suitable work area where the locknut is removed. Push the crankshaft all the way to one side to take up any thrust clearance that may be present. Remove nut (E). etc. If the proper equipment is not available. thermal growth. When at room temperature. the hub heated and pressed off the crankshaft. g. install lock nuts and Nylock setscrews.

Usually a result of a loose bolt. Exceeding the Table 5-6 values for alignment will reduce the service life of the coupling. Here are some of the more evident visual inspection criteria and recommended corrective procedures. This may also be caused by turning the bolt during installation. Do not turn the bolt during locknut tightening process. Replace the bolt and tighten locknut to proper torque. Another factor to be considered. 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. Replace disc pack and tighten bolts to specified torque value. Figure 7-4 Elongated Bolt Hole-Disc had broken through bolt hole.Disc is broken adjacent to washer face. 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. Consult Superior® or your nearest Cooper Energy Services Aftermarket facility for further assistance. and pounding which will eventually destroy the bolts and coupling discs. hammering. Proper evaluation of the disc packs and connecting parts may save considerable maintenance costs and down time. Indicates loose coupling bolts.WG Series Compressor Frame Instruction Manual of the coupling and are generally adequate for most installations. Realign equipment and replace disc pack. Troubleshooting Rexnord Couplings The Rexnord disc coupling is easily inspected. Figure 7-6 Misalignment failure. The primary advantage is that the reserve margin for accepting misalignment during the life of the machinery is thereby increased. Make HOT check of alignment to assure it is within coupling misalignment capacity. Usually indicates excessive shaft misalignment during operation. A visual analysis may point to possible drive system problems. t 00768 t 00769 Section 7: Maintenance Cooper Energy Services n Superior Compressors 4/3/03 Page 7-11 . t 00767 Figure 7-5 Scored Body Bolt -Discs embedded into bolt body. This type of disc failure usually starts in the outer discs in the pack and progresses through the disc pack.

This failure is typical of discs that have been in service for years or have been operating in an offshore environment. Re-torque locknuts. This means that the coupling was installed in a compressed condition or equipment has shifted axially during operation. verify that the operating center line of the motor rotor is properly positioned. Check for thermal growth. Loosen coupling locknuts and turn bolt slightly to remove friction. O v Torque Overload (Visible only with strobe light while running) The disc pack has a bulge near the center or is bowed toward one flange in every other chord position Figure 7-10. If distortion does not disappear. The remaining disc pack chordal t ! Caution Figure 7-10 Torque Overload If bulged or bowed condition only appears in one chordal section there may be a loose bolt on one side of the distortion. they should be replaced with stainless steel plating 00770 Figure 7-8 Compression-Disc pack is wavy and dimension between flange faces is smaller that indicated on installation instructions. replace disc pack. make sure operating centering on motor rotor is in proper position. This condition is a result of a large torque overload induced into the system above the peak overload capacity of the coupling. Breaks will first appear in the outer discs and will progress into the disc pack. Bulge should flatten out. t o r q u e Figure 7-9 Elongation-Disc pack is wavy and dimension between flange faces is larger than specified on installation instructions or applicable assembly drawing. If excessive corrosion exists.Figure 7-7 Fatigue Failure. If sleeve bearing motor. Realign position of equipment so coupling operates with a neutral flat disc pack. If the application is a bearing motor. Page 7-12 Cooper Energy Services n Superior Compressors .Disc is broken adjacent to the washer face with heavy corrosion along area of break. The coupling has been installed in an elongated position or equipment has shifted axially during operation.

This paragraph does not apply to non-lube operation. If the pipe plugs in the crank end of the drilled passages are removed. Replace as required. The piston end clearances are adjusted as specified in Section 6 and should be checked with the balance nut torqued to its proper value. be kept in stock at all times. Each cylinder is conservatively designed for very low stress at rated working pressures. The water seal grommets should also be checked. 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. the drilled passages should also be cleaned out.WG Series Compressor Frame Instruction Manual sections will be very straight and tight. Piston Rings And Piston Rod The piston is attached to the piston rod with six capscrews (for most piston sizes) and with four capscrews on remaining sizes. After removing a cylinder head. Prior to passing the piston rod through the piston rod packing. Cylinder Body A wide range of cylinder sizes is available. Check the driven equipment loading. for all cylinder sizes used. which surrounds the ring travel area of the bore. Lube oil. from the force feed lubricator tubing system. on all size of cylinders. prepare the rod as described in Section 5 . See Table 7-2 for proper torque values. Whenever the water jacket covers on the cylinder sides are removed to clean out deposits. which can be removed and indicator cocks inserted to take pressure readings. Some cylinder bodies are provided with drilled water passages. if desired. which connect the water inlet and outlet with the cooling muff. they should be coated with good waterproof sealer and replaced. examine the o-ring which provides a seal between the cylinder head and the cylinder body for nicks. This will prevent water seepage into the atmospheric vent space. contact the Cooper Energy Service facility immediately. Some pistons have a through rod and nut while others have a one piece piston and rod. It is recommended that a complete set of o-rings and grommets. Piston. Plugs are provided. Section 7: Maintenance Cooper Energy Services n Superior Compressors 4/3/03 Page 7-13 . If not correctable. tears and compression set. top and bottom. 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.

In order to reduce cylinder bore wear. Superior ® designed every piston to operate with rider compression rings or rider rings. If there is concern about proper lubrication rate. During initial operation. As the piston rod moves through a wiper packing.wiper packing and pressure packing. the rider compression rings. Experience has indicated that these factors may vary widely on different applications. The rider compression rings and rider rings are not collapsible in the piston groove. contact the nearest Cooper Energy Service Aftermarket office. Piston Rod Packing Piston rod packing comes in many different arrangements and designs. Replacing these elements before they wear beyond allowable limits will contribute to the successful operation of a non-lubricated cylinder. (See Figure 7-11 and Figure 7-12). In non-lubricated applications. but should contain enough detail to allow you to successfully remove. Contact the Superior ® Engineering Department for wear limits for your specific cylinder size and application. Figure 7-11 Typical Lubricated Wiper Packing Case Page 7-14 Cooper Energy Services n Superior Compressors . a packing may leak or tend to overheat. maintain and install the piston rod packing on your compressor. rider rings and the piston rod packing will wear with time. thus supporting the piston in the cylinder bore. Piston rod packing can be divided into two different groups based on packing function -. This temporary condition occurs while the packing rings are adjusting to the piston rod and packing case. oil is stripped off the rod and prevented from migrating in to another part of the compressor. This manual will not explain each individual design. Definite lubrication rates and time intervals for packing “wear in” are difficult to prescribe. The purpose of pressure packing is to prevent the loss of gases from the cylinder along the piston rod.

record the position of each ring and the direction each ring faces for proper reassembly. Figure 7-12 Typical Low Pressure Packing Case Section 7: Maintenance Cooper Energy Services n Superior Compressors 4/3/03 Page 7-15 . If components are not marked. it is possible to repair piston rod packings by replacing the packing rings only.WG Series Compressor Frame Instruction Manual Ordinarily. In order to remove a packing case from a crosshead guide or cylinder. Refer to Figure 7-13 for aid in identifying packing rings. Therefore. Before disassembling a packing case. It is good practice to keep a complete set of packing rings on hand for the packing assemblies of all your cylinders. Knowing your packing rings is very helpful when ordering new ones. identify each cup’s position relative to the adjacent cup or flange by numbering or marking them together. note all identification marks to ensure components are reassembled properly. packing cases t (cups and glands) are not severely worn. While disassembling a packing. the piston rod must be pulled out through the assembly and cylinder.

t Figure 7-13 Typical Packing Configurations 00776 Page 7-16 Cooper Energy Services n Superior Compressors .

Do not use a steel hammer as this may damage the sealing surface of the new gasket. i The rings must be placed in the packing cups in the same position (facing original direction) as the original set. burrs should be removed. take care not to damage the groove. After installing the packing cases and before connecting the oil tubing to the packing flange (for lubricated packing).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. Connect this tube to the respective hole in the packing flange and continue to pump the lubricator 12 to 15 more strokes. check to see if the lubrication rate is set properly per Section 3. If found. Before installing new packing assemblies. temperatures not tolerated by resting your hand on the packing case flange. Section 7: Maintenance Cooper Energy Services n Superior Compressors 4/3/03 Page 7-17 . after the unit is shut down. If the rod is worn. This can be determined by first inspecting the valve to see which direction the valve plates move while opening or compressing the springs. I CAUTION As a general guide. the piston end clearance must be set and the piston rod runout must be checked per Section 5 . Also. Gas will flow in that same direction (Figure 7-14) . pitted or has a taper. rough. 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. Tap the gasket into the groove with a hard rubber mallet. hand pump the force feed lubricator (when supplied) until oil runs from one of the disconnected tubes. The bore for the pressure packing nose cup must be cleaned and examined for burrs. replace the o-ring in the outside diameter of the wiper packing flange with a new one. Remove the old metallic gasket with a sharp tool. it must be replaced. Valves Valve Installation Suction and discharge valves must be installed in the proper direction. For a lubricated packing. indicate to fast of a wear rate. 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. After the piston and rod assembly has been reinstalled. Clean the groove thoroughly and install a new gasket. A new metallic gasket should be placed in the groove of the pressure packing nose cup. it is important that the piston rod be carefully checked.

To replace a valve in a bottom port (assume that this is a discharge port). Figure 7-14 Valve Installation c. Loosen set screw in valve retainer (bottom valves only). Force the valve cap into place by torquing the nuts or screws evenly to the values listed in Table 7-2. and on valve retainer and on valve cap. place o-ring if defective. Remove. Clean all gasket surfaces on valve and in valve pocket. proceed as follows: j. i The valve cap flange must not contact the cylinder body. as applicable. inspect and replace gaskets as needed. 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. Install new gasket in place on retainer.Valve Replacement Refer to Figure 7-14 . Loosen bolts or nuts holding valve cap. Slip gasket on valve. Insert threaded puller into valve retainer and remove. b. h. Proceed with valve removal in the following manner: a. e. i. Grease or oil the o-ring on the valve cap. Using threaded valve puller. i Before removing any gas containing part of the compressor or associated gas piping system. Place valve in pocket FACING PROPER DIRECTION . remove valve from seat in cylinder. Invert retainer. Page 7-18 Cooper Energy Services n Superior Compressors . d. f. g. Place valve on top of retainer with valve guard facing out (away from the cylinder). Install the retainer on top of the valve. inspect o-ring. Install new gasket in valve pocket. vent compressor and system to atmospheric pressure. DO NOT remove completely until after cap is pulled out far enough to vent any pressure trapped under cap. Remove valve cap.

making sure that the valve seat enters first. Lift the valve. and gasket up into the bottom port. t Figure 7-15 Valve Replacement 00778 Section 7: Maintenance Cooper Energy Services n Superior Compressors 4/3/03 Page 7-19 . l. Tighten the retainer lock screw just enough to hold retainer and other parts in place.WG Series Compressor Frame Instruction Manual k. retainer.

All questionable devices should be replaced. Grease or oil the o-ring on the valve cap. The most common ones and their recommended set points are listed in Table 7-16. to assure that they are operative. Alarms and Shutdowns Each unit is equipped with a specified complement of electrically or pneumatically operated alarm and/or shutdown devices. or at least once every six months . Several safety devices may be employed on compressor units. Place new gasket in place on valve cap. Questions regarding these and other devices and their set points may be referred to the Cooper Energy Services Aftermarket office. Table 7-16 Alarm/Shutdown Oil Pressure in Header Oil Temperature out of the Frame Vibration Gas Temperature Water Temperature Recommended Alarm Set point Normal Condition 45-55 psig (310-380 kPag) 160-180°F (71-82 °C) Out Nominal Suction (TS) or Discharge (TD) Tin or Tout Alarm Point 25 psig (173 kPag) 185 °F (85°C) Out 1/4-3/8 turn from normal condition 20°F (11 °C) above TS or TD 20°F (11 °C) above Tout or Tin 5% below PS 5% above PD Shutdown Point 20 psig (138 kPag) 190 °F (88°C) Out 3/8 . Force the cap into place by torquing the nuts or screws evenly to the values listed in Table 7-2 . Each device should be checked and reset after each shutdown. Special Tools Refer to the section 9 and 10 of this manual for information on special tools.m.whichever is sooner. as applicable. These devices are designed to protect the unit in the event of any abnormal operation or any malfunction which may occur.1/2 turn from normal condition 25°F (14 °C) above TS or TD 25°F (14 °C) above Tout or Tin 10% below PS 10% above PD Gas Pressure Suction (PS) or Discharge (PD) Page 7-20 Cooper Energy Services n Superior Compressors .

crosshead shoe and guide condition. Replace O-rings. Check cylinder bore. X X X X X X X X X X MECHANICAL/OPERATING SYSTEM . Check one compressor valve on each stage. Inspect frame. Collect a compressor oil sample for analysis. Listen for unusual noises. Roll out compressor thrust main lower shell for inspection.FRAME Check crosshead clearances. Remove head and piston of the first stage cylinder. Oil and filter change periods can then be extended out to 2000 hours of operation. Check compressor accessory drive gear lash and general condition. and packings. broken springs. and oil sight level. Hand check suction valve covers from coolness. Check temperatures of coolant to and from cylinders. Check calibration of all themometers and pressure gauges. Note and record cylinder discharge temperatures. lube oil cooler. and rod bearing. oil level regulator. piston.CYLINDERS Note and record inlet temperatures. and packing cases for leakage. gear tooth condition. Check lubricator line connections for leakage. Change lube oil filters when differential pressure reaches 12 to 15 psi. Clean and/or replace crankcase breather(s). Visually inspect frame interior for bearing material in frame. Inspect for broken plates. X X X X X X Section 7: Maintenance Cooper Energy Services n Superior Compressors 4/3/03 Page 7-21 . Check foundation bolt torques. Check compressor coupling for proper alignment. Change compressor oil and filters elements after the first 400 hours of compressor operation. and trapped solids or liquids. Check compressor force feed lubricator pump(s) for proper output rate. LUBRICATION SYSTEM Check oil levels. Remove the distance piece cover from the crosshead guide and inspect the packing area on each piston rod. piston rings.WG Series Compressor Frame Instruction Manual System Recommended Maintenance Schedule Adhering to Table 7-17 will result in less equipment down time and less operating costs. Check crosshead guide for wear metals. Note and record panel gauge readings. Table 7-17 SYSTEM Recommended Maintenance Schedule CONTROLS Daily Weekly Monthly Semi-Annually Annually or as Needed X X X X X X X X X Perform safety shutdown system tests. lubricator. MECHANICAL /OPERATING SYSTEM . Check for loose cylinder fasteners. packing rings.

) in cylinders. cracked welds. Defective shutdown device. Realign the compressor per Section 5. Improper pistonto-cylinder end clearance. piston rods. and parts. connecting rods. Replace balance nuts or crossheads to obtain this balance. piston rod runout. main bearings. lubricating system. contact your nearest Cooper Energy Services Aftermarket office for possible field assistance. etc. Check the control system and device for proper operation. Verify crankshaft alignment. or change foundation bolt breakage. Analyze the symptoms (clues) to pinpoint the exact location of the problem valves. or broken frame and crankshaft. and rings must be within 3 lbs. The following steps should be followed in all troubleshooting activities: a. or bearing clearances. operating speed. possible bent piston or connecting rods. The suggested corrective actions are supposed to direct you to those areas most likely to be at fault. or foundation bolt failure. change piping. Total weight of crosshead. Replace damaged parts and take measures to prevent future foreign material entrapment in the compressor cylinders. Gas pulsation. Return the unit to service and verify that normal operation is resumed. Compressor Opposing vibration cylinders are out of balance. Improper compressor installation and alignment.frame. piston rods. Worn bearings. Compressor Frame Troubleshooting Potential Damage Seized crosshead. valve damage. weld cracking. piston rod runout. Reverify alignment and runout. Foreign material (water. If symptoms persist. Foundation cracking. Page 7-22 Cooper Energy Services n Superior Compressors . Table 7-18 Symptom Compressor will not turn over Possible Cause Mechanical seizure of compressor. foundations. the typical origins or sources of these problems and suggestions on how to repair the trouble. Corrective Measure Replace all defective parts. bearings. Foundation damage. grout. Also possible change cylinder operating configuration. rods. Tables 7-18 through 7-22 list many typical symptoms. grout cracking. c. b. It may be necessary to refer to more than one symptom to locate the entire difficulty. d. etc. crankshaft.Troubleshooting Troubleshooting is the process of finding operational problems. Possible broken frame. Excessive vibration causing Analyze compressor with a vibration or indicator analyzer. foundation bolt failure. Determine what general area is affected . Check compressor for proper crankshaft alignment. Replace bearings as needed. Cylinder scoring. This section describes the difficulties which may arise during operation of a compressor.4 kg) of same components on opposite throw. Replace all defective or damaged parts. (1. Install orifices at the cylinder flange. causes and corrective measures. and lube oil system operation. cylinders. Tripped shutdown device. etc. non-lube packing. balance nuts. and connecting rods. Replace any damaged parts and properly set the pistonto-cylinder end clearances. Possible piston or rod damage. However. do not limit your analysis only to those areas found in the table.

Table7-19 Symptom No lube oil pressure Possible Cause Lack of oil Oil System Troubleshooting Potential Damage Scored bearings. or broken valve retainers. pressure crosshead shoes. springs. if dirty. Replace rings Replace with new rings Section 7: Maintenance Cooper Energy Services n Superior Compressors 4/3/03 Page 7-23 . Scored bearings. If and head mechanism damage damaged. Same as above. and defective parts. crankshaft. ring. Seizure of compressor is possible. Cylinder damage through broken valve parts in the cylinder bore. crankshaft. resulting in pin failure Possible broken plate valves or springs. and bore overheating discharge pressure rings Clean and replace any defective valve parts. Possible insufficiencies on rod load reversal If open. broken. Fill with oil to the proper level. or any other worn. Replace defective bearings. Excessive main and connecting rod bearing clearance. and pins. . High lube oil Lube oil cooler clogged temperature or dirty. broken valve bodies. Compressor Frame Troubleshooting Valve seat damage. Same as above. Replace filter element and/or strainer. Same as above. Replace broken parts. Same as above. crosshead shoes and pins. Lube oil pump or drive Same as above. Sticking or maladjusted pressure relief valve. Check all lubricated surfaces and replace parts as needed. Table 7-20 Symptom Failure to deliver gas Cylinder Area Troubleshooting Possible Cause Restricted suction line or filter screens Defective or missing valves Deposits on valves Potential Damage Clogged suction screens Corrective Measure Clean suction line and screen. replace defective parts. load compressor. Correct water flow problem or temperature. Air leak in suction piping.WG Series Compressor Frame Instruction Manual Table 7-18 Loose valves. Check all lubricated surfaces. Fill with oil to the proper level. Reduce viscosity resulting in Clean cooler. Replace defective plates. Same as above. Install new valves and tighten to proper torque. Check all lubricated surfaces and replace parts as needed. High or low discharge pressure between stages with insufficient rod reversal. Clogged strainer or filters. lower lubrication and filtration. Low lube oil Low oil level. Check pump end clearances. Review type and quantity of lube oil used. Same as above. Check mating gears and replace if needed. Open or defective clearance pocket Defective piston High discharge temperatures rings Low compressor cylinder Worn piston Piston. Corrective Measure Check all lubricated surfaces and replace parts as required. Same as above. Repair leaks as needed. Find and stop leak. Air leak on suction side of pump. Dye check the cylinder valve seat for cracks. Free or adjust valve. Remove valve and retainer. gear. Possible seizure of compressor. Clogged or dirty filters. Replace filter element and/or strainer. Insufficient warm cooling water through cooler.

rings. broken valve bodies and retainers replace any broken parts. damage to the crankshaft from excessive worn or broken parts. if suction line or dirty. springs. Clogged cooler. Collateral damage from broken parts entering the cylinder bore Same as above Replace plates. Open all pockets before starting. as well as damage to the piston rods. Clean suction line and screen. This can cause damage to the crankshaft from excessive heating. Replace defective parts. Improper Same as above. springs. filter screens. volume pocket(s) until discharge pressure decrease to a proper level. Defective or Insufficient rod load reversal. and bore overheating. scrubber. or other missing valves. repair or replace defective parts Symptom Possible Cause Potential Damage Corrective Measure Low compressor cylinder Loose valve(s) discharge pressure (Continued) High compressor cylinder discharge pressure. crossheads. Also. Replace discharge or any damaged parts. Same as above. Replace rings. or any other worn. Increase setting of variable of volume or discharge temperatures exceeding the volume pocket(s) or open fixed pockets. Properly install valves. Collateral damage from broken parts entering the cylinder bore. heating. Page 7-24 Cooper Energy Services n Superior Compressors . crosshead guides. Dye check the cylinder valve seat. check for valve seat Remove valve and retainer. crosshead guides. Same as above. Insufficient capacity Same as above. Replace any broken parts. seizure of the crosshead pin. Clean coolers. Unload the crank ends if this does not reduce pressure. rings. and connecting rods. broken or missing parts Open or defective fixed/ variable pocket head If damaged. If all valves are reversed. Restricted Clogged suction screens. Replace screen if damaged. NDANGER Loose valves. crossheads. and connecting rods. Possible damage to valve Remove valve and retainer. seizure of the crosshead pin. Worn piston Piston. Dirty suction Possible cylinder heat buildup. Open or Same as above. Dye check the cylinder valve seat. Suction valve in Same as above. excessive pressure can build up resulting in cylinder failure and injury. defective fixed/ variable pocket head. Clean scrubber. discharge valve in suction. Always follow performance curves provided with your compressor. valve bodies or retainers. This can cause Replace plates. as well as damage to the piston rods. maximum working pressure. Install new valves and properly torque down valve caps Improper setting High rod loads. damage. seat. insufficient rod load reversal.Table 7-20 Cylinder Area Troubleshooting (Continued) Defective or missing valves Insufficient rod load reversal. positioning in piping downstream of the compressor. Open valve.

Bent rods and crankshaft. If condensation is in gas. Possible Cause Suction side air leak. setting or close the fixed volume rod. Remove foreign material from cylinder. Unload the crank ends if this does not reduce pressure. use separators and check dump valve operation.W. and valve exchanger condition for proper damage. and cylinder overheating Rod load exceeding design. or cylinder damage. Leaking suction valves causing suction valve Replace springs or plates. crosshead guides. or crankshaft damage pocket on the higher stage until the interstage pressure decreases to an acceptable level Same as above Repair or replace the suction valves in the higher stage cylinder Replace with new rings Repair or replace defective valve parts High interstage pressure Improper settings of clearance pockets on the higher stage heads Missing or defective suction valve(s) on the higher stage.P. Head. High discharge temperature Corrective Measure Replace defective parts Low suction pressure High suction pressure Improper water cooling Increase setting of variable volume pocket(s) or open fixed volume pocket(s) until discharge pressure decrease to a proper level. crosshead. Loose piston nut. seizure of the crosshead pin. Blown off cylinder head. Corrective Measure Find and stop leak in line. Breakdown in cylinder lubrication causing Check pump for proper flow. Find and stop leak in line. Insufficient rod load reversal exceeding the M. or add water as required. as damage to the piston rods. cylinder scoring. rod.P. as well Discharge symptom.WG Series Compressor Frame Instruction Manual Table 7-20 Cylinder Area Troubleshooting (Continued) Rod load exceeding the design M. Overheating of compressor cylinder. Improperly installed valve. valve damage. Set end clearance to proper value. and connecting rods. Dye check valve seat. damaged O-rings. piston. Piston-to-cylinder end clearance set incorrectly. Remove valve and retainer. cooling. crosshead rod. scored or bent rods and crankshafts. heat overheating. Damage to relief valve and lubricated parts damage. Chatter in relief valve Air in oil lines. Replace damaged parts. Insufficient rod load reversal which can lead Try corrective measures listed for to damage to the crankshaft from excessive Low Compressor Cylinder heating. Loose valve. Seat damage on cylinder and broken valve bodies and retainers.W. pin. Open all pockets before starting. of the cylinder. Section 7: Maintenance Cooper Energy Services n Superior Compressors 4/3/03 Page 7-25 . of the Reduce variable volume pocket lower stage cylinder that results in piston. damage. Piston. Worn piston rings in the higher stage cylinder Defective relief valve Same as above Same as above Symptom High gas discharge temperature Possible Cause Defective discharge valves High discharge pressure Potential Damage Damaged gaskets. Knock in cylinder area Foreign material in cylinder (including water). Repair or clean cooling system. Cylinder scoring. or crankshaft damage. crosshead. Table 7-21 Symptom Growling in lube oil pump Troubleshooting Abnormal Noises Potential Damage Pump rotor and drive gear damage and lubricated part damage. and water supply for proper level. Replace damaged parts. crossheads. Always follow performance curves provided with your compressor.

Scored piston or cylinder. Reset gear lash.Table 7-21 Troubleshooting Abnormal Noises (Continued) Failure of piston and/or piston rod. Excess carbon deposits. Loose piston or piston rod. Excessive capacity being delivered. contact between piston and cylinder heads. Loose valve assembly. Same as above. Determine cause and correct. gaskets. Find and eliminate reason for scoring. or failure of running gear. Distortion of compression cycle Correct mechanical problems. resulting in excess load. bent piston rods. Same as above Remove any objects and repair damage.Check separation equipment Potential Damage Corrective Measure Damage to gasket seal surface Tighten head. Whine in auxiliary end Worn. Failure of individual components. Causes abnormal cylinder capacity performance. Damaged seating surfaces in Tighten assembly and check cylinder or on valve. Poor mechanical condition of unit. Foreign object in cylinder Symptom Possible Cause Knock in cylinder area Loose cylinder head. (continued) Loose variable volume pocket Damage to gasket seal surface. Scoured piston or cylinder. Loose packing assembly. Gas pulsation in vicinity of cylinders. Replace all damaged components. unloader. Tighten piston rod nuts. Piston seizure. Tighten. Piping strain. Apparent production loss. Low capacity High load Loose nuts on cylinder to frame mounting studs. Gas pulsation in vicinity of cylinders. Replace gear. Reset clearance. Overload. Damage to crosshead. pulsations. Properly design piping system. Piston seizure. Improper backlash setting. Possible Cause Piping system improperly supported. or chipped gear Gear damage. Damaged seating surfaces on Tighten assembly and check packing case. Check for stretched piston rod and/or rod studs. Loose piston. Incorrect piston to head clearance. Modify piping to eliminate pulsation. Table 7-22 Symptom Vibration General Troubleshooting Potential Damage Potential failure of piping system. Check for stretching of studs. Use correct measurement techniques. Tighten nuts. Abnormal cylinder horsepower Modify piping to eliminate performance. Same as above Remove carbon. broken. gaskets. Tighten components properly. Loss of production. Unit loose on foundation or rails. Gas measurement techniques are not correct. gear teeth. Check for loose crosshead nuts. Restore to proper mechanical condition. Excessive pressure drop in piping system. Gear damage. Page 7-26 Cooper Energy Services n Superior Compressors . Tighten variable volume pocket. Poor mechanical condition of unit. Corrective Measure Install proper piping support to raise the frequency of the vibrations.

and process. Oil check valve on cylinder faulty. Replace valves. High cooler pressure. Insufficient control. Same as above. Same as above. Carbon deposits. Add oil to proper level. Check operation of separation equipment and dump valves. High discharge pressure. Scored cylinder walls. Same as above. Clean up gas by proper separation and/or filtration. Dirty gas or foreign matter in High gas temperatures. Same as above. Same as above. Same as above. Plugged vent in lubricator tank.WG Series Compressor Frame Instruction Manual Table 7-22 Lubricator does not discharge oil General Troubleshooting Overheated and/or damaged packing. Check rings for proper clearance and packing case for clearance around rod. Feeds not vented of air. Scored piston or liner. Packing too tight. Prime lubricator pump to insure oil passage to the pump. Reduce lubrication. Liquids in process are not Same as above. Excessive lubrication. Check valves and/or process condition. Replace faulty compressor valves. Defective gauge. or worn piston rings or packing. Incorrect adjustment of pump stroke. Low oil level. Same as above. Unplug vent. Potential Damage Corrective Measure Same as above. Check proceeding stages of process. cylinder. Same as above. Low suction pressure. High suction gas temperature. Find source of liquid and correct. Possible piston and cylinder damage. Same as above. Same as above. Same as above. Same as above. or leaking seal in variable volume pocket unloader. On multistage units check suction valves of next higher stage. Faulty suction valves in high stage cylinder. Check valves. Leak in line or fitting. Broken valve and springs Section 7: Maintenance Cooper Energy Services n Superior Compressors 4/3/03 Page 7-27 . High discharge temperature Faulty valves. Condensate caused by cold Broken or bent rod. Cracked interstage piping. Same as above. Line leaking or kinked. compressor. Cracked or broken cylinder. Reassemble properly. Change to lubricant which forms less carbon. Unkink or replace line. Retighten fitting or replace line as needed. Check process operating conditions. Symptom High discharge temperature (continued) Possible Cause Insufficient lubrication (lubricated cylinder only). Check for possible control pressure leak. Improper operation of the Replace gauge. Same as above. Raise cooling water temperature. Pressure Same as above. Readjust pump stroke. Liquid in cylinder. Improper assembly. Increase lubrication. Reduce lubrication. gas stream. Damage to cooler. removed from the gas stream by separation equipment. Liquid in cylinder Same as above. bent rod. Replace oil check valve. Repair damage and replace damaged parts. coolers.

Unblock line. Rupture disk ruptures Disk rating incorrect. Clogged filter. Same as above. Divider block does not cycle. Same as above.Table 7-22 General Troubleshooting Trace line from designated rupture disk and fix malfunctions. Replace filter. Blocked main line. Page 7-28 Cooper Energy Services n Superior Compressors . Same as above. Overheated and/or damaged packing. Scored cylinder walls. Clean divider block interior. Unblock line. Same as above. Blocked secondary line.