ONSHORE INSTALLATION AND START UP INSTRUCTIONS

FOR
SEPARABLE DRIVER/COMPRESSOR PACKAGES

This is a general procedure. Different unit configurations may require different mounting
arrangements. Refer to the unit drawings and consult with UCI if there are questions
regarding the installation of your equipment.

Note: Due to variations in soil conditions, UCI cannot provide specific foundation or
sub-base recommendations. The customer is responsible for evaluating the site soil
conditions and modifying these procedures as appropriate.

UCI units generally fall into 3 categories

1. Units that must be grouted and bolted to a concrete foundation - Follow the procedure
outlined below (Preparing the Foundation for Receiving the Unit) for installation
instructions.

2. Units with wide concrete filled skids that may be set on a gravel bed without hold down
bolts - This type of unit should be set on a gravel bed which has been prepared as
follows:

1. Clear all vegetation and plant roots

2. Scarify soil
3. Recompact soil to 95% of a standard Proctor (ASTM D698) to grade level.
4. Install a 3"-4" layer of compacted 3/4" gravel with screenings above grade level.
5. Install a 1"-2" layer of compacted gravel screenings
6. The edges of the compressor base must slope away from the unit.
7. The area around the compressor base must slope away from the unit.
8. Insure that the mounting surface for the skid is level and flat to 1/2"
9. Depending on the piping arrangement to and from the unit, the customer should
consider the use of flexible connections to the skid piping connections.

3. Units that are mounted on steel structure such as an offshore platform, barge etc. -
Refer to UCI installation instructions for offshore installations.

Refer to the specific unit drawings to determine the mounting requirements for a particular
unit.

Preparing the Foundation for Receiving the Unit

1. Roughen or scar the top of the foundation to permit a good bonding surface for the
grout material.

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2. Clean all loose pieces of concrete, dirt, etc. from the top surface of the foundation.
Wash the top of the foundation to insure a good clean surface for bonding of the grout
material.

3. Remove the portion of the sleeve around the foundation bolts extending above the top
surface of the foundation.

4. Clean the anchorbolt threads of all concrete, burrs, etc.

Set the unit on the foundation

1. CAUTION: BEFORE ATTEMPTING TO LIFT THE UNIT FROM THE TRUCK, THE
INSTALLER MUST INSURE THAT LIFTING SLINGS, SHACKLES AND THE CRANE
ARE OF SUFFICIENT CAPACITY FOR THE WEIGHT OF THE UNIT AND ARE
PROPERLY CONNECTED.

2. Lower the unit over the foundation bolts and supports the skid with suitable timbers.
The timbers should be of the same size and thickness.

3. Cut a 3" x 3" x 1/4" piece of flat iron for each leveling screw to be used on top of the
foundation.

4. Grease the leveling screws to assure ease of operation and to prevent grout material
from bonding to threads. Install leveling screws in all of the nuts along each side of the
skid to protrude 2 inches through the bottom of skid.

5. Remove the paint from the bottom of the skid beams to insure proper bonding with the
grout.

6. Use suitable jacks to support the weight of the unit and remove the timbers from under
the skid.

7. Position the 3" x 3" x 1/4" flat iron plates under each leveling screw. Lower the unit
until the weight is supported on the leveling screws.

CAUTION: EXTREME CARE MUST BE EXERCISED WHEN WORKING NEAR THE

UNIT WHILE SUPPORTED BY JACKS.

Leveling the Compressor Frame

1. Remove the compressor frame top cover.

2. Place an accurate machinist's level on the compressor crankshaft to check for

longitudinal level.

3. Place the level on the machined surface at the top of the frame. Do this at both ends

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 of the frame to check side-to-side level. Note: Be sure the surface is clean before
placing the level.

4. Lower the unit using the leveling screws until the compressor frame is level within
.005" both longitudinally and side to side. Care must be taken to maintain the same
load on all the leveling screws. The skid bottom flange may bend or the leveling screw
may be damaged if one is much tighter than the others. The bottom of the skid should
be at least 1-1/4" above the concrete to allow for grout.

5. After leveling, install the nuts on the anchor bolts and tighten them to prevent any
further movement of the skid then proceed with coupling alignment as described
below.

Coupling Alignment

1. The coupling alignment must be checked before skid is grouted. The purpose of
coupling alignment checks before grouting the skid is to position the unit in as near a
level condition as possible in the field to duplicate the condition when the unit was
leveled in the shop during assembly. WE HIGHLY RECOMMEND THAT A UCI
SERVICE REPRESENTATIVE BE PRESENT FOR THE FINAL PRE-GROUT
ALIGNMENT. Refer to the compressor section of the instruction manual for the
detailed alignment procedure.

Correct the alignment by raising or lowering the driver end of the skid rather than
adding or removing shims at the front of the driver. After the driver end of the skid is
raised or lowered, re-check level on the compressor frame to assure that it is still
correct.

When it has been determined that all possible misalignment has been corrected by
raising or lowering the driver end of skid, proceed to align the coupling by adding or
removing shims from the shim packs and moving the driver from side to side using the
alignment screws on each side of the driver base.

The compressor frame should not be moved during the alignment process.

2. After the unit is aligned, the driver base distortion or crankshaft alignment must be
checked. Refer to the engine section of the instruction manual for the procedure.

If the unit will not be started within a week of the pre-grout alignment, the compressor and
engine should be represerved and sealed.

Grouting the Unit

1. After final leveling of the unit and alignment of off-skid components (see next page),
the grouting operation should take place as soon as possible. The unit should not be
allowed to be supported on leveling screws for a long period of time due to flexibility of
the skid, temperature changes, etc., that could cause the alignment to change.

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2. Build a suitable form around the skid approximately 10" to 12" higher than the top of
foundation. Seal all joints, etc., of the form to prevent leakage of the grout material,
using a caulking compound or other suitable means. Wet the top of the foundation
and flush away any loose dirt or cement.

3. UCI recommends using Epoxy grout. Its high strength, good durability and adhesion
make it well suited for insuring that the forces and moments from a reciprocating
machine are properly transferred to the foundation. A grout supplier should be
contacted for the correct formulation for this application.

4. Run a chain crosswise to the base to assist in working the grout into position under the
entire base of the skid. Pour the grout from one side of the base only, and work it into
position under the base of the skid using the chain. By pouring the grout to the level of
the top of the form boards, the head will cause the grout to flow under the skid base.
Remove any excess grout material from the outside of the skid as soon as it has
hardened sufficiently to prevent any flow when the form boards are removed.

5. After five (5) days, or when grout has hardened, (see grout Mfg. recommendation)
back off the leveling screws and tighten the foundation anchor bolts.

6. At some point before startup, and after grouting of the skid is complete, the coupling
alignment must be rechecked and corrected if needed. A final base deflection check is
required if the alignment is adjusted.

7. If the unit was shipped with cylinders and/or pistons removed, it will now be necessary
to install the compressor cylinders and/or pistons, set piston clearance and check the
piston rod run out.

Locating and Grouting Auxiliary Equipment

1. If the unit is furnished with a separate skid for other major equipment such as a cooler,
or a scrubber, it is necessary to position this equipment in relationship to the
prefabricated piping.

2. Prepare the skid foundation as was done for the driver foundation. Roughen surface,
clean, etc., move the skid onto the foundation to its approximate location over the
foundation bolts. Lower unit over the foundation and/or bolts, supporting weight of skid
on the leveling screws and 3" x 3" x 1/4" flat iron plates installed under leveling screw
on top of foundation.

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3. Install the connecting piping between the compressor skid and the auxiliary skid.
EXTREME CARE MUST BE TAKEN TO INSURE THAT ALL PIPING, BOTTLES,
ETC., BE CLEAN AND FREE OF RUST, DIRT, BEFORE INSTALLATION ON THE
UNIT. The assembly drawings furnished with the unit show the size and location of all
piping. Use the leveling screws on the auxiliary skid to line up piping and connections.
Care should be taken to properly support all piping so the weight, expansion, or
vibration of the piping does not cause undue stress on the connections.

4. Grout the auxiliary skid using same procedure as grouting the unit - 1, 2, 3, and 4.

5. Temporary line strainers of suitable size are recommended in the suction line system.
These strainers should remain in the piping until such time as there is no rust or dirt
carrying over from the field piping. A suitable gauge should be installed on the
upstream and downstream sides of the strainers to assist in determining when they
should be removed and cleaned.

Final Preparation for Start-up (we highly recommend a UCI service representative be
present for start-up)

Compressor

1. On units shipped with the cylinders and piston assemblies installed, it is necessary to
check piston end clearances, piston rod run out, crosshead shoe clearances, and
piston pin through-bolt torque and correct if necessary. Record these readings on the
frame setting record sheet for future reference.

2. Remove the suction valves from each end of the compressor cylinders to permit the
unit to run at no load for break in purposes. Reinstall and tighten the valve covers.

3. Remove the compressor crankcase cover and cross head inspection doors on the
engine and compressor. Inspect the compressor crankcase to insure that it is free of
all dirt, water and longterm preservatives (if used). Inspect the compressor oil filter
cases for dirt, rust, etc. Clean the filter cases if needed.

4. Fill all cooling system with coolant and bleed all air from the system. Allow the unit to
sit for 2-3 hours then check inside the engine and compressor cylinders for coolant
leaks.

5. If not already installed, install the compressor oil filter element and filter top using new
a gasket if needed. Consult the instruction manual for the correct type and weight of
oil to be used in the compressor crankcase.

Install oil in the compressor crankcase to the proper oil level. Using the prelude pump
system, whether hand or automatic, prelude the compressor frame. Bleed all air from
compressor oil filter. Continue to prelube the compressor until oil is delivered to all

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 lubrication points of the compressor frame. A visual check will determine if oil is
reaching the main bearing, rod bearings, and crosshead assemblies.

After it has been established that the frame is lubricated properly, reinstall the
crankcase top covers and the crosshead inspection doors.

6. Inspect the compressor lubricator reservoir for water that may have entered during
shipping and storage. Clean the reservoir if needed. Check the lubricator drive for
proper alignment and ease of operation. This is done by moving the lubricator oil
pump coupling back on the oil pump shaft and rotating the oil pump by hand. If
binding is found to exist, loosen the lubricator mounting bolts and move the lubricator
from side to side or up and down until unit turns freely. Tighten lubricator-mounting
bolts and connect the compressor oil pump drive coupling to the oil pump drive shaft.

If the lubricator is not fed from the compressor frame, be sure it is connected to a
supply with the proper type and weight of oil, as recommended in the instruction
manual, for the break-in of the compressor cylinders and packings and for the type of
operation under which the compressor will be run.

Using the hand primers on lubricator pump or a suitable hand primer gun, prime and
bleed all lubricator lines until they are free of air. Continue to hand prime the system
until there is oil in the cylinder bores and packing cases.

Engine (On engine drive units)

1. Consult the instruction manual for the correct type and weight of oil for the engine.

2. Make a visual check of oil in the engine. Add oil to the crankcase as needed to bring
the oil level up to the proper level.

3. Using the prelube pump system, whether hand or automatic, prelube the engine. Bleed
all air from the oil filter. Continue to prelube until oil is delivered to all lubrication
points. A visual check will determine if oil is reaching the main bearings and rod
bearings.

Motor Check (for motor drive units)

1. See the motor section of the instruction manual for the manufacturer's instructions for
start-up.

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Auxiliary

1. Fill all systems that require oil such as the mist lubricator for the starter and air/gas
prelube pump motors.

2. Grease the cooler fan shaft and idler bearings, if needed.

Control Panel

1. Make a preliminary inspection of the operation of the control panel. During break-in
period of the unit, it may be necessary to "lock out" certain parts of the control system
in order to keep the unit running. This depends on the type of panel used on the unit.
Do not, under any circumstances, lock out the low oil pressure shutdowns or
completely disable the panel and run the unit. Should a malfunction occur on the
engine or compressor during the break-in run, serious damage could occur before unit
can be shut down by the plant operator.

2. See the panel section of the instruction manual for complete details.

Instrumentation

1. A point-to-point continuity check must be made for all wiring and all spare wires must
be pulled.

2. Conduit seal fittings (if applicable) must be filled prior to start-up.

3. Any instrumentation, which was removed for shipping, should be re-installed at this
time.

Note: Use Heat sink compound (provided with unit) when installing temperature
instruments in thermowells.

Start-up Procedure

1. Start the unit and run for 5 minutes. If the driver is an electric motor, do not exceed the
maximum motor starts per hour. Stop the unit. Remove the compressor crankcase
covers and check for any overheating of the crankcase main bearings, rod bearings
and crosshead assemblies. Reinstall the crankcase covers if no heating is found.

2. Restart the unit and run for 30 minutes. Note the engine and compressor oil
pressures, oil temperatures and monitoring device for main bearing temperatures if
provided. Stop the unit and repeat the check for overheating of the compressor
bearings, (and motor bearings, if electric motor driver) and other items listed in
step 1.

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3. Remove the suction valve covers and inspect the cylinder bore for oil, scuffing and
debris. Check the packing glands for overheating.

4. If there is no indication of overheating of the crankshaft, cylinder bores or packing

glands, restart the unit and run for a second thirty-minute period. Note the oil
pressures and oil & water temperatures.

5. At the end of the second thirty-minute period, stop the unit. Make a final inspection of
the compressor crankshaft, main bearings, rod bearings, (motor bearings if the driver
is an electric motor) crosshead assemblies, rod packings and cylinder bores for
overheating and proper lubrication. Inspect the bores of all cylinders for a glazing
effect. If everything is found to be satisfactory, the unit can now be loaded. Install the
suction valves and valve covers, and the crankcase cover.

6. After all valve covers, piping, etc., have been installed, open the unit suction valve and
allow pressure to flow through the unit out the blowdown valve until the unit is
adequately purged. Once all air is expelled, allow the pressure to build to 50 psi or
normal suction pressure whichever is less.

Using a leak detector, check all valve covers, piping joints and flanges for leaks and
repair all leaks that are found. If the suction line pressure is greater than 50 psi, open
suction valve again until full suction pressure is reached in the unit, recheck the unit for
leaks. CAUTION: IF THE ACTUAL LINE PRESSURE EXCEEDS THE DESIGN
SUCTION PRESSURE OF THE UNIT, EXTREME CARE MUST BE TAKEN NOT TO
OVERPRESSURE THE UNIT.

After the final leak check is completed, the unit can be started and loaded normally.

CAUTION: ANY TIME THE GAS SYSTEM IS OPENED TO THE ATMOSPHERE OR

THE UNIT HAS BEEN IDLE FOR A LONG PERIOD IT MUST BE PURGED PRIOR
TO STARTING. AIR IN THE GAS SYSTEM CAN RESULT IN A COMBUSTIBLE
MIXTURE, WHICH CAN IGNITE CAUSING SEVERE INJURY OR DEATH AND
EXTENSIVE PROPERTY DAMAGE.

7. Bottle Supports - these supports should be placed under the discharge bottle at the
position shown on the drawings. The support plates should be leveled and grouted.
The wedge blocks should be left loose until all final alignments are complete. Once
the unit has been commissioned and has been brought to operating temperature, (a
minimum of 8 hours run time is recommended) these supports should be tightened
until they contact the bottle firmly. CAUTION: EXCESSIVE FORCE USED WHEN
TIGHTENING BOTTLE SUPPORTS CAN CAUSE MISALIGNMENT AND PUT
EXCESSIVE MECHANICAL FORCE ON THE BOTTLE, CYLINDER AND FRAME.
Once the unit has operated for approximately 30 days, it is recommended that these
supports be rechecked when the unit is at full operating temperature.

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