Professional Documents
Culture Documents
RAM54
RAM54 Operatio
Operatio n, Maint
Maintena
enance
nce & Part
Partss Instruc
Inst ruc ti
tion
on Manual
Sales Order
Sales Order #: 2582361
Revisio
Revisionn History
Rev
Rev No. Rev
Rev Descr
Descript
iption
ion Date Revised By
Section 2
Safety Precau
Precautions
tions and Guidel
Guidelines
ines ...............
....................................
........................................
........................2-1
.....2-1
Important safety information .........................................
................... ..........................................
...........................................
.............................................
..................................2-1
............2-1
Note, caution, and danger symbols.............................................................................................................2-1
Warning signs and labels ............................................................................................................................2-2
Specified precautions..................................................................................................................................2-3
Temporary
Tem porary shipping plugs in compressor equipment ..........................................
.................... .............................................
.......................................
................ 2-3
Compressor frame crankcase rapid pressure relief valves..........................................................................2-3
General precautions ....................................................................................................................................2-4
General maintenance precautions ...........................................
....................... ...........................................
.............................................
..........................................
.......................2-4
...2-4
Section 3
Lubrication
Lubricat ion And Cooling .....................
........................................
........................................
...................................
.............. 3-1
Compressor frame lubrication specifications............................................................................................. 3-1
General specifications .......................................
................ .............................................
.............................................
...........................................
........................................
........................
.... 3-2
Lubrication system maintenance................................................................................................................ 3-2
Compressor Cylinder and and Packing Lubrication ...........................................
.................... .............................................
..........................................
........................
.... 3-3
Lubrication Rate .........................................
................... ..........................................
...........................................
.............................................
.............................................
...............................
........ 3-3
Pump Per Point System .......................................
................... .............................................
.............................................
........................................
..........................................
...................... 3-4
Operations .......................................
................ ...........................................
.............................................
.............................................
........................................
..........................................
...................... 3-4
Maintenance ........................................
.................... ...........................................
.............................................
.............................................
...........................................
...................................
............... 3-5
Proportional Lubrication System ............................................................................................................... 3-6
Lubricator Worm and Gear Drive .......................................
................ .............................................
.............................................
...........................................
..........................
...... 3-7
Compressor Frame Lubrication Oil Cooling.............................................................................................. 3-7
Coolant Requirements .......................................
................ .............................................
.............................................
...........................................
........................................
........................
.... 3-8
Corrosion ...........................................
....................... ........................................
.............................................
.............................................
........................................
....................................
....................
.... 3-8
Scales and Sludge....................................................................................................................................... 3-8
Cooling System ........................................
................. .............................................
.............................................
...........................................
...........................................
...........................
.... ....3-10
Section 4
Sour Gas
General Compresso
Compressor
Information r ...........................................
Applicatio
Applications
..........................................
................... ns ....................................
.................. .....................................
........................................... ......................
............................................. .......4-1
..........................................
........................ 4-1
Hazards of Hydrogen Sulfide or "Sour Gas" ............................................................................................. 4-1
Concentration Levels ................................................................................................................................. 4-2
Trim Requirements..................................................................................................................................... 4-2
Hydrogen Sulfide (H2S) Concentrations Up To 2% By Volume......................................................... 4-2
Level 1-11p Trim (H 2S) Concentrations of 2% - 5% By Volume ....................................................... 4-3
Level 2-11 p Trim (H 2S) Concentrations
Concentrations > 5% ..................
...........................
..................
..................
..................
..................
..................
..................
...........
.. 4-3
Enhanced H2S Trim Requirements...................................................................................................... 4-4
Section 5
Installation
Installation...................
.....................................
.....................................
......................................
.....................................
........................
...... 5-1
General .......................................
................. .............................................
...........................................
...........................................
.............................................
..........................................
........................
.... 5-1
Section 7
Maintenance............................
Mainten ance...............................................
.....................................
.....................................
................................7-1
.............7-1
General........................................................................................................................................................7-1
Acceptable Tolerance Clearance Values ........................................
................. .............................................
.............................................
.......................................
................ 7-1
Torque Recommendations ..........................................................................................................................7-2
Specific Torque Values.........................................................................................................................7-2
General Torque Values ..........................................
................... .............................................
.............................................
...........................................
..................................
..............7-2
7-2
Thomas Coupling ...........................................
....................... ........................................
.............................................
.............................................
........................................
.....................7-2
.7-2
Hoebiger Valve.....................................................................................................................................7-2
Acceptable Tolerance Cylinder Clearance Values .............................................
.................... .............................................
.........................................
..................... 7-3
CT Valves....................................................................................................................................................7-3
Torque Recommendations ..........................................................................................................................7-3
Diagram and Torque for Proportional Lubrication System System ....................
........................................
...........................................
................................
.........7-4
7-4
Piston-to-Cylinder Bore Clearance.............................................................................................................7-5
Valve-in-Head Cylinder Torque Values .............................................
....................... .............................................
...........................................
..................................
..............7-6
7-6
Ty
Typical
pical Miscellaneous Flanging .............................................
......................... ...........................................
.............................................
..........................................
.......................7-7
...7-7
Precautions ..........................................
................... .............................................
.............................................
...........................................
...........................................
................................
.........7-7
7-7
Maintenance Frame.....................................................................................................................................7-8
Main and Connecting Rod Bearings ....................................................................................................7-8
Bearing Clearance ..........................................
...................... ........................................
.............................................
.............................................
.........................................
..................... 7-9
Changing Main/Connecting Rod Bearings ........................................................................................7-10
Connecting Rods ..........................................
................. .............................................
...........................................
.............................................
..........................................
...................... 7-11
Clearances
Cleara nces for Connecting
Connecting Rod Components Inspection Purposes Only ......... ..................
..................
..................
...............7-12
......7-12
Crankshaft ..........................................................................................................................................7-16
Force-Feed Lubricator........................................................................................................................7-19
Oil Filter
Hand .......................................
................... ...........................................
.............................................
..........................................
...........................................
.....................................7
..............7-21
Pump.........................................................................................................................................7-23 -21
Measuring Oil Pump Gear Lash.........................................................................................................7-26
Crankcase Pressure Relief Valve........................................................................................................7-28
Disc Pack Flexible Coupling..............................................................................................................7-29
Drive Coupling Hub .......................................
................... ...........................................
.............................................
..........................................
.......................................
...................7-29
7-29
Flexible Drive Coupling.....................................................................................................................7-30
Troubleshooting Rexnord Couplings .................................................................................................7-31
Elongated Bolt Hole ....................................................................................................................7-31
Scored Body on Bolt....................................................................................................................7-31
Misalignment Failure...................................................................................................................7-31
Compression ..........................................
................. .............................................
...........................................
.............................................
..........................................
.....................7-32
.7-32
Elongation....................................................................................................................................7-32
Fatigue Failure .......................................
................ ...........................................
.............................................
.............................................
........................................
.....................7-32
.7-32
Torque Overload (Visible only with strobe light while running) ................................................7-32
Section 8
Frame "as built" Bills of Materials.....................
Materials ........................................
......................................
...................8-1
8-1
Section 9
Cylinderr "as built" Bills of Materials .................
Cylinde ....................................
......................................
...................9-1
9-1
Section
Ordering10Parts .................
....................................
.....................................
.....................................
....................................
.................10-1
10-1
Service...................................................................................................................................................... 10-1
Replacement Parts.................................................................................................................................... 10-1
Using the Parts Listing............................................................................................................................. 10-2
Connecting Rod Assembly....................................................................................................................... 10-2
Aftermarket Service Locations ................................................................................................................ 10-3
International Aftermarket Service Locations ..........................................
...................... ...........................................
.............................................
..........................
.... 10-4
Section 11
Auxiliary
Auxiliary Equipment ...............
....................................
........................................
......................................
.........................
...... 11-1
Section 12
Engineering Standards
Section 1
Introduction to the RAM Series
Series Compressor
and Specifications
About This Manual
Thank you, for purchasing Cameron Compression equipment! This Instruction Manual
containss safety,
contain safety, operating and
and basic maintenanc
maintenancee instructions
instructions for the Superior®
Superior® RAM
RAM 52 and
RAM54 series
series compressor
compressor frames.
frames.
This manual contains confidential and proprietary information from the Superior Compressor
Productss Group of Cameron
Product Cameron Compression,
Compression, a division of Cameron
Cameron Corporation.
Corporation. This manual
manual is
given to users
users for the limited purpose
purpose of providing
providing information
information to facilitate
facilitate use
use and
maintenance
maintena nce of RAM
RAM series compressor
compressor frames
frames purchased
purchased from Cameron
Cameron Compressio
Compression.
n. By
All specifications and ratings are subject to change without notice. Superior ® is a trademark
of Cameron Corporation.
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.
cover. Either may be maintained independently.
Lube Oil is drawn from the sump through a strainer that protects the lube oil pump. A full-
flow lube oil filter with a differential pressure indicator capable of identifying a plugged filter,
protects all compressor frame running parts.
Although piston and rod lengths may vary according
Figure 1-4 Typical
Typical Variable
Variable Pocket
Pocket
to the model, all cylinders will fit interchangeably on
the standard crosshead guide. Careful attention is
given to the cooling of cylinders designed for a 1.5:1
to 5:1 pressure ratio.
Variable Volume
Volume Pockets
Pocket s are furnished
f urnished as standard
equipment on all cylinder classes.
Crankshaft Rotation
When facing the oil pump end of the frame, Figure 1-6 RAM Cylinder
Cylinder Specifications
Specifications
the crankshaft rotates in a
counterclockwise direction.
Figure 1-5 RAM Convertible
Convertible Cylinder
Cylinder
and when the units are assembled at the factory, care is taken to select the connecting rods so that the
kg). Every effort should be made
weight variation for opposing throws does not exceed 1 pound (0.45 kg). Every made
to achieve as near equal
equal balance between
between opposite
opposite throws
throws as possible.This
possible.This does not apply to
adjacent throw pairs, which sometimes vary by 100 pounds (45 kg) or more, depending on cylinder
sizes.
Figure 1-9 Balance Sheet Example
The estimated balance for the original assembly
of a compressor is recorded on the Compressor
Vent Fill
Fi ll Plug Torsional and Balance Data Sheet. A copy of the
data sheet for each compressor is included in the
Upper Operation Manual, and should be referred to in
Plug the event
. a change which would affect the bal-
ance is contemplated.The actual weight of parts
can vary. from the estimated weights. Also, when
replacing crossheads, connecting rods, pistons, or
changing piston ring material, the new parts
should be weighed, in order to reaffirm the actual
Drain Plug
00752 unit balance.
Additional Information
Please visit the Cameron Compression web site: http://www.c-a-m.com
Unrestricted copies of Service Bulletins are available at the Cameron Compression web site.
You must have Adobe® Acrobat® Reader version 3.0 or later in order to view the bulletins.
Prerequisites
Personnel using this guide should be familiar with compressor systems, standard mechanical service
tools, and compressor terminology. Service personnel should have adequate experience in good
maintenance and troubleshooting techniques. Cameron Compression recommends that all personnel
using this manual should complete Cameron Superior Reciprocating Compressor Training. Training
includes the following:
• Frame,
Frame, crossh
crosshead
ead guide,
guide, and
and lubri
lubricati
cation
on syste
systems
ms
• Compressor
Compressor details
details including:
including: rings,
rings, rider bands, pressure packings, valves, and
and unloaders
unloaders
• Support
Support syste
systems
ms to include:
include: Coolers
Coolers,, water
water pumps,
pumps, and
and control
control systems
systems
• Description
Description of
of installation,
installation, inspection,
inspection, and set up procedures
procedures for
for rod run out,
out, web deflection
deflection,, cou-
pling alignment
• Description
Description of recommen
recommended
ded operational
operational procedures include: startup, normal & emergency
emergency shut-
down and compressor performance control
• Description
Description and application
application of recommended
recommended maintenanc
maintenance:
e: maintenance,
maintenance, critical repairs, and trou-
trou-
bleshooting
If training is needed, contact the Cameron Learning Center by calling (713) 354-4062.
• Section 6: Operation
Operation Start-up.
Start-up. This section provides procedure
procedure for startup, recommended
recommended operat-
ing conditions, and form to request for performance curves.
• Section 7: Maintenance.
Maintenance. This section contain precautions,
precautions, tolerance
tolerance limits, and recommended
recommended
torque values.
• Section 8: Frame
Frame "as built" Bills
Bills of Materials unique to your
your compressor
compressor.. Included are exploded
views of the assemblies.
• Section 9: Cylinder
Cylinder "as built"
built" Bills of Materials
Materials unique
unique to your compressor
compressor.. Included are exploded
exploded
views of the assemblies.
• Section 10: Ordering Parts. This section explains how to order replacement
replacement parts.
• Section
Section 11:
11: Auxiliar
Auxiliary
y Equip
Equipmen
ment.
t. This
This sectio
section
n my
my include
include bulletin
bulletins.
s.
• Section 12: Engineering
Engineering Standards.
Standards. This section is a comprehen
comprehensive
sive reference regarding the stan-
dards.
Related Publications
The following related publication contain more information about the Superior RAM
RAM Series Com-
pressor
•Superior RAM Technical Data Book.
Standards
Cameron Compression has developed several standards for our compressor addressing cooling water
quality, lubrication, and packaging. Cameron recommends that users of Superior compressor under-
stand and follow these standards to get the best performance possible from the equipment. Cameron
also recommends that oil and gas production service packagers follow the guidelines for prime mov-
ers described in the American Petroleum Institute’s Specification for Packaged Reciprocating Com-
pressors for Oil and Gas Production Services (API Specification 11P). American Petroleum
Institute http://www
http://www.api.
.api.org
org will default you to http://www.global.ihs.com 1-800-854-7179
1-800-854- 7179 ext 7969
for a copy of API 11P.
Pa g e 1 1 0 Cameron Compression Superior
Section 2
Safety Precautions and Guidelines
Important Safety Information
DO NOT OPERATE
OPERATE OR ATTEMPT TO REPAIR
REPAIR THIS EQUIPMENT UNLESS YOU
HAVE
HAVE HAD THE PROPER TRAINING APPROVED BY SUPERIOR. FOR TRAINING
INFORMATION,
INFORMA TION, CONTACT
CONTACT THE CAMERON COMPRESSION TRAINING
DEPARTMENT
DEPARTMENT IN HOUSTON, TEXAS, PHONE (713) 354-4062.
Most accidents involving equipment operation, maintenance and repair are caused by failure
to observe basic safety rules or precautions. An accident can often be avoided by recognizing
potentially hazardous situations before an accident occurs. A person must always be alert to
potential hazards. Equipment operators should also have the necessary training, skills and
tools to perform these functions properly.
Safety precautions and warnings are provided in this manual and on the equipment. If these
hazard warnings are not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by a safety alert symbol and followed by a signal word such as
"DANGER!" as shown in the Note, Caution and Danger Symbols portion of this section.
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.
When changing the
frame l ubricating
ubricating
The NOTE symbol is an alert indicating an essential operating oil, change the oil filter.
procedure or condition. The following is an example of a NOTE:
Cameron Compression cannot anticipate every possible circumstance that might involve a
potential hazard. The warnings in this publication and on the equipment are therefore not all
inclusive. If a tool, procedure, work method or operating technique not specifically
recommended by Cameron Compression is used, you must satisfy yourself that it is safe for
you and others. You should also ensure that the equipment will not be damaged or made
unsafe by the operation, lubrication, and maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are presented on the basis
of information available at the time it was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These
changes can affect the service given to the equipment. Obtain the complete and most current
information before starting any job. Authorized Cameron Compression Distributors have the
most current information available.
Make sure that you can read all safety signs. Clean or replace these if you cannot read the
words or see the pictures. When cleaning the labels use a cloth, water and soap. Do not use
solvents, gasoline, etc., to clean safety signs. The use of solvents, gasoline, etc., could loosen
the sign's adhesive and cause the sign to fall off.
You must replace a label if it is damaged, missing or cannot be read. If a label is attached to a
part, and that part is replaced, make sure a new label is installed on the replaced part. See your
Authorized Cameron Compression Distributor
Compression Distributor for new labels.
Pa g e 2 - 2 Cameron Compression Superior
Specified Precautions
It is important that these precautions be read and clearly understood. All of the precautions
that follow are interpreted as having a CAUTION or DANGER status.
DANGER
cylinders are components are often sealed at the factory with
temporary plastic plugs. These temporary plugs protect the
equipment from dirt, water and other contaminants during shipping
Stainless steel plugs are rec-
and storage. The type of plug used is usually a “push-in” insert that ommended. Always verifyverify
can be easily identified, even when painted. A threaded plastic pipe that all temporary plastic
plug may occasionaly be found on older compressor cylinders. plugs are replaced before
using the compressor equip-
Painted threaded plastic pipe plugs may look like painted steel pipe ment.
plugs. Any Plastic plugs found must be replaced. The equipment
installer must determine the purpose of all empty ports (i.e. vent,
lubricator oil connection, cooling water connection, etc.) and insure each port is properly
connected to its specific application or plugged.
Ports that are not used must be filled with a properly installed steel plug. If the existing plugs
are painted, scrape off enough paint to verify that the plug is made of steel and not plastic. If
any plug is in question, replace it.
Cameron Compression recommends the installation of Bicera crankcase rapid pressure relief
valve. These valves protect the compressor frame from excessive pressure.
General Precautions
Be absolutely sure the remote starting system is disabled and/or If Poisonous or suffocating
disconnect the starting system on the equipment being serviced. gases are being compressed,
follow all plant safety pro-
cedures prior to and during
Use caution when removing cover plates. Gradually loosen (do not mainenance on any gas
remove) the last two bolts or nuts located at opposite ends of the equipment or piping to
avoid injury or death due
cover or device. Pry cover loose to relieve any spring or other to inhalation of such sub-
pressure, before removing the last bolts or nuts. stances.
•Always wear
wear safety
tive head safety
gear
gear. glasses or goggles
glasses or
. Additional goggles,, steel-toe safety
equipment steel-toe
may be safety
requiredshoe , hearing
by sthe protection and
job conditions. and protec-
protec-
• Do
Do not wear loose clothing, neckties ,
, or
or jewelry that can catch on controls or other parts of
the moving
the moving equipment. Keep long hair tied back.
•Make certain all protective guards and covers are secured in place.
•Use only non-flammable, non-toxic cleaning slovents. Never use gasoline or other flamma-
ble products for cleaning purposes.
to remove
•Use fans, blowers, etc. during maintenance and clean-up work in enclosed areas to remove
fumes released by cleaning solvents and vented gases.
•Never put maintenance fluids into glass containers;since glass containers break.
•Report all needed repairs.
•When operating this equipment in an enclosed area,
area, vent the exhaust to the outside
the outside..
•Keep the area around the unit clean and orderly with ample space to walk safely around the
unit. Clean up spills and leaks quickly to prevent accidents caused by slipping and falling.
or checks. To help prevent an accident caused by parts in rotation, work carefully around
them.
•Make sure all nearby personnel are aware of the start-up and do not allow unauthorized per-
sonnel on or around the equipment when maintenance or repair is being performed.
• Do notinjury
sonal disable or equipment
and bypass automatic
damage.alarm/shutoff circuits. They are provided to prevent per-
•Before replacing any studs, measure the stud's height from the machined surface and install
the replacement stud to the identical height.
Fluid Precautions
Always use a board or cardboard when checking for a leak. Escaping fluid under pressure
(even a pinhole size leak) can penetrate body tissue, causing serious injury or possible death.
If fluid is injected into your skin, a doctor familiar with this type of injury must treat it
immediately.
Asbestos Precautions
Cameron Compression equipment and replacement parts shipped from the factory are
asbestos free. Cameron Compression recommends the use of ONLY genuine Superior® parts.
If any replacement parts containing asbestos are used, the following guidelines should be used
in handling these parts and asbestos debris.
Caution should be used to avoid breathing dust when handling components containing
asbestos fibers. If this dust is inhaled, it can be hazardous to your health. The asbestos used in
components is usually bound in a resin or sealed in some way. Normal handling is not
hazardous as long as airborne asbestos dust is not generated.
If dust, which may contain asbestos, is present, there are several common sense guidelines
that should be followed.
•Never use compressed air for cleaning. Avoid areas where airborne asbestos particles may be
present.
•Avoid brushing or grinding of asbestos containing materials.
•For clean up, use wet methods or a vacuum equipped with a high efficiency particulate air
(HEPA) filter.
•Use exhaust ventilation on permanent machining jobs.
•Wear an approved respirator.
•Comply with applicable rules and regulations for the work place. (i.e. U.S.A. OSHA require-
ments 29 CFR 1910.1001).
•Follow environmental rules and regulations for disposal of asbestos.
Inspect all pipes, fittings, connectors, lines, tubes and hoses carefully. Do not use your bare
hands to check for leaks. Tighten all connections to the recommended torque (Section 5).
Burn Precautio
Precautions
ns
Do not touch any part of operating equipment. Allow the equipment to cool before any repair
or maintenance is performed on the equipment.
Make sure that all clamps, guards and heat shields are installed correctly to prevent vibration,
rubbing against other parts and excessive heat during operation.
Relieve all pressure in air, oil, fuel or cooling systems before any lines, fittings or related
items are disconnected or removed.
Coolant Precautions
Remove the cooling system filler cap slowly to relieve pressure. Use caution when removing
vent release valve, grease fittings, pressure taps, breathers or drain plugs. Hold a cloth over
the cap or plug to prevent being sprayed or splashed by liquids under pressure.
At operating conditions, the equipment coolant is hot and under pressure. The cooling system
and all lines to heaters or the equipment contain hot water. When pressure is relieved rapidly,
this hot water can turn into steam.
Allow cooling system components to cool before draining. Any contact with hot water or
steam can cause severe burns. Check the coolant level only after the equipment has been
stopped and the filler cap is cool enough to remove with your bare hand.
Cooling system additive (conditioner) contains alkali. To prevent personal injury, avoid
contact with the skin and eyes and do not drink. (Remember: Antifreeze/glycol solutions, as
well as most lubricants, are flammable.)
Oil Precautions
Hot oil and components can cause personal injury. Do not allow hot oil or components to
contact the skin.
Fire may result from lubricating oil or fuel sprayed on hot surfaces causing personal injury
and property damage. Inspect all lines and tubes for wear or deterioration. They must be
routed, supported or clamped securely. Tighten all connections to the recommended torque
(Section 7). Leaks can cause fires.
Chips or other debris can fly off objects when struck. Take care to insure no one can be injured
by flying debris before striking any object.
Section 3
Lubrication And Cooling
The complete lubrication system of the compressor is divided into two parts, of equal importance:
1.) The system that provides lubrication to the frame running parts (see the compressor Frame
Technical Data Book ))..
2.) The system that provides lubrication for the cylinders and packings.
Both systems can use oil from the frame sump. However; if required, the cylinder system may use oil
from an external tank. (This is especially done when the oil for the cylinder and packing system is a
different type compared to the frame oil) .The lube oil sump capacity
capacity for a RAM52 is 10 US gals and
RAM54 is 30 US gals.
suitable. In applications where the compressor cylinders are handling corrosive gases such as H 2S or
CO2, a lubricant with a higher TBN or method for adequate retention of the original TBN is recom-
mended for service in the frame.
General Specifications
The general specification for lubricating oil for use in Superior ® compressor frames is as follows:
(Reference Superior Engineering Standard ES-1002).
Table 3-2 Viscosity Information-this information is equivalent to the ranges above and provided for
information only
The compressor oil and filters should be changed after the first 500 hours on
Low lube oil pressure alarm
a new or overhauled compressor. After the first oil change, the oil and filters
and shut down device(s)
should be changed when visible indicator moves to red or every 2000 hours must monitor compressor
whichever comes first. Cameron Compression strongly recommends that frame’s lube oil pressure
down stream of the com-
customers use a laboratory analysis program to ensure proper lubricant pressor frame’s lube oil fil-
performance. An experienced, reputable lab should be used and results ter, recommended location
is at driver end of lube oil
should be carefully analyzed and trended. Regular monitoring of the
header when possible.
crankcase oil condition can help establish oil change out periods for a
specific unit. Oil condition and trace metal element trends can be effective
Figure 3-3 The
compressor frame
fr ame
lubrication system
consists of a gear
driven pump,
pressure relief
rel ief
valve, check valves,
oil cooler and
an d oil
filter. This Figure
illustrates the
lubrication oil
system fl o
oww.
Lubrication Rate
C A U T I O N
IT IS IMPORTANT that during start up safe and ample lubrication should The lubrication rate
be provided. This is accomplished by properly adjusting the force feed for break-in should be
lubricator pump(s). Observe the detailed instructions, given in Section 6 , double that for nor-
when first starting up the compressor. With all lubricator pumps set at full mal operation.
stroke, bring the cylinder pressure up slowly until the unit is running at full
rated speed and load. Watch for any signs of malfunction.
malfunction. After the first 48 hours at full load, the
lubrication rate should be gradually reduced to the amount necessary for correct lubrication.
Adjustment should be made slowly, a little each day, and should take several days to accomplish.
See Figure 3-4 for
See Figure 3-4 for an example of a force feed lubricator. A quantity of 1/5 (0.2) pint per inch of
cylinder bore is equivalent to one drop per minute per inch of bore for a very heavy oil and ranges up
See section 6-2 thru 6-3 for
to two drops per minute per inch of bore for very light oils. See section 6-3 for information
on the sight glass oil level.
The gas being compressed, its cleanliness and Figure 3-4 Force Feed Lubricator
Lu bricator
tendencies to act as an oil dilutent, and the type of
the oil being used all influence the lubrication rate
required.
If a cylinder has more than one feed point, and more than one pump, the requirements for lubrication
evenly. On a normal force feed lubricator ( Figure
must be split evenly. Figure 3-4
3-4), the proper proportioning of oil
to cylinders and packings should, as a first approximation, be adjusted by the cycle time method. To
validate the lubrication rate, it must be measured using actual oil consumption for a 24 hour period.
A visual inspection of the lubrication rate is required for this type of system. This is done by
removing a valve at each end of the cylinder after 48 hours of continuous operation at the final
lubrication settings. There should be a film of oil over the entire circumference of the ring travel
section of the
the cylinder
cylinder bore.
bore.
As a result of the inspection, 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.
Operation
The cylinder lubrication system consists of a force-feed lubricator and distribution block system that
provides lubrication for the cylinder walls and piston rod packing (see Fig 3-5 for a typical setup).
The lubricator is directly driven off the compressor shaft through a right-angle-drive worm and spur
gear set mounted on the lubricator box. Lubricator pump(s) fed directly from the crankcase lube system
or from an external tank are used to provide oil to the cylinders. (Note that oil from the lubricator box
is not used.) A packager-supplied external tank is used when the requirements of the cylinder oil are
different from those of the crankcase.
crankcase. A shutoff valve is supplied to isolate the external tank and the
lubricator box. The oil flows to the pumps and then pumped to a common manifold feeding the
automatic divisioning system. The automatic divisioning system consists of a rupture indicator (set
for the job), a 10-micron strainer, a digital no-flow and counter, divider blocks and optional pin
Pa g e 3 - 4 Cameron Compression Superior Compressors
The lubricator box uses the same oil as in the frame or external tank to lubricate its
i ts cams and bearings.
The right-angle-drive gear on the lubricator box requires a gear oil that meets ISO 680 AGMA-8
(Exxon TK-680 Cylesstic is acceptable).
If a blockage or other anomaly occurs, and the system pressure continues to build up, the s afety
rupture relief in the collector manifold bursts , relieving pressure throughout the entire system and
causing the no-flow shutdown to activate and stop the compressor. The protruding pin in the indicator
on the distribution block gives a visual indication of the point where the blockage occurred. Before
restarting, new rupture discs of the same color and thickness as originally installed must be replaced
at the location where rupture occurred. It is the thickness of the “color coded” discs that determine the
in Auxiliary Equipment
rupture pressure. Refer to rupture disc data sheet in Auxiliary Equipment section of
section of this manual.
Maintenance
In order to operate properly, the lubrication system must be completely purged of air. This is done by
LOOSENING, BUT NOT REMOVING the nuts of the lube lines at the point of injection to permit
purging of oil and air.
air. The nut at the entry to the distribution block, all pin indicators and 1/8-inch
pipe plugs in the face of the block must be loosened also, for the same reason.
Section 3: Lubrication and Cooling 10/17/06
! Caution
High pressure oil streams may puncture skin. Use proper wrench and keep hands away from the immediate
point where the system
s ystem is purging air.
ai r.
Loosen the vent screws in the top section of the distribution block. Continue to operate the lubricator
pump manually until clear, air-free oil appears at either of the two loosened vent screws. Retighten
this vent screw and continue pumping until air-free oil emerges at the other vent screw. When this
occurs, retighten second vent screw. Continue to operate the pump manually until air-free oil has
emerged from tubing nuts at every injection point. Then, and only then, tighten the nuts on the tubing
lines, the pin indicators, and pipe plugs.
Note
If distribution
distribution block must be disassembled
disassembled for cleaning,
cleaning, observe the following:
following:
a. Record order of manifold sections and outlet positions in order to facilitate reassembly.
reassembly .
c. Avoid vise marks; protect ground surfaces, and NEVER grip the ground mating surfaces in a vise.
e. Pistons are removed by hand-punching with a brass rod (either way). If the distribution block is
disassembled, carefully
observe the torque used
f. Clean all sections with an approved solvent.
when reassembling mani-
folds:
g. Do not disassemble check valves - - clean with
with compressed air. Replace •Distribution Block Tie
defectivee parts, as required.
defectiv Rod Nuts = 20-25ft.
lbs. (27-34Nm)
•Check Valves = 15-20
The distribution block type lubrication system is a metered, positive, displacement method of
lubricating the compressor cylinders and packing.
The force feed lubricator pumps oil into a single main line leading to a proportional distribution
block. Hydraulically balanced pistons in the block divide the oil into accurate metered amounts for
each lubrication point it serves. Selection and make-up of the distribution block allows for accurately
measured “shot” sizes, and precise proportioning to meet different or equal oil requirements.
Pa g e 3 - 6 Cameron Compressors Superior Compressors
Because of the positive, metered operation, central warning equipment can sense trouble anywhere in
the system.
Safety equipment includes pin fault indicators, in each outlet from the distribution block, a pneumatic
or electric shutdown switch in the event of lubricant flow failures, and a rupture disk in the lubricator
collector manifold.
Since the system operates on a proportional basis, a single adjustment at the force feed lubricator
pump increases or decreases the flow to every lubrication point.
Oil flow rates given in percent of lubricator pump stroke accompany each compressor. These settings
must be followed and checked to provide adequate lubrication for both “break-in” and normal
operation.
When starting a compressor for the first time, or after servicing, be sure that the gear box is filled with
Exxon TK-680 Cylesstic Worm Gear Oil (ISO680 AGMA-8). It is advisable to check periodically to
be certain that the supply of gear oil is maintained. New units are filled with oil at the factory, and
should not need filling. See Figure 3-6.
Figure 3-6 Gear Box Filling
The compressor frame is lubricated by the pressurized lubrication system. The oil must be cooled by
the shell and tube cooler provided with the compressor (shipped separate for mounting by the
packager). Oil should be circulated through the shell side and coolant through the tube side of the
cooler.
Section 3: Lubrication and Cooling 10/17/06
@1200 RPM 18,000 BTU/hr (18,990 kj/hr) 36,000 BTU/hr (37,980 kj/h r)
@1500 RPM 26,000 BTU/hr (27,430 kj/hr) 52,000 BTU/hr (54,860 kj/h r)
The maximum recommended oil temperature for oil returning to the frame is 175 oF (79oC). To insure
this oil temperature, coolant temperature and flow must be selected to remove heat according to
Table 3-7 .
Coolant Requirement s
R equirements
C A U T I O N
The primary purpose of any water treatment is to protect the surfaces of the Cleanliness is critical. protect
cooling system from cavitation, corrosion, scaling, or sludge deposits that cooling water from impurities
would reduce the transfer of heat to the coolant. and always use clean tools.
It is the responsibility of the operators/users to consult with reliable vendors of cooling system
treatments in order to adequately protect the equipment from damage caused by cavitation, corrosion,
scale and sludge formation and other water treatment related problems.
Corrosion
Corrosion is a chemical reaction in a metal such that the surface of the metal exposed to cooling water
is changed into one or more of its various compounds, especially iron to iron oxide (rust). As the
depth of the corrosion increases iron oxide particles will flake off, exposing more new surface
material to attack. Where it will occur in the cooling system and to what degree it will progress
depend on factors such as quality of water, metals in the cooling system, surface temperature, and
mechanical conditions of surfaces. The types of corrosion commonly found in cooling systems can be
crevice, cavitation and erosion, fretting or galvanic.
The most important consideration for the cooling system is good water quality. Table 3-8
3-8 shows the
range of maximum limits for raw cooling water quality. If raw water is tested and is found to have
higher concentrations than those shown on the chart, the water will require treatment or deionizing. If
concentrations are below those shown, the water is suitable for use with inhibitors added.
Table 3-8 Ra
Raww Cooling Water Specifications
Specificatio ns
Category Standard System Steam System
p H Le ve l 7.5 MIN / 9.5 MAX 7.5 MIN / 9.5 MAX
Total Hardness PPM 100.0 -170.0 MAX 5.0 MAX
Chlorides PPM 25.0 MAX 25.0 MAx
Sulfates PPM 20.0-100.0 MAX 20.0-100.0 MAX
Tota l D issolved Solids PPM 300.0-4 00.0 MAX 300.0-400.0 MAX
Silica PPM ----- 50.0 MAX
An inhibitor is a chemical part of coolant treatment that reduces corrosion by forming a protective
film on the metallic surfaces of the cooling system. These protective films can be of anti foam or
coating nature. The anti foam nature reduces the formation of air bubbles in the coolant. The coating
effect gives a protective layer between the metal surfaces and the coolant. During cavitation, the
violent collapse of the vapor bubble literally blasts small holes in the film. The job of the inhibitor is
to recoat these areas. Because the inhibitor is recoating the metal surfaces, its concentration levels
must be maintained to continue adequate protection. Therefore, the coolant inhibitor concentration
must be checked periodically, and added when needed.
Good industrial grade antifreeze should be used in all closed-type cooling systems. All industrial
grade antifreezes have some corrosive inhibitors. When exposed to heat, these inhibitors break down.
This characteristic requires periodic adjustments to maintain the corrosion protective qualities of the
coolant.
Corrosion inhibitors vary in the chemical make-up and concentrations depending upon the
manufacturer. Most of the products will do an adequate job when quality water (deionized and
demineralized) is used. Corrosion inhibitors are ineffective in hard or sub-quality water. The key to
adequate cooling water is to begin with clean water and use a reliable water treatment specialist.
Chemical treatment of a closed water system is simplified by the use of proprietary inhibitor
compounds. The low make-up water requirements of closed systems and, therefore, minimum
compound additions place a minimum burden on the user for materials and maintenance.
Periodic testing of the coolant, whether by the user or the vendor of the treatment system, is
absolutely necessary in order to assure that a proper level of protection is maintained. The equipment
user must obtain the specific instructions for the use and testing requirements of the inhibitor
A clean system is a prerequisite for establishing protection of any cooling system. Adequately
protected closed cooling systems seldom, if ever, present problems caused by scaling, corrosion,
deposits or cavitation.
Cooling System
There are three types of cooling systems used for stationary equipment: open, closed and
combination.
Open systems involve cooling towers, spray ponds, etc., and cool the water by evaporation.
Closed systems involve heat rejection through or shell and tube-type or radiator-type heat exchangers.
Combination systems have the engine and compressor cooling water in a closed system using shell
and tube-type heat exchangers to transfer the heat to an open system using cooling towers, etc, as
above.
Closed type systems are commonly used and approved cooling methods; however, because open-type
systems involve not only large volumes of make-up water, but also the ease of airborne
contamination, Cameron Compression do not recommend using these for this equipment.
Pa g e 3 - 1 0 Cameron Compression Superior Compressors
Section 4
DANGER
Sour Gas Compressor Sour gas or hydrogen sul-
fide (H2S) is a highly cor-
Caution should be taken when working in or around hydrogen sulfide (H 2S). This chemical is
dangerous and can cause harm to personnel. H2S is colorless and smells like rotten eggs. In
higher concentrations it will kill your sense of smell and impede your ability to detect it. DO
NOT relay on your sense of smell as a detection method.
Table 4-1 gives some general information on the concentrations levels of H2S and its effect on
the body. This should be thoroughly read and understood before working in an H 2S
environment.
Section 4: Sour Gas Compressor Applications RAM-10/17/06
100 ppm (0.01%) Kills sense of smell in 3 to 5 minutes. May burn eyes and throat.
200 ppm (0.02%) Kills sense of smell rapidly. Burns eyes and throat.
1, 00
000 p
pp
pm (0.10%) Immediat e unconsciousness. P e
errmanent brain dam a
ag
ge m a
ay
y result if
not rescued immediately.
The equipment specifications are based on three levels of sour gas plus additional National
Association of Corrosion Engineers’ (NACE) requirements as defined by the following
percentages of H2S:
Trim Requirements
For Hydrogen Sulfide (H 2S) Concentrations Up To 2% By Volume:
•For any concentration of H2S up to 2% by volume in lubricated service, special trim will not
be required. Standard material is acceptable and special lubrication practices are recom-
mended.
•The frame lubricant used must have a total base number (TBN) of 15 or higher to help pre-
vent the lubricant
lubricant from turning acid and damaging bearings and bushings. This alkalinity
must be maintained during operation in the machine at no less than approximately 30% of
the original TBN number by appropriate timely make-up or complete oil changes.
•The frame lubricant must meet or exceed the requirements of MIL-L-2104B, Supplement
No1.
Pa g e 4 - 2 Cameron Compression Superior Compressor Product Group
•A complete oil analysis program on the frame lubricant is required to determine proper oil
change intervals as well as to monitor the condition of the lubricant and the unit.
•Compressor cylinder lubricants must adhere to the requirements of Superior Engineering
ES1002.. Viscosities are to be on the high side of the pressure conditions normally
Standard ES1002
Standard
required and a 3% to 5% compounding (similar to steam cylinder oils) is also required.
•The compressor cylinder lubricant rate is to be double the normal rate for equivalent non-sour
gas applications.
•All brass, bronze, copper and other copper alloys are to be avoided on hardware for all gas
wetted parts.
•The distance piece is to be properly vented in accordance with local safety standards to pro-
vide maximum safety to personnel.
•Soft iron or aluminum gaskets are to be used between the valve and valve seat.
•The O-ring material used for standard equipment is Viton (Spec. 473) and this is also accept
able for H2S service. For lower temperature operations (< 27 F (<-3 C) Neoprene (Spec.
° °
Level 2-11p Trim (H2S Concentrations > 5%) All of the requirements for H 2S
concentrations of 2%-5% apply plus the following:
•Valve components made of carbon steel or AISI 4140 alloy steel shall have a maximum hard-
ness of 22 HRC (Heat Treat Spec. H 2S). This reduces the pressure differential capability of
any specific
neering will valve design
evaluate theseand
on thus the pressure
an individual differential
basis and selectcapability of the
appropriate cylinders.
alternative Engi-
designs
to meet the application requirements.
•This reduced hardness requirement also includes steel valve cages (retainers) when they are
used.
•Compressor valve components may also be made of AISI 416 stainless steel with a maximum
hardness of 22 HRC.
•Valve plates wherever possible are to be plastic to better prevent seat wear against the softer
valves seats.
•When metallic plates are required, 410 stainless steel with a hardness of 17 to 22 HRC will
be used.
•Nimonic 90 valve spring material will be used.
•Two compartment configuration of distance pieces is required. The outer compartment must
be purged with inert gas to a pressure of 3 to 5 inches (7.6 to 12.7 cm) H 2O.
•All compressor cylinder and distance piece critical bolting, capscrew, studs, and nuts which
come in contact with the process gas stream shall conform to ASTM A193-B7M (bolts and
studs) and ASTM A194-2HM (nuts).
•All instrumentation that comes into contact with the process stream (liquid level controls,
shutdowns, bourdon tubes, process valving, relief valves, etc.) shall meet the full require-
ments of NACE MRO175 except stainless steel tubing fittings. This requirement is the
packager’s responsibility.
•The distance piece shall be purged with inert gas. The packager is responsible for purging
purging
per these requirements. If other venting or purging systems are desired the details are to be
negotiated between the purchaser and the packager (i.e., vacuum systems or sweet natural
gas purge). The final detailed system should provide for the safety of persons around the
equipment and should prevent contamination of the frame oil with sour gas. Packing cases
will not be purged unless required by the customers.
Enhanced H2S Trim Requirements are based on guidelines established by NACE MR0175.
That standard specifies more rigid H2S trim levels than required for standard API 11P trim.
Pa g e 4 - 4 Cameron Compression Superior Compressor Product Group
The following requirements should be followed when H2S trim in excess of API 11P
requirements is needed to meet NACE. This enhanced level of trim can also be used for any
concentration of H2S as required by the customer.
Pa g e 4 - 6 Cameron Compression Superior Compressor Product Group
Section 5
Installation
General
Installation of the compressor will be determined by the fabricator and the end customer.
Since the method employed will vary due to application, the following is offered as a guide to
aid in the installation. These instructions are based on previous installations that have proven
satisfactory.
There are two basic compressor mountings: the baseframe or skid mount and the direct to
block mount. (See Figures 5-1 and 5-2.) The baseframe/skid mount is most commonly used
whereby the fabricator sets up the complete installation as a package. This package is then
moved to location and placed on a foundation. With the block mounting, there is no
intermediate (baseframe) between the compressor and foundation, thus the compressor is
mounted direct to the foundation (block). This type installation is of a more permanent nature.
If you have a choice as to the location of the compressor, select a site where the ground under
and around the unit will be firm and dry at all times. Filled ground, wet clay, unconfined sand
and gravel, or similar soils provide poor support. Be sure that sufficient space is available for
necessary maintenance. For instance, there should be ample space to permit removing the
piston and rod assembly out the outboard end of the cylinder. See that provisions can be made
for an overhead hoist, or that a portable crane can be moved into position as necessary for
removal or installation of major parts or assemblies. Electrical outlets, lighting and cleanliness
are other important factors. Adequate ventilation is essential to safety and the welfare of the
operating personnel.
The responsibility for an adequate foundation is that of the customer. Thus, 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, but on surrounding machinery, buildings, or
personnel. Often times, a neighboring installation on similar soil will serve as a clue to the soil
conditions.
However, unless the nature of the ground is well known, it is advisable to dig several test pits
at the proposed site. Cameron
Cameron will
will gladly furnish data on weights and unbalanced forces
required for calculations by a foundation engineer. In any case where increasing the size of the
standard minimum foundation is necessary, the area of the base should be increased to
Section 5: Installation 10/18/06
decrease the soil loading and the possibility of rocking. When freezing temperatures are likely
to occur, the foundation must be carried well below the lowest expected frostline as
determined by the foundation engineer.
Figure 5-2 Block (Concrete)
(Concrete) Mounting
Mounting
00757
Foundation Bolts
To locate the foundation bolts, make a wooden template to temporarily position the bolts
according to the dimensions given on the foundation plan. Set up the template in the exact
position to be occupied by the compressor, allowing space for the grout as indicated. ( Figure
Keep all jackscrews snug. After levelling, foundation bolt nuts Responsibility for the grout
belongs with the customer
should be secure but NOT TIGHTENED. It is very important the unit
or their contractor. Grouting
is aligned as accurately as possible so that after grouting or shimming material instructions should
has been completed, the foundation bolts may be pulled down be carefully followed. Fail-
ure to comply with this
without any resulting stresses. warning may result in dam-
age to your unit.
When the grout has completely hardened, LOOSEN THE
JACKSCREWS and tighten down all the foundation bolt nuts
evenly. Make sure that no stresses are set up when pulling down the nuts by checking
alignment with a dial indicator.
Section 5: Installation 10/18/06
c. With engine and compressor moved into position, as shown on the outline drawing,
reassemble coupling. Dimension (D) must be maintained during the following alignment
procedure.
Figure 5-5
5-5 Dial Indicator
Indicator Method
Method of Alignment
Alignment
00761
10/18/06
The recommended procedure for establishing final alignment is called the “indicator method.”
Proper lining up may take a little time, but it is absolutely essential. Flexible couplings should
not be required to compensate for any misalignment that can be eliminated. The closer the
initial alignment, the greater the capacity of the coupling to take care of subsequent
operational misalignment.
d. Attach dial indicator as shown in Figure 5-5 (view B). Rotate coupling 360 degrees to
locate point of minimum reading on dial; adjust indicator to zero.
g. Reset indicator to zero and repeat steps (d), (e), and (f); if either, the engine or
compressor is moved during aligning trials.
h. The coupling should be turned several revolutions to make sure no “end-wise creep” in
the crankshaft is measured.
i. Mount dial indicator (Figure 5-5 (view C)) to check for parallel misalignment. Set
indicator stem on outer diameter surface of flange B and adjust to zero.
n. Alignment should be checked periodically. Realign unit when parallel misalignment
exceeds 0.014 inch (0.036 cm) T.I.R. and/or angular misalignment exceeds 0.020 inch
(0.051 cm) T.I.R.
Section 5: Installation 10/18/06
Cylinder Mounting
When reassembling the cylinder to the crosshead guide, use a criss-cross pattern nut
tightening sequence. See Table 7-2 for recommended torque values.
Outer end cylinder supports, if supplied, are intended to support the weight of the cylinder
only. Do not use them to force the cylinder into alignment. If a cylinder cannot be aligned,
check for dirt, burrs, or other irregularities at the mounting surfaces.
10/18/06
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.
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
Clearance
working freely.
and cylinder
larger shouldhead. Pistons
use solder 10 inches
inserted (25
from cm)sides
both and 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 10/18/06
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.
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 rod-
to-crosshead nut, and rotate the piston one quarter turn before re-torquing. If the runout still
limitations, contact your Cameron Aftermarket facility for assistance.
exceeds limitations,
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 int eh sequence shown in Figure 5-12 . If the runout is still beyond
acceptable limits, contact your Cameron Aftermarket facility
facility for assistance.
•Vertical run-out should fall within ranges indicated on the curve for the given cylinder diameter in
Figure 5-11
5-11
10/18/06
Figure 5-11
5-11 Allowable
Allowable Rod Run-Out
Run-Out Graph
Figure 5-12
5-12 Nut Tighting
Tighting
Sequence
Section 5: Installation 10/18/06
10/18/06
Section 6
Operation Start-up
conditions, and the gases being handled all have a significant effect pany’s safety procedures
before attempting to start
on how well a lubricant performs in the given application. 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.
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
compresso r with a lint free cloth
DANGER
to remove any water or foreign material that may have accumulated Vent the compressor and the pro-
cess system to the atmosphere
during shipment or storage. before removing any gas-con-
taining part of the compressor or
d. Check the crankshaft for web deflection. its associated piping.
i. Check the force feed lubricator for cleanliness and fill to the proper level with oil.
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.) Oil level in frame
should be filled to
the level in the Kenco level
o. Replace all covers with their respective gaskets and tighten regulator
the frame NOT the level in
bull’s-eye.
screws according to Table 7-2. Distance piece covers may be left
off to check for packing leaks on start up if not using sour gas. For
sour gas applications, see warnings in sour gas trim Section 4.
p. Check to see that all crosshead guides or distance pieces and packings are individually
vented with the proper size of vent lines. Refer to Engineering Standard ES3 for the most
up-to-date recommendations.
q. Verify that all safety switches, shutdown devices, and relief valves are properly set and
operational. See Table 7-16 for normal operation, alarm, and shutdown settings.
s. Unload the compressor for startup by placing the bypass line between the first stage
suction and last stage discharge lines.
The frame lubricant must be capable of operating with the type of gas being handled by the
see page 3-3 and
compressor cylinders. For viscosity requirements see page 3-3 and Table 3-2 & 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.
10/18/06
When starting the compressor, verify a lube oil header pressure of 20 psi (138Kpa) or greater
occurs within 5 seconds of compressor startup. To prevent damage to the crankshaft and other
lubricated parts, all compressors are equipped with low oil pressure shutdowns. This is
triggered when the oil pressure falls below 20 psi (138 kPa).
The oil level in the frame is normally at the center of the sight glass. An alarm should sound if
the oil level rises 1 inch during compressor operation, this will submerge the gaskets on the
bottom of the front and rear covers. A shutdown should occur if the oil level rises an
additional 1.5 inch (3.8 cm) or if the oil level falls 1 inch (2.5 cm) from normal level.
The oil level in the frame sump should be checked while the compressor is running. The
correct level is shown by the round sight gauge on the auxiliary end of the compressor. Oil
level (while running) should be no higher than the top and no lower than the bottom of the
sight gauge. Oil may be manually added through the breather cap hole in the top cover. The
breather cap is designed to be threaded into its bushing by hand and no wrenches should be
used. Make up oil may also be continuously added through an optional, frame mounted oil
level controller connected to an oil supply tank.
Initial Startup
1. Open the valves supplying water to the compressor cooling C A U T I O N
3. Run compressor for 2 to 5 minutes at 600 RPM. If driver is a constant speed electric
motor run compressor for only 1 to 2 minutes.
4. Shut system down and check all bearings and packings for high temperatures.
5. Remove crosshead guide covers and check all lubricated surfaces for high temperatures.
7. Start system and compressor up again and run for approximately 20 to 30 minutes. Add
oil to the crankcase to bring the oil level
le vel (while running) up to the middle of the sight glas
glass.
s.
Shut down and recheck as above.
Section 6: Start-up 10/18/06
9. During the initial period of operation, pay close attention to the equipment covers after
the compressor has been
the machine for any unusual high temperature, pressure, or
stopped. Allow the unit to
vibration. In the event of equipment malfunction where
cool down to prevent possi-
excessive vibration, noise, high temperature, or any other ble explosion due to in rush
dangerous condition exists, the compressor should be stopped of air or injury caused by
immediately. contact with hot surfaces.
Normal Startup
Not all of the instructions provided for initial startups are required for routine starting. The
following notes comprise the normal starting procedure:
1. Set all clearance devices at positions suited for the planned operating conditions. Unload
the fixed volume pockets or suction valve unloaders.
Normal Shutdown
1. Decrease speed to 600 RPM (engine driven units only).
6. Relieve pressure by venting compressor cylinders, suction piping, and discharge piping
to remove any remaining gas.
Emergency Shutdown
In an emergency situation, the shutdown devices will shut down the system. In such as case,
the cause of the shutdown must be identified and corrected before restarting the compressor.
Refer to the Troubleshooting Page 7-23 thru 7-31 to troubleshoot compressor.
The compressor should only be operated at speeds, pressures, and temperatures listed on the
data sheets or performance curves. The unit should never be operated at conditions other than
those specified on the data sheets without contacting the manufacture.
Note
Superior attempts to furnish performance curves and/or computer printouts to assist you with com-
pressor operation.
operati on. If they have been omitted
o mitted please fill out the following
followin g form and new curves will
w ill
be provided to you.
yo u. If compressor operating
op erating condi
conditions
tions change, contact your
you r Cameron Aftermarket
Aftermark et
Sales Office.
Section 6: Start-up 10/18/06
10/18/06
Model
Elevation
Ambient Temperature ( F or C)
° °
Specific Gravity
“N” Value
Section 6: Start-up 10/18/06
10/18/06
Section 7
Maintenance
General
The diligent observation of the inspection and maintenance procedure, given in this section, will go a long way
toward insuring satisfactory operation of the compressor. Superior ® recommends planned periodic inspections
of equipment. Malfunctions can occur regardless of the designed reliability of the gas compressors. Faithful
preventive maintenance and the use of genuine Superior ® parts will help prevent costly down time, repairs,
and replacement costs. Planned shutdowns for doing preventive maintenance will result in minimum
maintenance costs and maximum mechanical efficiency of your equipment. Good preventive maintenance
practice includes a periodic check of critical bolt torques, such as compressor main and connecting rod bolts
and drive coupling bolts.
Table 7-1 shows clearance values for some critical components when new. When a part is first installed, the
clearance should be within the range shown in Table 7-1.
7-1. If not, the part is defective or has been incorrectly in-
stalled. During inspections, clearances found exceeding the clearance range indicate worn parts that should be
replaced ( ES19
ES19).
).
Cr
Cross
osshe
head
ad P
Pin
in to
to Co
Conne
nnect
ctin
ing
g Ro
Rod
d Bushi
Bushing
ng 0.
0.00
003
3 - 0.
0.00
0045
45 ((0.
0.07
076
6 - 0.
0.11
114)
4)
Crank
ankshaft E
En
nd P
Pla
lay
y - Thru
hrust Beari
aring 0.006 - 0.014 ((0
0.152 - 0.356)
Cros
Crossh
shea
ead
d Pi
Pin
n Bu
Bush
shin
ing
g In
Inte
terf
rfer
eren
ence
ce Fit
Fit 0.
0.00
0035
35 - 0.
0.00
006
6 (0
(0.0
.088
88 - 0.
0.15
152)
2)
S
Sttub Shaft Run-out 0.000 - 0.005 (0.0 - 0.127)
L u
ub
be Oi
Oil P
Pu
ump D
Drrive G
Ge
ear Ba
Backlash 0.006 - 0.010 ((0
0.152 - 0.356)
Cameron Compression Pa g e 7 - 1
Pa g e 7 - 2 Cameron
Cameron Compression Superior Compressor Product Group
Torque Re
Recommendations
commendations
C A U T I O N
Cameron Compression Pa g e 7 - 3
Cameron Compression Pa g e 7 - 5
Step 1. Outside the head, torque all nuts to 70% full torque in the following sequence: Inner
bolt circle, next bolt circle, outer bolt circle, as shown on ( Figure 7-8 ).
Step 2.Torque nuts to 100% full torque in the same sequence as Step 1.
It is critical that the following preventative maintenance schedule be followed to prevent major
damage to your compressor (SB168 ( SB168).Check
).Check all critical bolt torques on components as follows:
• OneOne (1)
(1) mont
monthh afte
afterr unit
unit is
is plac
placed
ed in
in serv
servic
icee
• Six (6
(6)) mont
months
hs afte
afterr unit
unit is
is plac
placed
ed in
in servi
service
ce..
• Ever
Every
y twel
twelve
ve (12
(12)) mont
months
hs the
there
reaf
afte
ter.
r.
Repeat this schedule when the compressor is rebuilt, overhauled, or has major repairs.
All torque values shown in Table 7-2 are based on threads which are clean, free of burrs, paint, etc.
and lubricated with engine oil or similar petroleum base lubricants. Unless specified, DO NOT USE
any compounds containing molybdenum disulfide as a thread lubricant. Due to its high lubricity,
excessive stresses will result if used with the torque values given in Table 7-2.
The nuts holding the compressor cylinder heads must be torqued in a specific pattern. Use the
diagonal ( Figure
Figure 7-9
7-9) or cross pattern sequence for all bolting except for the valve-in-head( Table 7-7
& Figure 7-8).
7-8).
Pa g e 7 - 6 Cameron
Cameron Compression Superior Compressor Product Group
such a way
pressor thatturn
cannot the over.
com-
Block valves must be
closed on the suction and
discharge lines. Air or gas
must be bled off from the
cylinders. Precaution must
be taken to prevent the
opening of any valve which
would release pressure
against a piston, causing it
to rotate the unit at a critical
moment.
Precautions
b. Remove all gas by unloading, venting, and then “blinding” the compressor. Blinding means to shut
off all block valves so there can be no process gas flow to the compressor.
c. Eliminate all internal pressures by removing cylinder indicator plugs or vent through indicator
cocks, if provided.
d. Prevent clogged oil lines or filters by using only lint free cloths.
e. Ensure all tools and work areas are clean and free of oil, water, dirt, dust or grit.
f. Never file, grind or scrape any lubricated parts (i.e. bearing shells or saddles).
g. Never distort or mark the piston rod with any tool or device. Rods that are bent or have burrs will
damage the packing or prevent it from sealing. In severe cases, the rod could break.
h. Never torque or tighten any nut, cap screw or stud if threads or mating threads are covered with
paint or other materials that are not specified by Superior ® for use on threads.
i. Genuine Superior ® parts must replace any components which are changed.
k. When reassembling parts during maintenance, replace all worn or damaged gaskets and seals.
l. Always install
install new cotter
cotter pins or lock wire.
Cameron Compression Pa g e 7 - 7
m. Check and clean all lubricating oil passages when the unit is down for repair or normal maintenance.
maint enance.
n. After a long period of shutdown or a major overhaul, frequently check the unit during the first 300
hours of operation.
o. After completing maintenance, remove any locking or blocking devices before attempting to rotate
the equipment.
Bearing Clearance
To check bearing clearances, use a dial indicator along with a hydraulic jack proceeding as
follows:
a. Remove the top cover of the frame to gain
gai n access to the igure 7-13 Dial Indicator
bearings and crankshaft.
d. Support the jack with a piece of wood. Jack the crankshaft up and down sufficiently to get a
clearance reading on the indicator.
e. Compare the clearance reading with the tolerance value given in Table 7-1.
7-1. If the clearance reading
exceeds the maximum limit, replace the bearing with two new bearing shells.
Section 7: Maintenance 10/18/06
Cameron Compression Pa g e 7 - 9
All bearing shells are precision bored with the proper running clearance. When installing replacement
shells, do not scrape or shim the bearings to achieve proper clearance. If you cannot achieve proper
running clearance once the cap has been torqued, check the frame alignment. If the problem persists,
contact your nearest C ameron distributor representative for trained field assistance.
ameron
When changing the main bearings, follow all the precautions found in
Section 2. Replace only one set of bearing shells at a time. When you’ve
changed one set, tighten the bearing caps to the proper torque value of 350 ft-
C A U T I O N
a. Remove a bearing shell by inserting the neck of the main bearing removal Figure 7-14
tool ( Figure
Figure 7-14
7-14) into the oil passage hole in the crankshaft journal.
When the unit is rolled over, the tool pushes the shell out from underneath Main Bearing
Removal Tool
the journal and around to the top where it can be removed. Using the same
steps, you can install a new set of bearings.
b. Change the connecting rod bearings by following the same precautions in
Section 2. Roll the connecting rod until it reaches its highest point on the
journal shaft.
shaft. This offe
offers
rs easy access
access to the rear cap
cap bolts. Support the
the
shaft with a sling or some safe means of suspending the rod for easy access to both bearing halves .
c. With the rod supported, remove the bearing cap and bearing half. Taking
extreme care and keeping clear of the rod assembly, continue to roll the DANGER
crankshaft slightly back to access the other bearing half.
Always support the connect-
ing rod so it can not drop and
d. Carefully install the new bearing against the exposed half bore in the damage equipment or cause
injuries.
connecting rod. The tang recesses within the rod should support the bearing
so you can roll the crankshaft carefully back into position against the supported rod.
e. Complete the assembly process by putting the other half of the bearing and
The caps and rods are
numbered by throw
the cap back into position and tightening the two bolts to their proper and have their weights
torque as stated in Table 7-2.
7-2. stamped on them. Always install
rods with this information dis-
played up.
Pa g e 7 - 1 0 Cameron Compression Superior Compressor Product Group
a. Shut down the driver and compressor, and Figure 7-16 Top Cover Assembly
isolate it from the power source.
g. Bar the compressor over to access the connecting rod bolt nuts.
h.Remove the connecting rod nuts (7), washers (6), bolts (2) and rod caps (5)
C A U T I O N
Cameron Compression Pa g e 7 - 1 1
k. Refer to Figure
Figure 7-19
7-19 and remove the snap Figure 7-17 Frame, covers & components
components
rings (5) and the crosshead pin (4).
Inspection
maximum
changed orwear limitations.
limitations.
the rod If youto
needs re-bored discover
restore the crosshead
proper runningpin bushingssend
clearance, need If you need to change the cross-
head pin bushings, contact your
the rod to the nearest CES
CES authorized
authorized distributor for prompt attention. nearest CES distributor to
arrange for transportation or pos
Table 7-18 Clearances for Connecting Rod Components Inspection sible route truck pickup. The
bushings need to be frozen into
purposes only
the connecting rod, then bored
Item Clearance range in inches (mm ) for proper running clearance by
Con
Conne
nect
ctin
ing
g Ro
Rod Eye
Eye Bo
Bore
re Diam
Diamet
eter
er 3.
3.74
7485
85 - 3.7
3.749
490
0 ((95
95.2
.212
12 - 95.
95.22
224)
4) an authorized machine shop.
b. Check all parts for physical distortion, wear, cracks, and pitting.
c. Check sealing surfaces for nicks, burrs, and scratches which may damage seals and O-rings.
d. Examine sediment adhering to the drain plug for accumulations of grit or fine metal particles,
which may indicate actual or potential component failure.
e. Examine bearings for rust, pitting, brinelling, abrasion and serious discoloration. Also replace the
bearings if you notice cuts or grooves parallel to bearing rotation.
6. Refer to Table 7-1 to check important clearances.
Installation
Since you're installing two bushings (one for each side of the eye), it's important to align them
properly. Insert the bushings so that the joint of the bushings rests either on top of the eye (0°) or on
the bottom of the eye (180°). Face the open end of the bushings'oil grooves toward the inside of both
bushings. This allows lubrication to travel from the lubricating point within the eye of the rod to the
entire pin area. The bushings are now ready to be bored.
At assembly, "mike" the crosshead pins to assure they're the correct size and
that the proper pin-to-bushing clearance is held. The following procedure
guides you through reinstallation of the connecting rod assembly:
C A U T I O N
c. Bar the compressor to achieve the maximum clearance between the crankshaft and connecting rod.
d. With access through the crosshead cover opening ( Figure 7-17), install the
connecting rod (Figure 7-15) into the crosshead (Figure 7-19). C A U T I O N
i. Inspect and install the crosshead as described under the next corrective
Loctite grade 515 is
the required sealant
maintenance topic, Crosshead and Crosshead Pin.
for the top cover.The
correct application o
j. Install
Install the crosshead cover (10)
(10) and
and O-ring
O-ring (9)(9) and secure with screws (13) this sealant to mating surfaces is
essential to prevent oil leakage.
and washers (11) and (12) ( Figure 7-16
7-16 ))..
k. Apply sealant to the top opening of the frame.
Cameron Compression Pa g e 7 - 1 3
( Figure 7-16
l. Install the top cover (1) using screws (4) and washers (2) and (3) ( Figure 7-16 ))..
Figure 7-19
The crosshead (
and is machined to accept two ) isaluminum
made of ductile
shoes. iron
Proper
clearance is built into the shoes. No shimming is ever
required. If a maximum allowable shoe-to-guide
clearance is exceeded, (Table 7-1) replace the shoes.
c. Remove screws (13). washers(11) and (12), crosshead cover (10) and O-
C A U T I O N
f. Bar the compressor over to achieve maximum clearance between the connecting rod and crosshead
(3).
g. Loosen the jam nut (7) with the wrench provided to separate the nut from the crosshead.
Pa g e 7 - 1 4 Cameron Compression Superior Compressor Product Group
i. Turn the piston and rod assembly out of the crosshead using the spanner wrench ( Figure 7-20).
k. Carefully rotate the crosshead with special tools (Figure 7-20) until you can remove it between the
edges of the crosshead guides and out the crosshead cover opening.
l. Referring to (Figure 7-19), remove screws (1) and crosshead shoes (2)
Inspection
b. Check all parts for physical distortion, wear, cracks, and pitting.
c. Check sealing surfaces for nicks, burrs, and scratches which may damage seals and O-rings.
Installation
b. Install crosshead shoes (2), securing with screws (1). Refer to Table 7-2 for correct torque.
c. With access through the crosshead cover opening, use the special tools shown in Figure 7-20 to
install the crosshead onto the connecting rod.
Cameron Compression Pa g e 7 - 1 5
d. Tighten the jam nut (7) with the wrench provided. See Table 7-2 for proper torque.
e. Install crosshead pin (4) and snap rings (5). Crossheads and
balance weights are
stamped with throw
f. Referring to Figure 7-17, install crosshead cover (10) and O-ring (9), numbers and must
be replaced accordingly.
securing with screws (13) and washers (11) and (12).
g. Re-check the pin-to-bushing and shoe-to-guide clearances, and compare these measurements to
those recommended in this section.
When using the crosshead installation handles, more care and feel is required. DO NOT USE
FORCE as this is the first indication that the job is being done incorrectly and damaged crosshead
shoes may result.
result. The correct procedure is to stand to one side of the crosshead guide and feed the
crosshead across, attempting to roll it in at short intervals. From the proper position, the crosshead
will roll in easily without damage to the shoes.
During the reassembly procedure, the machined face of the jam nut must be toward the crosshead.
Check piston end clearances and then make sure that the jam nut is torqued properly ( Table 7-2)
against the crosshead.
Crankshaft
crankshaft Figure 7-21
The crankshaft Figure 7-21 is a one-piece design. Drilled holes carry lubricating oil from the main
bearings to the crank pin journals and bearings. Lubrication continues from this point to the crosshead
end of the connecting rod. Ample lubrication is also provided to the pin and rod bushings.
The crankshaft extends beyond the frame at Figure 7-21 Crankshaft and
and component
componentss
the opposite end of the oil pump. A hub
mounted on this extension allows the
compressor
At the point to be coupled
where with theextends
the crankshaft driver.
beyond the frame wall, a seal prohibits oil
leakage. This seal allows removal and
maintenance using special tools ( Figure 7-
20).
20 ). Remove the crankshaft to replace this
seal. We recommend crankshaft removal be
performed by authorized CES
CES distributor.
distributor.
The crankshaft seal should be changed
whenever you detect leakage. The steps for
removal, inspection, and installation are
presented in the following procedures.
Pa g e 7 - 1 6 Cameron Compression Superior Compressor Product Group
Removal of Crankshaft
Removal Crankshaft ( Figure
Figure 7-21
7-21)):
a. Shutdown the driver and compressor, and isolate it from the power source.
to Figure 7-17
f. Referring to Figure 7-17 , remove screws (1), lockwashers (2) and drive-end cover (3).
to Figure 7-17 , remove spacer bar nuts (7) and o-rings (6).
g. Again referring to Figure
h.While holding the spacer bar (4) with one hand, withdraw the spacer bar stud (5) and remove both
the bar and stud.
to Figure 7-15
i. Referring to Figure 7-15, bar the compressor over to access the connecting rod bolt nuts. Remove
nuts (7), washers (6) and rod caps (5).
to Figure 7-21,
k. Referring to Figure 7-21, remove bolts (1), washers (2) and main bearing caps (3).
to Figure 7-22,
o. Referring to Figure 7-22, remove screw (10), lockwashers (9) and auxiliary end cover (7).
q. To remove the crankshaft, attach a strong web lifting strap to the crankshaft (7) at two points.
Place the stap over the hook of a hoist and slowly raise the crankshaft out of the base. Be careful
not to damage any bearing surfaces. Make sure the hoist lifting capacity exceeds 600 lb (272 kg).
r. Remove bearing shells (4) and thrust bearings (8) from the base.
Section 7: Maintenance 10/18/06
Cameron Compression Pa g e 7 - 1 7
Inspection
Follow these
these steps to complete crankshaft
crankshaft inspection:
inspection:
a. Clean all parts before inspecting.
b. Check all parts for physical distortion, wear, cracks, and pitting.
c. Check sealing surfaces for nicks, burrs, and scratches which may damage seals and O-rings.
d. Examine sediment adhering to the drain plug for accumulations of grit or fine metal particles,
which may indicate actual or potential component failure.
e. Examine bearings for rust, pitting, brinelling, abrasion and serious discoloration. Also inspect for
cuts or grooves parallel to bearing rotation.
and related
related components:
components:
a. Install bearing shells (4) and thrust bearings (8) into the base ( Figure
Figure 7-21
7-21).
b. Install the new crankshaft and lubricator drive shaft seals using appropriate tools.
c. Attach a strong web lifting strap to the crankshaft (7) at two points. Place the strap over the hook of
a hoist and slowly lower the crankshaft into the base. Be careful not to damage any bearing
surfaces.
( Figure 7-22
d. Assembly gear (2) onto stub shaft (3) ( Figure 7-22). Loctite grade 515 is the
required sealant for the
drive end, auxiliary
e. Install stub shaft assembly (1) with screws (4). end, and top covers.
The correct application of this
sealant to mating surfaces is
f. Apply sealant to the auxiliary end opening. essential to prevent oil leakage.
g. Install auxiliary end cover (7), securing it with the top four lockwashers (9) and screws (10).
Pa g e 7 - 1 8 Cameron
Cameron Compression Superior Compressor Product Group
( Figure 7-21
k. Install bearing shells (4) into the main bearing caps (3) ( Figure 7-21).
l. Install caps, bolts (1) and washers (2). Refer to Table 7-2 for correct torque.
m. Inspect and install the connecting rods as described earlier in this section.
to Figure 7-17 , install spacer bar (4) and spacer bar studs (5). Secure with nuts (7) and
n. Referring to Figure
O-rings (6). Refer to Table 7-2 for correct torque.
p. Install the drive-end cover (3), securing with screws (1) and lockwashers (2).
q. Check the crankshaft for proper alignment. See the alignment discussion under the Installation
topic in Section 5 of this manual.
s. Install the top cover (1), securing with screws (4) and washers (2) and (3) ( Figure 7-16).
u. Referring to Figure 7-21, reconnect coupling (5) between the driver and frame.
Removal
Cameron Compression Pa g e 7 - 1 9
g. Remove the setscrew from the coupling half attached to the frame. Remove the coupling half and
key from the
the stub shaft. Then remove the stub shaft seal.
h. Remove the remaining screws and lockwashers from the lubricator bracket.
c. Check sealing surfaces for nicks, burrs, and scratches, which may damage the seal.
e. Examine tubing for kinks or leaks. Inspect fitting threads for damage.
C A U T I O N
Installation
When heating anything to a
high temperature, take the
Refer to Figure 7-22 as you replace the lubricator, and follow these steps: necessary precautions to
prevent burns.
a. Install the lubricator bracket with screws and lockwashers.
b. Heat the drive gear to between 470 °F and 600 °F (243 °C and 316 °C). Install the gear onto the
stub shaft.
Pa g e 7 - 2 0 Cameron
Cameron Compression Superior Compressor Product Group
c. Install the stub shaft seal, key and coupling half onto the stub shaft. Secure with the setscrew.
d. Install the key and coupling half onto the lubricator shaft. Secure with the setscrew.
i. Replace the drain plug. Remove the vent fill plug and refill the lubricator with 90-weight gear oil.
Referring to Figure 7-24 loosen the upper plug and add oil to the vent fill hole until oil starts to leak
from the upper plug. Tighten the upper plug, then reinstall the vent fill plug.
Cameron Compression Pa g e 7 - 2 1
d. Remove screws (15), lockwashers (7) and oil header flange (14).
e. Remove the reducer bushing (2) from the reducing tee (1).
h. Unscrew the filter housing (18) from the filter head (4).
i. Remove the filter element (19) and O-ring (20) from the housing.
k. Remove the bracket (5) by removing screws (6) and lockwashers (7) that secure it to the base.
Inspection
a. Examine the filter and housing for metal particles, foreign material, or other contamination.
b. If metal particles are found, search the frame further for the source of the debris before restarting.
c. Check all parts for physical distortion, wear, cracks and pitting.
Installation
a. Install bracket (5) to the base with screws (6) and lockwashers (7).
b. Add a clean element (19) and new O-ring (20) to the filter housing (18)
d. Install the oil filter head (4) onto bracket (5) with screws (6) and lockwashers (7).
f. Install the reducing tee (1) and close nipple (3). Loctite grade 515 is
the required seal-
ant for the oil
g. Install the reducer bushing (2) to the reducing tee. header flange. The
correct application to mat-
ing surfaces as described
h. Apply sealant to the oil header flange (14), and install the oil header flange in the manufacturer’s
with screws (15) and lockwashers (7). directions is essential to
prevent oil leakage.
j. Reconnect
Reconnect the tubing
tubing to the reducer
reducer bushing
bushing (2).
Hand Pump
components*
Figure7-27 Hand pump & components
The hand pump is a manually operated
pump (Figure 7-27). It provides priming
and pressurization of the running gear
lubrication system. To assure total
total
lubrication of all frame components, use the
pump before starting the unit and after
shutting down the unit. The following
procedures guide you in removing,
inspecting, and installing the hand pump.
Removal
Cameron Compression Pa g e 7 - 2 3
Inspection
b. Check all parts for physical distortion, wear, cracks, and pitting.
Installation
To reinstall the hand pump, simply reverse the steps for Removal.
See the RAM 52 & 54 frame bills of material for complete parts identification
Removal
Pa g e 7 - 2 4 Cameron
Cameron Compression Superior Compressor Product Group
components con-
nected if you are
d. Remove reducing tee (25), nipple (15) and bushing (24). inspecting the
pump with the strainer in
place.
e. Remove nipple (19), elbow (18), nipple (17), check valve (16), nipple (15),
strainer (11) and nipple (10).
f. Remove nipple (19), elbow (18), nipple (15), threaded tee (21), nipple (23) and bushing (24).
h. Carefully pull pump (2) and gear (4). Leave adapter (9) doweled in place.
Inspection
c. Check all parts for physical distortion, wear, cracks, and pitting.
d. Check sealing surfaces for nicks, burrs, and scratches which may damage seal.
Cameron Compression Pa g e 7 - 2 5
c. Install the pump to the adapter plate (9) with screws (5) and lockwashers (6).
e. Install the pump so that gear (4) meshes with the auxiliary end of the crankshaft. You may have to
twist the pump a little to allow the gears to mesh.
f. Check the gear backlash (see the gear lash measuring procedure below). Compare the reading to
the recommended value in Table 7-1.
g. Reassemble strainer (11), strainer screen (12), bushing (13) and magnetic plug (14).
i. Install threaded tee (21), nipple (15), elbow (18) and nipple (19).
d. Take care to position the flat end of the Figure7-31 Measuring rod & dial indicator
indicator
measuring rod so it rests on the tooth
nearest measuring position 2 (Figure 7-31).
If you think of the pump gear face as a
clock, the flat end of the measuring rod
should rest on a gear tooth nearest the 3
o'clock position.
compressor frame is 2, 1, 4 and 3. Since the oil pump gear on a RAM 52 ter of the oil pump
gear is different
compressor frame is smaller, the correct sequence for measuring backlash is 2, between RAM 52s
1, 4, 3, 2 and 1. The backlash at each position should be 0.0006 to 0.014 inch, & RAM54s. This means
the backlash measuring
with a variation of no greater than .004" .
points are different. Pay
close attention to assure
you take the backlash mea-
surements at the correct
positions for each com-
pressor frame.
i. Repeat adjustments until the backlash readings are 0.006 to 0.010 inch at all You can leave these
change the parts. Repeat the backlash process after parts are replaced. The
readings should be .010 to .014 with a variation of .004.
Section 7: Maintenance 10/18/06
Cameron Compression Pa g e 7 - 2 7
c. Remove locknut (8A), washer (12), and cover (2). Note the orientation of the opening for
reassembly.
d. Remove spindle nut (8) while holding down the spring (5) with your hand. This is to assure the
spring does not fly off spindle (4) when the nut is removed.
e. Remove the spring, upper and lower spring caps (11), retainers (10), valve plate (6), and spindle O-
rings (9) and (9A).
f. Inspect wire screen (3) for any tears or holes. Replace damaged screens since flame may escape
through a damaged during an explosion.
g. Slide a new valve plate (6) over the spindle so the molded rubber seal seats on the carrier.
h. Lightly grease the spindle and slide the large O-ring (9) Figure 7-33 Spindle Seal Installation
and small O-ring (9A) over the spindle ( Figure 7-33).
k. Place the other retainer on the top spring cap. Compress the spring by hand and thread the spindle
nut (8) onto the spindle. Tighten the nut all the way down.
l. Place the cover over the spindle so the opening faces down. Thread the locknut on and tighten so
the cover fits tight against the adapter plate.
m. Clean the mounting surfaces of the frame. Check and repair any A routine service and mainte-
surface irregularities tht may cause the joint to leak. nance program will limit the
extent of damage occu ring to
your equipment in the event of
n. Check door gaskets for breaks or misalignment. Install new cover a crankcase rapid pressure event.
Disc Pack Flexible coupling gives relatively trouble-free service and reasonably long life if installed
and maintained according to the manufacturer's recommendations. The Disc Packing Coupling was
selcted based on known loads and operating conditions of the driver and driven equipment.
You can easily inspect the disc coupling. Visual analysis may point to possible drive system
problems. Proper evaluation of the disc packs and connecting parts may save considerable
maintenance costs and downtime.
The information below describes some of the more evident visual inspection criteria and
recommended corrective procedure.
Cameron Compression Pa g e 7 - 2 9
c. Tighten nuts on cap screws (H) per torque values given in Table 7-2.
d. Torque jackscrew (J) up against the crankshaft per torque values given in Table 7-2.
e. Connect a 10,000 psi hand hydraulic pump to the 3/8" pipe tap (F) in the hub.
f. Operate the hand pump until the hub becomes loose and slides against the lock nut (E).
h. Remove nut (E); the hub can then be lifted off by crane or by hand.
If the proper equipment is not available, the most practical method of removing the coupling hub
from the crankshaft is by first removing the crankshaft from the base. The crankshaft and drive end
cover plate may now be taken to a suitable work area where the locknut is removed, the hub heated
and pressed off the crankshaft.
Install the coupling hub onto the crankshaft
cr ankshaft as follows:
a. When at room temperature, push the hub on the crankshaft taper as far as possible.
b. Push the crankshaft all the way to one side to take up any thrust clearance that may be present.
c. Use gage blocks and shims to fill the space between the coupling and the compressor end cover.
e. Heat the coupling hub and slide it on the shaft until it engages the gage block (with the reduced
amount of shims as defined in item d above).
above).
Pa g e 7 - 3 0 Cameron
Cameron Compression Superior Compressor Product Group
The more attention paid to initial alignment, the larger the reserve margin that will exist for
accomplishing the intended purpose of the coupling. See page 5-4 to 5-5 for the recommended limits.
These limits represent about one-third of the total misalignment capacity of the coupling and are
generally adequate for most installations. It should be kept in mind that there are definite advantages
to be gained from aligning the equipment to more precise values than those shown. The primary
advantage is that the reserve margin for accepting misalignment during the life of the machinery is
thereby increased. Exceeding the Table 5-6 values for alignment will reduce the service life of the
coupling.
Another factor to be considered, and one of the most important to good performance is adherence to
the bolt torquing recommendations Table 5-6. Loose bolts can induce fretting corrosion, hammering,
and pounding which will eventually destroy the bolts and coupling discs.
The Rexnord disc coupling is easily inspected. A visual analysis may point to possible drive system
problems. Proper evaluation of the disc packs and connecting parts may save considerable mainten-
ance costs and down time. Here are some of the more evident visual inspection criteria and recom-
mended corrective procedures. Consult Superior ® or your nearest authorized CES distributor for
further assistance.
Cameron Compression Pa g e 7 - 3 1
O
v
! Caution
Figure 7-41 Torque Overload If bulged or bowed condition
only appears
appear s in one chordal section
s ection there may be a loose
l oose bolt on
one side of the distortion. Loosen coupling locknuts and turn bolt
slightly to
t o remove friction. Bulge
Bu lge should flatt
flatten
en out. Re-torque
locknuts. If distortion does not disappear, replace disc pack.
Pa g e 7 - 3 2 Cameron
Cameron Compression Superior Compressor Product Group
The disc pack has a bulge near the center or is bowed toward one flange in every other chord position
Figure 7-41. This condition is a result of a large torque overload induced into the system above the
peak overload capacity of the coupling. The remaining disc pack chordal sections will be very
straight and tight. Check the driven equipment loading. If not correctable, contact the nearest
authorized CES distributor immediately.
Cylinder Body
A wide range of cylinder sizes is available. Each cylinder is conservatively designed for very low
stress at rated working pressures.
Some cylinder bodies are provided with drilled water passages, top and bottom, which connect the
water inlet and outlet with the cooling muff, which surrounds the ring travel area of the bore.
Whenever the water jacket covers on the cylinder sides are removed to clean out deposits, the drilled
passages should also be cleaned out. If the pipe plugs in the crank end of the drilled passages are
removed, they should be coated with good waterproof sealer and replaced. This will prevent water
seepage into the atmospheric vent space.
Lube oil, from the force feed lubricator tubing system, passes through a check valve and into a fitting
on the outside should be cleaned out and all steel tubing checked for soundness and tightness. This
paragraph does not apply to non-lube operation.
Plugs are provided, on all size of cylinders, which can be removed and indicator cocks inserted to
take pressure readings, if desired.
Cylinder Head
After removing a cylinder head, examine the o-ring which provides a seal
between the cylinder head and the cylinder body for nicks, tears and
compression set. Replace as required. The water seal grommets should also
C A U T I O N
be checked. It is recommended that a complete set of o-rings and grommets, The cylinder head must be
properly indexed on the mount-
for all cylinder sizes used, be kept in stock at all times. ing studs so that the valve cut-
outs in the head align with valve
locations in the cylinder body.
Piston, 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. Some pistons have a through rod and nut while others have a one piece
piston and rod. See Table 7-2 for proper torque values.
Prior to passing
Section 5. the piston rod through the piston rod packing, prepare the rod as described in
Cameron Compression Pa g e 7 - 3 3
The piston end clearances are adjusted as specified in Section 6 and should be checked with the
balance nut torqued to its proper value.
In order to reduce cylinder bore wear, Superior ® designed every piston to operate with rider
compression rings or rider rings. The rider compression rings and rider rings are not collapsible in the
piston groove, thus supporting the piston in the cylinder bore.
In non-lubricated applications, the rider compression rings, rider rings and the piston rod packing will
wear with time. Replacing these elements before they wear beyond allowable limits will contribute to
the successful operation of a non-lubricated cylinder. Contact the CES authorized distributor for wear
limits for your specific cylinder size and application.
application.
Piston rod packing can be divided into two different groups based on packing function -- wiper
packing and pressure packing. ( Figure 7-42 & 7-43). As the piston rod moves through a wiper
packing, oil is stripped off the rod and prevented from migrating in to another part of the compressor.
The purpose of pressure packing is to prevent the loss of gases from the cylinder along the piston rod.
During initial operation, a packing may leak or tend to overheat. This temporary condition occurs
while the packing rings are adjusting to the piston rod and packing case.
Definite lubrication rates and time Figure 7-43 Typical Low Pressure Packing Case
intervals for packing “wear in” are
difficult to prescribe. Experience has
indicated that these factors may vary
widely on different applications. If
there is concern about proper
lubrication rate, contact the nearest
CES authorized
CES authorized distributor.
rings only.set
complete It of
is good practice
packing rings to
onkeep
handa
for the packing assemblies of all your
cylinders.
In order to remove a packing case Figure 7-44 Typical High Pressure Packing Case
from a crosshead guide or cylinder,
the piston rod must be pulled out
through the assembly and cylinder.
Cameron Compression Pa g e 7 - 3 5
Pa g e 7 - 3 6 Cameron
Cameron Compression Superior Compressor Product Group
The packing cups and glands that are not being replaced by new ones must
be soaked and thoroughly cleaned in a non-acid solvent. They should then be
blown dry and examined closely for unusual nicks or burrs which might
C A U T I O N
interfere with the rings free floating or contact with the rod. Particular care As a general guide,
must be taken with rings made of soft metals and it is very important that temperatures not
wiper rings be handled and installed carefully to prevent damage to the tolerated by resting your
scraping edges. hand on the packing case
flange, after the unit is
shut down, indicate to
Before installing new packing assemblies, it is important that the piston rod fast of a wear rate. For a
be carefully checked. If the rod is worn, rough, pitted or has a taper, it must lubricated packing,
be replaced. check to see if the
lubrication rate is set
The bore for the pressure packing nose cup must be cleaned and examined properly per ES1002
per ES1002..
for burrs. If found, burrs should be removed. Also, replace the o-ring in the
outside diameter of the wiper packing flange with a new one.
packing nose
care not to cup. the
damage Remove theClean
groove. old metallic gasket
the groove with a sharp
thoroughly tool; take
and install a
placed
cups inin
thethe packing
same posi-
tion (facing original direction)
new gasket. Tap the gasket into the groove with a hard rubber mallet. Do not as the original set.
use a steel hammer as this may damage the sealing surface of the new
gasket.
After installing the packing cases and before connecting the oil tubing to the packing flange (for
lubricated packing), hand pump the force feed lubricator (when supplied) until oil runs from one of
the disconnected tubes. Connect this tube to the respective hole in the packing flange and continue to
pump the lubricator 12 to 15 more strokes.
After the piston and rod assembly has been reinstalled, the piston end clearance must be set and the
piston rod runout must be checked per Section 5.
Valves
Valve IInstallation
nstallation
Suction and discharge valves must be installed in the proper direction. This can be determined by first
inspecting the valve to see which direction the valve plates move while opening or compressing the
springs. Gas will flow in that same direction ( Figure 7-45).
Valve Replacement
Valve Replacement
Cameron Compression Pa g e 7 - 3 7
a. Loosen bolts or nuts holding valve cap. DO NOT remove completely until after cap is pulled out far
enough to vent any pressure trapped under cap.
b. Remove valve cap, inspect o-ring, place Figure 7-46 Valve Installation
o-ring if defective.
h. Install the retainer on top of the valve. Install new gasket in place on
Before removing
retainer, as applicable. any gas containing
part of the compres-
sor or associated gas pip-
i. Grease or oil the o-ring on the valve cap. Force the valve cap into place by ing system, vent
torquing the nuts or screws evenly to the values listed in Table 7-2.
7-2. compressor and system to
atmospheric pressure.
To replace a valve in a bottom port (assume that this is a discharge port), proceed as follows:
j. Invert retainer.
retainer. Place valve
valve on top of retainer
retainer with valve guard
guard facing out
The valve cap flange
(away from the cylinder). Slip gasket on valve. must not contact the
cylinder body. Clear-
ance must exist at this point to
k. Lift the valve, retainer, and gasket up into the bottom port, making sure that
insure that pressure is applied
the valve seat enters first. to the valve and retainer gas-
kets when the relief cap bolts
l. Tighten the retainer lock screw just enough to hold retainer and other parts or nuts are tightened.
in place.
m. Grease or oil the o ring on the valve cap. Place new gasket in place on valve cap, as applicable.
Force the cap into place by torquing the nuts or screws evenly to the values listed in Table 7-2.
7-2.
Cameron Compression Pa g e 7 - 3 9
abnormal
reset after operation or any or
each shutdown, malfunction which
at least once may
every sixoccur.
monthsEach device should
- whichever be checked
is sooner, and
to assure that
they are operative. All questionable devices should be replaced.
Several safety devices may be employed on compressor units. The most common ones and their
recommended set points are listed in Table 7-48. Questions regarding these and other devices and
their set points may be referred to the CES
CES distributor.
distributor.
Table 7-48 Recommended Alarm Set point
Alarm/Shut down Norma l Condition Al a r m P o i n t Shutdown Point
Oil Pressure in H
He
eader 45-55 psig (310-380 kPag) 25 psig (173 k
kP
Pag) 20 ps
psig ((1
138 kPag)
the Frame
Vibration Nominal 1/4-3/8 turn from normal 3/8 - 1/2 turn from normal
condition condition
Gas T
Te
emperature Suction ((T
TS) or
or D
Diischarge 20 F (11 C) above TS or
° ° 25 F (14 C) above TS or
° °
(TD) TD TD
Tin Tin
Troubleshooting
Troubleshooting is the process of finding operational problems. This section describes the difficulties
which may arise during operation of a compressor, the typical origins or sources of these problems
and suggestions on how to repair the trouble. The following steps should be followed in all
troubleshooting activities:
a. Determine what general area is affected - frame, cylinders, lubricating system, etc.
d. Return the unit to service and verify that normal operation is resumed.
Tables 7-50 through 7-54 list many typical symptoms, causes and corrective measures. It may be
necessary to refer to more than one symptom to locate the entire difficulty. The suggested corrective
actions are supposed to direct you to those areas most likely to be at fault. However, do not limit
your analysis only to those areas found in the table. If symptoms persist, contact your nearest CES
CES
distributor for possible field assistance.
Table 7-50 Compressor Frame Troubleshooting
Symptom Possible Cause Potential Damage Corrective Measure
Compressor Mechanical Seized crosshead, rods, main Replace all defective parts. Check compressor for proper
will not turn
seizure of bearings. crankshaft alignment, piston rod runout, and lube oil
over compressor. system operation.
Tripped Defectiv
Defective
e shut
shutdow
down
n devi
device.
ce. Che
Check
ck tthe
he co
contr
ntrol
ol s
syst
ystem
em and devi
device
ce ffor
or p
prop
roper
er o
oper
perati
ation.
on.
shutdown
device.
Foreign material Cylinder scoring, valve Replace damaged parts and take measures to prevent
(water, non-lube damage, possible bent piston future foreign material entrapment in the compressor
packing, etc.) in or connecting rods. cylinders.
cylinders.
Improper piston- Possible piston or rod damage. Replace any damaged parts and properly set
set the piston-
to-cylinder end to-cylinder end clearances.
clearance.
Compressor Opposing Foundation cracking, weld Total weight of crosshead, balance nuts, piston rods,
vibration cylinders are out cracking, or foundation bolt connecting rods, and rings must be within 3 lbs. (1.4 kg) of
of balance. failure. same components on opposite throw. Replace balance b alance
nuts or crossheads to obtain
o btain this balance.
Worn
Worn bea
bearin
rings.
gs. Possibl
Possiblee bro
broken
ken frame,
frame, Verify crankshaft alignment, piston rod runout, and
connecting rods, crankshaft, or bearing clearances. Replace bearings as needed.
piston rods. Reverify alignment and runout.
Improper Foundation damage, Realign the compressor per Section 5.
compressor foundation bolt failure, grout
installation and cracking, or broken frame and
alignment. crankshaft.
Gas
Gas pul
pulsat
satio
ion.
n. Exc
Exces
essi
sive
ve vi
vibra
brati
tion
on caus
causing
ing Analyze compressor with a vibration or indicator analyzer.
cracked welds, foundations, Install orifices at the cylinder flange, change piping,
grout, and parts. Also possible change cylinder operating configuration, or change
foundation bolt breakage. operating speed.
Lo
Loos
ose
e va
valv
lves
es.. Va
Valv
lve
e se
seat
at d
dam
amag
age,
e, bro
broke
ken
n Remove valve and retainer. Replace broken parts. Dye
valve bodies, or broken valve check the cylinder valve seat for cracks.
crack s. Install new valves
retainers. and tighten to proper torque.
Pa g e 7 - 4 2 Cameron
Cameron Compression Superior Compressor Product Group
Table 7-52
7-52 Cylinder Are
Area
aTTroubleshooting
roubleshooting
S y mp t o m Possible Cause Potential Damage Corrective Measure
Fa
Fail
ilur
uree tto
oddel
eliv
iver
er ga
gass Re
Reststri
rict
cted
ed Clogged suction screens Clean suction line and screen, if
suction line or dirty.
filter screens
Defective or Cylinder damage through broken valve parts Replace defective plates, springs,
missing valves in the cylinder bore. High or low discharge
di scharge or any other worn, broken, and
pressure between stages with insufficient rod defective parts.
reversal, resulting in pin failure
Deposits on Possible
Possible bbrok
roken
en plate
plate valves
valves or spr
spring
ings.
s. Cle
Clean
an a
and
nd rep
replac
lace
ea any
ny def
defect
ective
ive
valves valve parts. Review type and
quantity of lube oil used.
Open or Possible insufficiencies on rod load reversal If open, load compressor. If
defective and head mechanism damage damaged, replace defective parts.
clearance pocket
Defective piston High discharge temperatures Replace rings
rings
Low compressor cylinder Worn piston Piston, ring, and bor
oree ove
overh
rhe
eat in
ing Replace
ace with new ring
ings
discharge pressure rings
Defective or Insufficient rod load reversal. This can cause Replace plates, springs, or any
missing valves damage to the crankshaft from excessive other worn, broken or missing
heating, seizure of the crosshead pin, as well
we ll parts
as damage to the piston rods, crossheads,
cr ossheads,
crosshead guides, and connecting rods.
Collateral damage from broken parts
entering the cylinder bore
Cameron Compression Pa g e 7 - 4 3
Worn
rings. piston Pist
Piston
on,, ring
rings
s, and bore
ore ov
overh
rhea
eatting
ing. Repl
eplace rirings.
gs.
Restricted Clogged suction screens. Clean suction line and screen, if
suction line or dirty. Replace screen if damaged.
filter screens.
Defective or Insufficient rod load reversal.
reversal. This can cause Replace plates, springs, or other
missing valves. damage to the crankshaft from excessive worn or broken parts.
heating, seizure of the crosshead pin, as well
as damage to the piston rods, crossheads,
cr ossheads,
crosshead guides, and connecting rods.
Collateral damage from broken parts
entering the cylinder bore.
Open or Same as above. Replace defective parts.
defective fixed/
variable pocket
head.
Suction valve in Same as above. Properly install valves. Replace
discharge or any damaged parts.
discharge valve
in suction.
If all valves are reversed, excessive pressure can build
DANGER up resulting in cylinder failure and injury.
Loose
Loose valves
valves.. Same as ababove.
ove. Possible
Possible dama
damage ge to valve
valve Remove valve and retainer.
seat, valve bodies or retainers. Replace any broken parts. Dye
check the cylinder valve seat.
High interstage
interstage pre
pressure
ssure Improp
Improper
er Rod load exceeding the design M.W.P. of o f the Reduce variable volume pocket
settings of lower stage cylinder that results in piston, setting or close the fixed volume
clearance rod, crosshead, or crankshaft damage pocket on the higher stage until
pockets on the the interstage pressure decreases
higher stage to an acceptable level
heads
Missing or Same as above Repair or replace the suction
defective suction valves in the higher stage cylinder
valve(s) on the
higher stage.
Worn piston Same as above Replace with new rings
rings in the
er stage high-
cylinder
Defective relief Same as above Repair or replace defective valve
valve parts
Pa g e 7 - 4 4 Cameron
Cameron Compression Superior Compressor Product Group
Cameron Compression Pa g e 7 - 4 5
Table 7-53
7-53 Troubleshooting Abnormal Noises (Continued)
Symptom Possible Cause Potential Damage Corrective Measure
Knock in cylinder area Loose cy
cyllinde
nder h
he
ead.
ad. Damage t o gaske
kett seal s
su
urf
rfa
ace Tigh
ighten h
he
ead.
(continued)
Loose variable volume pocket Damage to gasket
gasket seal surface.
surface. Tighten variable volume pocket.
unloader.
Whine in auxiliary end Worn, broken, or chipped gear Gear damage. Replace gear.
gear teeth.
Improper backlash setting. Gear damage. Reset gear lash.
Cameron Compression Pa g e 7 - 4 7
Pa g e 7 - 4 8 Cameron Compression Superior Compressor Product Group
Section 10
Ordering Parts
This section provides directions for ordering parts to aid in the assembly of various sections of
the compressor.
The right is reserved to change the construction or material of any part without incurring the
obligation of installing such changes on units already delivered.
Broken or damaged goods should be refused. All items leaving the factory are sound, so any
damage incurred has been the result of shipping. Make a complete description of the damage
on the freight bill. If this is done, full damage costs can generally be collected from the
transportation company.
Service
Replacement Parts
Cameron Compression Systems maintains a multi-million dollar inventory of genuine
Superior ® replacement parts at reasonable prices. These parts are designed and engineered
specifically for your Superior ® power equipment and are recommended to keep your
equipment operating within design parameters. CCS part
part distribution center makes parts
available 24 hours a day, seven days a week.
item. Description is the name of the part Qty refers to the total Proper length
length of
number of that part in the assembly/module above it. The UOM studs and bolts
bolts is
refers to the "unit of measure" of the specific part. A module is listed important for
followed by its component parts. . proper thread
thread
•A module is an assemblage of parts that combine to form a specific engagement.
component of the machine. Module number, description, and quan- Before removing
removing
tity are highlighted above the list of parts itemized below it. any studs,
studs, mea-
•Multiple modules may be shown on a single illustration. sure stud height
height
•If a detail part is in turn an assembly, its detail parts will be listed fol- from machined
machined
lowing it, and will be index numbered numerically, alphabetically, surface and
and posi-
and (if necessary) again numerically (e.g., 1a1, 1a2, 1a3). tion replacement
replacement
stud to same
•
height.
Connecting Rod Assembly
Some parts that make up an assembly cannot be purchased by themselves. An example of this is the
Crankshaft. The crankshaft can
can be purchased through the Crankshaft
Crankshaft Assembly part number. Other
parts can be purchased individually, but for convenience it may be easier to purchase the subassembly.
United States
Casper, Wyoming PHONE:(307) 265 - 7653
CAMERON COMPRESSION SYSTEMS FAX:(307)
FAX:(307) 266 - 6847
1950 North Loop Ave.
Casper, Wy 82601
Alice, TX 78332
Houston, Texas PHONE:(713) 354 - 1900
CAME
CA MERORONN CO
COMP
MPRE
RESSSI
SION
ON SYST
SYSTEM
EMS
S FAX:
FAX: (713
(713)) 354
354 - 1923
1923
16250 Port Northwest
Houston, TX 77041
International Locations
Brazil
Sao Paulo, BRAZIL Phone: 55-1
Phone: 55-11-32
1-3284-1
84-1164
164
Cameron Compression Systems Fax: 55-11-3284-3874
Alameda Santos, 455
Conj. 212 - Paraiso
CEP: 01419-000
CSao Paulo, Brazil
China
Beijing, CHINA Phone: 86 - 10
10 - 82255700
82255700
Cameron Compression Systems Int’l. Fax: 86 - 10 - 82255711
Tower A, Room 1701-17031590, 540 5th Avenue S.W.
Chengjian Plaza
No. 18 Beitaipingzhuang
Haidian District
Beijing, 100088, China
Italy
Milan, ITALY Phone: 44-20-8990-1901
44-20-8990-1901
Cameron Compression Sy
Systems Fax: 44-20-8990-1911
Viale Brianza 20
20092 Cinisello Balsamo (MI)
Italy
Mexico
Mexico City, MEXICO Phone: 5255 - 5395- 1114
Cameron Compression Systems Int’l.
Homero 1804 Deso. 403 Fax: 5255 - 5395 - 4162
Col. Chapultepec Morales
Deleg. Miguel Hidalgo
11050
MexicoMexico,
City D.F.
Singapore
SINGAPORE Phone: 65 - 6863 - 3631
Phone: 3631
Cameron Compression Sy
Systems In
Int’l. Fax: 65 - 626267 - 6460
14 Benoi Crescent
Singapore 629977
United Kingdom
Liverpool, ENGLAND Phone: 44(0) 1695
1695 - 575760
575760
Cameron Compression Systems U.K. Fax: 44(0) 1695 - 574974
The Malthouse Business Centre
48 Southport Road
ORMSKIRK
Lancashire L39 1QR
United Kingdom
Venezuela
Anaco, VENEZUELA Phone: 58 - 282
282 - 4246615
4246615
Came
Cameron
ron Compr
Compress
ession
ion System
Systemss de Venez
Venezuel
uela,
a, S
S.A
.A Fax:
Fax: 58 - 282
282 - 422265
4222659
9
Carretera Negra, KM. 97
Apartado No. 12
Anaco, Estado Anzoategui, Venezuela
Section 10: Introduction to Servicing the RAM Series Compressor 10/16/06
Pa g e 1 0 - 6 Cameron Compression Systems Superior Compressors
R A M Se
Se rie s C om p re ssor Fr
Fra m e Instr
Instruc
uc tion M a nua l
The vendor bulletins immediately following are included for the convenience
of our customer to provide service instructions and design detail for the vari-
ous accessory items supplied on the contract.
contract. In some instance
instances,
s, information
is provided for more than one vendor.
Accessory
covered byparts ordered warranty.
the standard through aftermarket are inspectedCANNOT
RESPONSIBILITY and testedBE
andAS-
are
SUMED FOR SATISFACTORY OPERATION OF PARTS PUR-
CHASED ELSEWHERE.
Section 11: Auxilary Equipment 10/12/06
C A U T I O N
Proper length
length of
studs and bolts
bolts is
important for
proper thread
thread
engagement.
Before removing
removing
any studs, mea-
mea-
sure stud height
height
from machined
machined
surface and
and posi-
tion replacement
replacement
stud to same
height.
Section 8: Frame "as Built" Bill of Materials and Illustrations RAM-10/18/06
VENT FILL PLUG 1. REMOVE VENT/FILL PLUG. PART NO. QTY SPARE PARTS AVAILABLE FROM CAMERON ITE
ITEM
M P A RT NO. QTY DE SCRIP TION OF P A RTS S HOWN ON S K ETCH
2. LOOSEN UPPER PLUG. RESERVOIR SIZE: 4 PINT
LUBRICATOR
3. FILL WITH EXXON TK-680 CYLESSTIC 904-462-001 1 PUMP, 1/4" PLUNGER 1 620-159-001 1 LUBRIC
RICA
A TIO
ONN CY CLE TIME
BOXFILL DRIVE TYPE: L.H. GEAR HD
WORM GEAR OIL UNTIL OIL STARTS TO
LEAK AT UPPER PLUG. 62
25
5 --6
6 04
04 --0
0 01
01 1 O-RING KIT (9EA) 2 9 04
04 -4 59
59 -0
-0 00 1 P -5
-5 5 L UB
UB RI CA
CA T
TO
OR
G EA
EA R R A
AT
T I O: 40: 1
4. TIGHTEN PLUG, REPLACE VENT/FILL
PLUG. 625-603-005 1 RUPTURE DISC KIT (25PCS, 2050-PSI) 3 9 04
04 --4
4 62
62 --0
0 01
01 1 PUMP, 1/4" PLUNGER
CAM QUANTITY: 5
5. NEW UNITS NORMALLY ARE PROVIDED
626
626-- 551-
551- 001 3 3 S E CTIO
TION
N B A SE P LATE 4 625-602-005 1 RUPTURE INDICATOR, 2050-PSI
FILLED WITH THE CORRECT OIL AND THE
VENT FILL PLUG WIRED TO THE
626
626-- 552-
552- 008 1 HP -24S
2 4S M ETE
ETE RING E LEM E NT 5 6 26
26 -0 69
69 -0
-0 01 1 P UR GE P O
OR
R T C HE CK V AL
AL VE
LUBRICATOR BOX LOOSE. THE SHIPPING
PLUG SHOULD BE REMOVED AND THE 9
50
02
2 18
18 99
99 4 2 H P-
P- 15
15 S M ET E
ER
R IN
IN G E LE
LE M
ME
E NT
NT 6 626-068-001 1 ELBOW
VENT FILL PLUG INSTALLED BEFORE
PUTTING THE UNIT INTO SERVICE. 50218996 2 HP-15T METERING ELEMENT 7 911-997-001 1 MA NI F
FO
O LD
6. FILL LUBRICATOR BOX PER 10
DRAIN PLUG OPERATING INSTRUCTIONS. 626
626-- 552-
552- 007 1 HP -12T M E TE RIN
NGG E LEM E NT 8 620-209-001 1 FILTER, 10-MICRON
UPPER PLUG
626
626-- 552-
552- 004 4 HP -09T M E TE RIN
NGG E LEM E NT 9 5023 6348 1 DNFT-PRG, DIGITAL NO-FLOW TIMER
626
626-- 553-
553- 002 1 CROS S PORT B A R RIGHT 10 1 MASTER DV BLOCK HP-3 (24S-15S-15S)
13 626-
626- 555- 001
001 14 CHECK V A LV E W/ INT
INTE
E GRA L TUBE
TUBE FIT
FITTIN
TING
G
8 7 6 5 15 16 6 25
25 -9 99
99 -0
-0 01 1 P RE
RE SS UR E R EG
EG UL AT O
OR
R
12 12
20
00 2 1 S EC
EC ON
ON DS 15 SE
EC
C ON
ON D
DS
S 4
11
NOTES:
7.00" CYL, THROW #2 7.00" CYL, THROW #4 1. COMPRESSOR APPLICATION MAY REQUIRE MORE OR LESS THAN
CALCULATED FEED RATES, PERIODIC VISUAL INSPECTION OF
7.00" CYL, THROW #2 7.00" CYL, THROW #4 CYLINDER BORES & PISTON RODS DURING THE FIRST FEW WEEKS
AFTER THE BREAK-IN I S RECOMMENDED TO ENSURE THAT
LUBRICATION IS ADEQUATE. PUMP LUBE RATE MAY BE ADJUSTED UP
PACKING, THROW #2 PACKING, THROW #4
AND DOWN TO OBTAIN PROPER LUBRICATION OF SURFACES.
2. REMOVE DIVIDER BLOCKS EVERY 6 MONTHS AND PRESSURE TEST.
3. TO INSURE FLOW OF LUBRICATION TO THE CYLINDER BORES &
PACKINGS, THE CYLINDER LUBE SYSTEM MUST BE PROPERLY
13 PURGED AND PRIMED AT THE FOLLOWING EVENTS:
A) BEFORE INITIAL STARTUP.
B) AFTER EXTENDED SHUTDOWN.
14 C) AFTER CYLINDER LUBE SYSTEM SHUTDOWN OR BLOWN RUPTURE
DISC.
2 1 16 D) AFTER PERFORMING ANY LUBE SYSTEM MAINTENANCE.
4. CONTINUED RUPTURE DISC FAILURES INDICATE THAT:
A) THE LUBE SYSTEM IS NOT PROPERLY PURGED AND PRIMED.
B) THE LUBE SUPPLY TO THE LUBRICATOR HAS BE INTERRUPTED
CAUSING SYSTEM TO LOSE PRIME DUE TO INTRODUCTION OF AIR INTO
THE SYSTEM.
C) DEBRIS IN THE DIVIDER BLOCKS, PREVENTING THEIR OPERATION.
9.50" CYL, THROW #3 9.50" CYL, THROW #1
D) PLUGGED FILTER.
5. DO NOT, IN ANY EVENT, DOUBLE THE RUPTURE DISCS OR
9.50" CYL, THROW #3 9.50" CYL, THROW #1 OTHERWISE PLUG THE SYSTEM. IF, AFTER PERFORMING THE PROPER
MAINTENANCE RUPTURE DISC BLOWING IS STILL PROBLEMATIC,
CONTACT A SERVICE REPRESENTATIVE FOR A HIGHER PRESSURE
PACKING, THROW #3 PACKING, THROW #1
RUPTURE DISC.
TH
HR
ROOW
W C YL
YL S IZ
IZ E PA
AC
C KI
KI NG
NG C YL
YL T OP
OP CY
YL
L BT
TM
M 6. FOR DNFT: VIOLET WIRES (2) MUST BE ISOLATED FROM GROUND OR
CONTACT WITH ALL OTHER WIRING. FOR "NORMALLY CLOSED SWITCH"
1 9.50" 1.14 1.42 1.42
(SWITCH IS OPEN WHEN COMPRESSOR IS RUNNING) ISOLATE YELLOW
2 7.00" 1.14 1.14 1.14 WIRES FROM CONTACT. FOR "NORMALLY OPEN SWITCH" (SWITCH IS
CLOSED WHEN COMPRESSOR IS RUNNING), CONNECT THE WIRES.
3 9.50" 1.14 1.42 1.42 7. USE 1/4" OD X .065" WALL THICKNESS STAINLESS STEEL HIGH
PRESSURE TUBING ONLY (SUPERIOR P/N 04TU070240).
4 7.00" 1.14 1.14 1.14
OIL REQUIREMENT
CUSTOMER: BY D A TE
LUBRICATION SYSTEM FOR
50245895
ISO 150 SHANDONG KERUI
(MINIMUM VISCOSITY) DWN OS 05/13/13 DRAWING NUMBER
RAM 54 COMPRESSOR
CKD SS 05/20/13
NOTE: DO NOT TAKE PUMP SETTINGS ON FAITH - CHECK
OIL CONSUMPTION
LSB-13R1158
RLSD TLD 05/20/13
Compressor Plant
BALANCE DATA SHEET
CYL S/N 5A13C1161 CYL DIA 7.0" CYL S/N 5A13C1159 CYL DIA 9.5"
2 1
CASTING S/N 773B CYL CLASS C15C # # CASTING S/N 451C CYL CLASS C15E
2 1
# CONN ROD W T. 61.20 W W CONN ROD W T. 60.60 #
O O
W PISTON RINGS AND ROD ASSY. W T: 111.40 R R PISTON RINGS AND ROD ASSY. W T: 96.80 W
O CROSS HEAD W T: 56.60 H H CROSS HEAD W T: 56.20 O
R T T R
H BAL. NUT P/N & W T: BAL. NUT P/N & W T: 15.00 H
T 2-600-020-002, 2-600-020-001 T
TOTAL W T: 229.20 IMBALANCE TOTAL W T: 228.60
0.60
CYL S/N 5A13C1162 CYL DIA 7.0" CYL S/N 5A13C1160 CYL DIA 9.5"
4 3
CASTING S/N 747B # # CASTING S/N
CYL CLASS C15C 481C CYL CLASS C15E
4 3
#
CONN ROD W T. 58.80 W W CONN ROD W T. 58.60 #
W PISTON RINGS AND ROD ASSY. W T: 111.30 O O
R R PISTON RINGS AND ROD ASSY. W T: 96.80 W
O CROSS HEAD W T: 57.20 H H CR O S S HEAD W T: 56.80 O
R T T R
H BAL. NUT P/N & W T: BAL. NUT P/N & W T: 14.95 H
T 2-600-020-001, 2-600-020-002 T
TOTAL W T: 227.30 IMBALANCE TOTAL W T: 227.15
0.15
C A U T I O N
Proper length
length of
studs and bolts
bolts is
important for
proper thread
thread
engagement.
Before removing
removing
any studs, mea-
mea-
sure stud height
height
from machined
machined
surface and
and posi-
tion replacement
replacement
stud to same
height.
Shando ng Kerui-NIS
Keru i-NIS a.d. -Model: 410KC - Class: C15E - SN's: SN's: 13C1159-
13C1159-60-
60- SAP
SAP#
# 2582361
2582361
Note: Quanities are per Cylind er
Dr aw i n g It em Mat er i al Mat er i al Des c r i p t i o n Qt y UOM
YC-600-496 Z600-496-602 VALVE COMPR SUCT 1 EA
. 1 Z757-831-075 SUCTION SEAT 1 EA
E
.
C
2 Z758-134-389 SUCTION GUARD ASSY INCLUDES ITEM 3 1 EA
& 3 Z757-135-001 LOCATING PIN 2 EA
.
E
. 4 Z757-136-008 12 POINTCAPSCREW 7/16-20UNF 1 EA
EA
H 5 Z757-828-123 VALVE PLATE 1 EA
N
O 6 Z753-138-001 W AFER SPRING 1 EA
I
T 7 Z757-832-078 GUIDE RING 1 EA
C
U 8 Z757-833-008 CLOSING SPRINGS 28 EA
S
9 Z758-145-002 THREADED W ASHER 1" - 8UNC 1 E
EAA
YC-600-497 Z600-497-605 VALVE COMP DISCH 1 EA
E
. 1 Z757-831-073 DISCHARGE SEAT 1 EA
C
& 2 Z758-134-394 DISCHARGE GUARD ASSY INCLUDES IT. 3 1 EA
.
E 3 Z757-135-001 LOCATING PIN 2 EA
.
H 4 Z757-136-012 12 POINTCAPSCREW 7/16-20UNF 1 EA
E 5 Z757-828-123 VALVE PLATE 1 EA
G
R 6 Z753-138-001 W AFER SPRING 1 EA
A
H 7 Z757-832-078 GUIDE RING 1 EA
C
S
I 8 Z757-833-003 CLOSING SPRINGS 28 EA
D 9 Z758-145-002
Z7 THREADED W ASHER 1" - 8UNC 1 E
EAA
C15 E 000 0 ZC15E COMA 0000 COMMON PARTS 1 EA
2 Z937-206-006 NUT 4 EA
3 Z01CS1420PC BOLT HEX HEAD 4 EA
4 Z900-835-071 SEAL O RING 1 EA
5 Z914-175-001 NAMEPLATE 1 EA
6 Z620-154-005 NAMEPLATE 1 EA
7 Z01VS0604C0 SCREW DRIVE 8 EA
22 Z01CS1426PC BOLT HEX HEAD 10 EA
23 Z900-838-037 SEAL O RING 1 EA
33 Z900-838-001 SEAL O RING 1 EA
43 Z620-174-001 NUT 1 EA
46 Z600-126 NUT JAM 1 EA
62 Z04TU070240 1 TUBING STAINLESS 2 FT
63 Z061-369-009 CONNECTOR - MALE NPT 2 EA
64 Z922-084 VALVE CHECK 2 EA
65 Z061-538-002 ELBOW - STREET, NPT 2 EA
66 Z061-638-002 BUSHING - REDUCING 2 EA
67 Z06TU070240 1 TUBING STAINLESS 1 FT
68 Z061-397-023 ELBOW - M TUBING 2 EA
69 Z061-397-010 ELBOW - M TUBING 1 EA
88 Z620-173-001 W ASHER 1 EA
Z631-300-012 KIT - SHIPPING COVER 1 EA
ZC15E-T01A-0950 CYLINDER BODY 1 EA
1 Z600-207-007 CYLINDER COMPRESSOR 1 EA
55 Z01CS1426PC BOLT HEX HEAD 8 EA
55 Z01CS1426PC BOLT HEX HEAD 8 EA
Shando ng Kerui-NIS
Keru i-NIS a.d. -Model: 410KC - Class: C15E - SN's: SN's: 13C1159-
13C1159-60-
60- SAP
SAP#
# 2582361
2582361
Note: Quanities are per Cylind er
Dr aw i n g It em Mat er i al Mat er i al Des c r i p t i o n Qt y UOM
ZC15E-T02A-0950 HEAD END HEAD - VV POCKET 1 EA
21 Z600-206-003 HEAD COMPRESSOR 1 EA
24 Z600-128-024 PISTON/ROD ADJ CLEAR 1 EA
25 Z600-077-007 RING COMPN 1 EA
26 Z900-838-029 SEAL O RING 1 EA
27 Z926-404-001 RING BACK UP 2 EA
28 Z01EN1600PF NUT PLAIN HEX 1 EA
2 9 .1 Z
ZBBM-10046 FITTING GREASE 1 EA
30 Z
Z9902-042 HANDLE 1 EA
31 Z904-463-002 NUT 1 EA
32 Z0 6 W K 1 4 0 0 1 1 KEY W OODRUFF 1 EA
34 Z01PP0200SP PLUG PIPE 1 EA
ZC15E-T03A-0950 CAST IRON PISTON / CFT RINGS 1 EA
40 Z620-176-001 PISTON END 2 EA
44 Z903-118-050 RING COMPN 3 EA
48 Z620-172-002 W ASHER 1 EA
89 Z620-189-002 CARRIER RING 1 EA
ZC15E-T04A-0000 PISTON ROD - STANDARD LENGTH 1 EA
49 Z600-469-011 ROD COMPR PSTN 1 EA
ZC15E-T05A-0000 RETAINER/CAP/GSKTS-SUCTION 2 EA
51 Z9 0 9 9 8 1 1 9 9 GASKET FLAT RD 2 EA
51 Z909-981-199 GASKET FLAT RD 2 EA
52 Z600-079-001 RETAINER VALVE 2 EA
53 Z600-173-001 CAP COMPR VLV 2 EA
SUPPLIED BY
PACKAGER
49 D
44
46 3 2
B 45
88
40 E
E
89
40 47
7
SEE ASS EMBL
EMBLY
Y
4
BREAKDOWN
E
CRANK-END
55
6 1
E
48 32 24
C 53
43
25
26
23 27
54
REPLACE ZERK GREASE 21
FITTING WITH PIPE PLUG HEAD-END
58
BEFORE OPERATING THE
A
COMPRESSOR D
29 52
E
56 57
30
31 DISCHARGE
ONLY
33
34
22 51
Section 10
Ordering Parts
This section provides directions for ordering parts to aid in the assembly of various sections of
the compressor.
The right is reserved to change the construction or material of any part without incurring the
obligation of installing such changes on units already delivered.
Broken or damaged goods should be refused. All items leaving the factory are sound, so any
damage incurred
on the freight bill.has
If been
this isthe result
done, ofdamage
full shipping. Make
costs canagenerally
completebe
description of thethe
collected from damage
transportation company.
Service
Cameron Compression Systems maintains a large staff of qualified service representatives and
mechanics that are familiar with your equipment and will be able to handle any problems that
may arise. Field Service, diagnostic equipment, tools, and engineering support are available
to assist you upon request. Field service rates are highly competitive; contact the nearest CCS
Aftermarket facility for further details.
Replacement Parts
Cameron Compression Systems maintains a multi-million dollar inventory of genuine
Superior ® replacement parts at reasonable prices. These parts are designed and engineered
specifically for your Superior ® power equipment and are recommended to keep your
equipment operating within design parameters. CCS part
part distribution center makes parts
available 24 hours a day, seven days a week.
are does
list installed, CCS cannot
cannot guarantee the furnishing of correct parts. Be aware that this parts
not include any subsequent parts supplied by the packaging agent of the equipment.
item. Description is the name of the part Qty refers to the total Proper length
length of
number of that part in the assembly/module above it. The UOM studs and bolts
bolts is
refers to the "unit of measure" of the specific part. A module is listed important for
followed by its component parts. . proper thread
thread
•A module is an assemblage of parts that combine to form a specific engagement.
component of the machine. Module number, description, and quan- Before removing
removing
tity are highlighted above the list of parts itemized below it. any studs,
studs, mea-
•Multiple modules may be shown on a single illustration. sure stud height
height
•If a detail part is in turn an assembly, its detail parts will be listed fol- from machined
machined
lowing it, and will be index numbered numerically, alphabetically, surface and
and posi-
and (if necessary) again numerically (e.g., 1a1, 1a2, 1a3). tion replacement
replacement
stud to same
•
height.
Connecting Rod Assembly
In the parts list example, there are 6 Connecting Rod Assemblies (Item Number 1) within the
compressor. There are 4 Conn Rod Bolts (Item Number 1a) to each Connecting Rod Assembly.
Therefore, there are four conn rod bolts to a connecting rod; the total number of conn rod bolts forthe
compressor is 24 (4 per conn rod x 6 conn rods).
Some parts that make up an assembly cannot be purchased by themselves. An example of this is the
Crankshaft. The crankshaft can
can be purchased through the Crankshaft
Crankshaft Assembly part number. Other
parts can be purchased individually, but for convenience it may be easier to purchase the subassembly.
International Locations
Brazil
Sao Paulo, BRAZIL Phone: 55-1
Phone: 55-11-32
1-3284-1
84-1164
164
Cameron Compression Systems Fax: 55-11-3284-3874
Alameda Santos, 455
Conj. 212 - Paraiso
CEP: 01419-000
CSao Paulo, Brazil
China
Beijing, CHINA Phone: 86 - 10
10 - 82255700
82255700
Cameron Compression Systems Int’l. Fax: 86 - 10 - 82255711
Tower A, Room 1701-17031590, 540 5th Avenue S.W.
Chengjian Plaza
No. 18 Beitaipingzhuang
Haidian District
Beijing, 100088, China
Italy
Milan, ITALY Phone: 44-20-8990-1901
44-20-8990-1901
Cameron Compression SySystems Fax: 44-20-8990-1911
Viale Brianza 20
20092 Cinisello Balsamo (MI)
Italy
Mexico
Mexico City, MEXICO Phone: 5255 - 5395- 1114
Cameron Compression Systems Int’l.
Homero 1804 Deso. 403 Fax: 5255 - 5395 - 4162
Col. Chapultepec Morales
Deleg. Miguel Hidalgo
11050 Mexico, D.F.
Mexico City
R A M Se
Se rie s C om p re ssor Fr
Fra m e Instr
Instruc
uc tion M a nua l
The vendor bulletins immediately following are included for the convenience
of our customer to provide service instructions and design detail for the vari-
ous accessory items supplied on the contract.
contract. In some instance
instances,
s, information
is provided for more than one vendor.
WHITLOCK
HITLO Kw
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PRG-GeneralPurpose
e
WHITLOCK INSTRUMENT 2
2
1
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1300 N. Texas
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INSTRUMENT
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U.S. PAT. NO. 5,835,372 1.800.337.3412 www.noflo.com ODESSA, TX USA
DNFT-PRG
SPECIFICATIONS
Material......................................Stainless Steel, Aluminum
0 0
DIGITAL NO-FLOW TIMER WHITLOCK
HITLO Kw
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2
1
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Temperature Range.... ........
.........
.........
........
.........
.........
.... -40 F to +185 F
w
Switch Rating............
.........................
...........................
..................2.5VA/240
....2.5VA/240 VDC
4
4
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U.S. PAT. NO. 5,835,372 3
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002196 o
Factory Sealed
MODEL PRG
RG Power ...........................
.............................Field
..Field Replaceable Lithium Battery
R II 2G EEx md IIC T5 CE RATED 2.5VA/240VDC
5VA 240VDC
Cl I; Zone 1; Ex md IIC T4
Alarm/Shutdown.............
C US P/N
186200 Cl I; Div 1; Grps. A,B,C,D;T4 0344
SERIAL # ....................Programmable
.......Programmable - 20 sec to
KEMA 00ATEX1090 X Amb. -40° C...+80°C
Warning: Do not open when an explosive gas ALARM P RR OO GG RR A M
MMM A B LL EE
4 min 15 sec alarm
atmosphere is present.
ORANGE-SWITCH
ORANGE-SWITCH GRN-GND. VIO - OPEN - N.O.
N.O. VIO - SHORT -N.C. Battery............
..........................
...........................
..........................
......................P/N000505
.........P/N000505
DNFT-PRG Divider Block Application.........SB/Lubriquip/Lincoln/
Dropsa
Warranty.............................................................2.5 Years
MONITORS MOVEMENT OF DIVIDER
VALVE PISTON FOR DEPEN DABLE
"TI M ED" SH U TDO W N PRO TECTI O N RATINGS
CLOSED LOOP OR OPEN LOOP OPERATIO N II 2G EEx md IIC T5
CE
R
C US
Cl I; Zone 1; Ex md IIC T4
186200 Cl I; Div 1; Grps. A,B,C,D;T4 0344
INSTALLS DIRECTLY TO DIVIDER VALVE
KEMA 00ATEX1090
00ATEX1090 X Amb. -40° C...+80°C
NOT AFFE CTE D BY TEMPE RATU RE OR OIL
VI SCO SI TY
DESCRIPTION
REQUIRES NO EXTERNAL POWER The DNFT-PRG is a totally enclosed electronic device, combining
the latest technology in microprocessor and transistor components
for detecting Slow-Flow and No-Flow of divider block lubrication
FIELD REPLACEA BLE BATTERY
systems. The DNFT incorporates an oscillating crystal to
accurately monitor
monitor the cycle time of the lubrication system to to
LED INDIC ATOR AND LCD DISPL AY enable precisely timed shutdown
shutdown capability. The magnet assembly
and control housing mount directly to to the divider valve to become
an integral part of the lubrication system. The DNFT-PRG operates
operates
PRG IS PROGRAMMA BLE TO DISPLAY: on field replaceable lithium battery.
battery. If battery voltage drops below
TOTAL PINTS normal operating levels, the DNFT goes into alarm mode and the
PIN TS PER DAY PUM P RATE unit cannot be restarted. The PRG utilizes a LED to indicate each
TOTAL DIVID ER VALVE CYCLES cycle of the divider valve. This enables the operator to easily set
and monitor lubrication rates. The PRG comes with a liquid crystal
CYCLE TIME OF DIVI DER VALVE display to display total pints, cycle time of divider valve, total cycles
of divider valve, and pints per day pump rate. The PRG can easily
PROGRA MMABLE ALARM TIME be programmed for an alarm time from 20 seconds to 4minutes 15
seconds.
DEDI CATED SWITCH CLOSURE TO MONITOR
EACH DIVID ER VALVE CYCLE (PS OPTION) OPERATION
Lubricant flow through the divider valve assembly forces the
pistons to cycle back and forth causing a lateral movement of a
magnet linked to the piston. Movement is monitored by the
microprocessor which resets the timer, lights the LED, and allows
al lows
the unit to continue operation. This indicates one complete cycle
of the lubrication system. The microprocessor must receive this
cycle in a predetermined time or a shutdown will occur. The DNFT
will automatically reset alarm circuit when normal operation of
divider valve resumes.
WHITLOCK
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WHITLOCK INSTRUMENT 2
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INSTRUMENT
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U.S. PAT. NO. 5,835,372
1.800.337.3412 www.noflo.com ODESSA, TX USA
TROUBLESHOOTING DNFT-PRG
NOTICE: WHEN MORE THAN ONE DNFT IS INSTALLED ON THE COMPRESSOR
COMPRESSOR OR ENGINE, EACH DNFT MUST BE WIRED TO A SEPARATE ALARM
CIRCUIT ON THE CONTROL PANEL, ANNUNCIATOR OR PLC TO SIMPLIFY TROUBLESHOOTING THE LUBRICATION SYSTEM AND DNFT.
B. Spring or Magnet is Loosen set screws, remove DNFT from magnet housing. Remove magnet
magnet
Broken in Magnet assembly from divider valve. Remove magnet, spacer and spring. Check
Assembly components for damage. Replace damaged spring or magnet and install on
divider valve. If necessary, adjust DNFT, check for LED blink or number change on LCD.
Purge air from system with lubrication system
sy stem purge gun.
STRAIGHT OK ! Loosen set screws, remove DNFT from magnet housing. Check for damaged or bent
magnet housing. Remove magnet assembly from divider valve. Replace magnet
C. Bent Magnet Housing housing, magnet,
magnet, spring and spacer. Re-install DNFT on magnet housing. If necessary,
BENT REPLACE ! adjust DNFT,
DNFT, check for LED blink or number change on
on LCD. Purge air from system with
lubrication system purge gun.
Loosen set screws, remove DNFT from magnet housing. Check for correct magnet
3. After installation of A. Wrong Magnet
Magnet Housing housing for divider valve manufacturer. Remove and replace with correct magnet
DNFT, Rupture Disc is Installed on Divider Valve housing. If necessary, adjust DNFT, check for LED blink or number change on LCD.
Blown and Divider Valve is (See magnet assy. Below) Purge air from system with lubrication system purge gun.
Locked up.
B. Air or Debris in Check system pressure to insure oil is flowing
flowing to divider valves. If necessary install
Divider Valve pressure gauge to monitor operation of lubrication system.
System. 1. Loosen outlet plugs in front of valve blocks. Fast purge the system with lubrication
system purge gun until clean, clear, air free oil appears from plugs.
2. Loosen each piston enclosure plug individually to purge air from behind piston D o not
remove piston enclosure plugs. Tighten all divider valve plugs. Adjust DNFT. To insure
proper operation of the divider block lubrication system, it is absolutely necessary
that all tubing and components be filled with oil and free of air before start-up.
1. NORMALLY OPEN
OPEN - Attach ohmmeter
ohmmeter to orange wires, violet wires should be
insulated from each other. Ohmmeter should read 10 ohms or less in alarm state
Electrical Testing of PRG 2. NORMALLY
2. NORMALLY CLOSED - Attach ohmmeter to read red wires. Violet should be
shorted together. Ohmmeter should read infinity in alarm mode
Check system pressure to insure oil is flowing to divider valve. If necessary, install
pressure gauge to monitor operation of lubrication system. Check gauge
to insure pump will build sufficient pressure to inject oil into cylinder. You
You cannot check for
C. Faulty Lube Pump oil flow into cylinder by removing tubing from check valve and pumping
oil to atmosphere. Replace pump.
TYPICAL DNFTINSTALLATION Magnet Assemblies and Applications DNFT must be installed with correct magnet
O-RING assembly for each divider valve manufacturer.
LIQUID CRYSTAL DISPLAY
SB &TRABON
(F) ALLEN HEAD
O-Ring Seal Magnet Assy # 000004
SET SCREWS (2) DNFT (LCD) #22 AWG 18" LEADS
INTERNAL VIEW OF (G)
(5) STANDARD
7/16"-20
(A) (B) (7) WITH PROXIMITY SWITCH OPTION
DIVIDER VALVE HOUSING
24S Trabon Metal Gasket Seal
DIGITALNO-FLOWTIMER WHITLOCK
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1994 or Earlier
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1
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CYCLE INDICATION
VIOLET
7/16"-20
INSTRUMENT
NSTRUMENT
ODESSA, TX USA
R
FactorySealed
I I 2G E Ex md I IC T 5 CE
MODEL PRG
RG
RATED 2.5VA/240VDC
5VA 240VDC
ORANGE
24S C US
KEMA00A
TEX10
ClI;Zon e1;Exmd IICT4
186200 ClI; Div1;Grps.A,B,C,D;T4
90XAmb.-40°C...+80°C
C T4
0344 P/N
SERIAL#
ORANGE Lincoln O-Ring Seal
GREEN
Warning: Do not open when an explosive gas ALARM P RROOGG R
atmosphere is present.
ORANGE-SWITCH
CH GRN-GND.VIO -OPEN -N.O. VIO-SHORT- N.C.
R A MMMMA B LL EE
WHITLOCK
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WHITLOCK INSTRUMENT 2
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DNFT
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Odessa, TX 79761 -
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INSTRUMENT
NSTRUMENT
U.S. PAT. NO. 5,835,372 1.800.337.3412 www.noflo.com ODESSA, TX USA
TYPICAL DNFTINSTALLATION
O-RING ALLEN HEAD #22 AWG 18" LEADS
(F) ALLEN HEAD LIQUID CRYSTAL DISPLAY
HEX MAGNET SET SCREWS (2) DNFT (5) STANDARD
SET SCREWS (2) DNFT (LCD)
INTERNAL VIEW OF (G) HOUSING (A) (B) (7) WITH PROXIMITY SWITCH OPTION
(A) (B) (C) SPACER SPRING
DIVIDER VALVE HOUSING MAGNET
(H) VIOLET
24S DIGITALNO-FLOWTIMER WHITLOCK
HI TLO K w
2
2
1
1
4
4
3
-
7
7
w
w
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VIOLET
VIOLET
R f
002196
3
3
U.S. PAT. NO. 5,835,372 l
ORANGE
3
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VIOLET
1
CYCLE INDICATION INSTRUMENT
NSTRUMENT
ODESSA, TX USA ORANGE
R
FactorySealed
I I 2 G EE xmdI I C T 5 CE
MODEL PRG
RG
RATED 2.5VA/240VDC
5VA 240VDC
ORANGE GREEN
24S C US ClI;Zon e1;Exmd IICT4
186200 ClI; Div1;Grps.A,B,C,D;T4
C T4
0344 P/N
SERIAL#
ORANGE
KEMA00ATEX1090XAmb. -40°C. ..+80°C
Warning: Do not open when an explosive gas ALARM P RROOGGRRA M
MMM A B LL EE GREEN O-RING (F)
atmosphere is present.
ORANGE-SWITCH GRN-GND. VIO-OPEN -N.O. VIO-SHORT- N.C.
FIELD REPLACEABLE
DNFT-PRG 000518 BATTERY WIRE LEADS
PROGRAMMABLE w/ REPLACEABLE BATTERY (I)
24S P/N 000505
PISTON ENCLOSURE PLUG
(D) WIRE LEADS
DIVIDER VALVE (I) PROGRAMMING
(E) MAGNET 1/8" RECESSED OPENING
FOR PROGRAMMING MAGNET
Note: The DNFT shall be installed in such a way that WIRING LEGEND
VIOLET: WIRES SHORTED
SHORTED - NORMALLY CLOSED OPERATION
OPERATION
there is a low risk of mechanical danger. VIOLET: WIRES ISOLATED - NORMALLY
NORMALLY OPEN OPERATION
ORANGE: SWITCH
SWITCH ORANGE: SWITCH
SWITCH
GREEN: CASE GROUND
Warning: Do
Do not open
open when an
an explosive gas NOTICE: GROUND MUST BE CONNECTED . UNIT MUST BE
SECURELY
atmosphere is present. GROUNDED. DISCONNECT ALL WIRING PRIOR TO WELDING
ON SKID.
WHITLOCK
HITLO Kw
w 518LIT PRG-GeneralPurpos
PRG-GeneralPurpose
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WHITLOCK INSTRUMENT 2
2
1
1
4
4
w
w -Complete-4
3
3
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DNFT
7
1300 N. Texas
7
3
3 f
l
3
3 oo
R
Odessa, TX 79761 -
0
0
o
.
c
8
8 m
m
INSTRUMENT
NSTRUMENT
U.S. PAT. NO. 5,835,372 1.800.337.3412 www.noflo.com ODESSA, TX USA
PROGRAMMING PROCEDURE
HEX MAGNET SET SCREWS 1/8" RECESSED OPENING LCD (LIQUID CRYSTAL DISPLAY)
SPRING LOADED ALLEN HEAD
HOUSING SPACER
SPRING FOR PROGRAMMING MAGNET
MAGNET ASSEMBLY SET SCREWS (2)
DIGITAL NO-FLOW TIMER WHITLOCK
HI TLO Kw
2
2
w
w
1
1
4
4 w
3
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7 o
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002196
U.S. PAT. NO. 5,835,372 3 ol
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1
CYCLE INDICATION INSTRUMENT
NS T RUM E NT
ODESSA, TX USA
Mode 2 - LCD Displays Cycle Time of Divider Valve in Seconds. LCD will count each cycle of the
divider valve in seconds,
seconds, counting up from "0" until the divider valvevalve completes one full cycle. When divider valve
completes one full cycle, the LCD will reset to zero and begin counting each second until another cycle is completed.
Mode 4 - LCD Displays Pump Rate in Pints Per Day . FOUR (4) SECOND MINIMUM
MINIMUM CYCLE TIME.
TIME.
to anyall
store mode by inserting
programmed and removing
information programmingmagnet
until programming magnetisuntil desired
inserted and mode
springisloaded
displayed by LCD.
magnet Please Note: DNFT
Note:
is depressed. DNFT
If spring will
loaded
magnet is depressed with programming magnet in place, unit defaults to zero and must be reprogrammed.
WHITLOCK
HITLO Kw
w 518LIT PRG-GeneralPurpos
PRG-GeneralPurpose
e
WHITLOCK INSTRUMENT 2
2
1
1
4
4
w
w -Complete-5
3
3
-
.n
n
N T
o
DNFT
7
1300 N. Texas
7
3
3 f
l
3
3 oo
R
Odessa, TX 79761 -
0
0
o
.
c
8
8 m
m
INSTRUMENT
NSTRUMENT
U.S. PAT. NO. 5,835,372 1.800.337.3412 www.noflo.com ODESSA, TX USA
DNFT BATTERY
BATTERY REPLACEMENT INSTRUCTIONS
IN STRUCTIONS
ALLEN HEAD
MAGNET SET SCREWS(2) #22 AWG 18" LEADS (5)
(I)
HOUSING (A) SPACER SPRING (I)
(C)
VIOLET
VIOLET
GREEN
ORANGE
ORANGE
LED
MAGNET FIELD REPLACEABLE
+
BATTERY
(H) _
510
P/N:000505
O-RING
(F)
1/2“ PIPE PLUG
CONTROL HOUSING POLARIZED CONNECTOR Atex Eex Certified
(B)
3. Remove the battery from the DNFT and disconnect from the polarized connector.
connector.
flushing unitItuntil
union nut. may air be
freenecessary
oil is observed around
to install a
manual hand priming gun in the inlet of the
pump to expel the air from pump. After this is
accomplished tighten union nut.
Flow Rate
Standard Rocker Arm
• Loosen lock nut on flushing unit.
•
Tighten lock nut when desired flow rate is
achieved.
Union Nut
Flushing Unit
Lock Nut
Model P-55U
PREMIER LUBRICATION
LUBRICATION SYSTEM - 14105 Packard Street - Houston, Texas 77040 USA Pump Flow
Telephone (713) 462-5255 - Fax (713) 462-7919 - E-mail: sales@premier-lubrication.com - Website: www.premier-lubrication.c
www.premier-lubrication.com
om Chart
Suitable For Use with Petroleum and Plunger Size 3/16” ……………….....7,500
……………….....7,500 PSI*
Synthetic Based Lubricants (6,000 PSI Standard)
Maximum Oil Viscosity 8000 SUS Plunger Size 1/4” ……………………..8,000 PSI*
Minimum Oil Viscosity 90 SUS (6,000 PSI Standard)
One Drop = .002 Cubic Inches, The Cubic Plunger Size 3/8” ……………………..3,500 PSI
Volume of a Pint of Oil is 28.87
28.87 Cubic Inch
Inches
es
* With Optional Roller Rocker Arm
Approximately 14,500 Drops = One Pint
CAMSHAFT 1 2 3 4 5 6 7 8 9 10
RPM
3/16” 0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00 4.50 5.00
PLUNGER Pints/Day Pints/Day Pints/Day Pints/Day Pints/Day Pints/Day Pints/Day Pints/Day Pints/Day Pint/Day
1/4” 0.90 1.80 2.70 3.60 4.50 5.40 6.30 7.20 8.10 9.00
Plunger Pints/Day Pints/Day Pints/Day Pints/Day Pints/Day Pints/Day Pints/Day Pints/Day Pints/Day Pints/Day
3/8” 2.00 4.00 6.00 8.00 10.00 12.00 14.00 16.00 18.00 20.00
Plunger Pints/Day Pints/Day Pints/Day Pints/Day Pints/Day Pints/Day Pints/Day Pints/Day Pints/Day Pints/Day
PUMP EFFICIENCY
2. With all outlets open to atmosphere, pump oil into the Divider Valve and verify that oil is
being discharged from all outlets in the base plate. The pressure at the Hand Priming Gun
3,000 PSI. If the Divider Valve Element above the plugged outlet is good, the pressure
should not drop below 2,000 PSI within 30 seconds. A 1,000 PSI pressure drop in less than
30 seconds indicates a worn element which should be replaced. Repeat this step for all
outlets.
Progressive Equipment Incorporated - 14028 Aston Avenue - Houston, Texas 77040 USA
Telephone (713) 462-1061 - Fax (713) 462-4027
E-Mail: sales@progressive-equipment.com
Website: www.progressive-equipment.com
SUPERIOR
SUPERIOR Compressor Frame Instruction Manual
Engineering Standards
Revisions may not be reflected in the manual
Section 12: Engineering Standards 08/09
SUPERIOR
SUPERIOR Compressor Frame Instruction Manual
Technical Documentation
Section 13: Technical Documentation 08/09