Ram 54

RAM Instruction Manual
Operation
Maintenance
Parts
Instruction Manual
RAM 54 COMPRESSOR
CUSTOMER P.O.#2000000645-676-679
SAP#368360 SAP#368363 SAP#368367 SAP#368370
Serial # Serial # Serial # Serial #
RAM54 Frame 04R1338 04R1340 04R1342 04R1344
15.5" Cylinder #417DC 01C1240 01C1250 01C1245 01C1342
15.5" Cylinder #417DC 04C1241 N/A 04C1246 N/A
9.5" Cylinder #434DC 04C1339 04C1232 04C1343 04C1345
6.5" Cylinder #423CC 01C1305 01C1306 01C1307 04C1346
Customer: Valerus Compression Services

End User: Agave Energy
RAM Compressor Frame Instruction Manual
RAM Instruction Manual

Table of Contents
Section 1
Introduction................................................................................................. 1-1
About this manual ...................................................................................................................................... 1-1
Identifying your compressor frame and cylinder serial numbers ............................................................... 1-1
Compressor Frame Overview .................................................................................................................... 1-2
General................................................................................................................................................. 1-2
Crankshaft Rotation ................................................................................................................................... 1-3
Compressor Specifications ......................................................................................................................... 1-4
Compressor System Vibration ................................................................................................................... 1-5
Balancing Compressor Frames .................................................................................................................. 1-5
Additional information-website ................................................................................................................. 1-6
Prerequisites ............................................................................................................................................... 1-6
How to use this manual .............................................................................................................................. 1-7
Related Publications ................................................................................................................................... 1-7
Standards.................................................................................................................................................... 1-7
Our Quality Policy ..................................................................................................................................... 1-8
Warranty ..................................................................................................................................................... 1-8
Section 2
Safety Precautions and Guidelines ............................................................ 2-1
Important safety information...................................................................................................................... 2-1
Note, caution, and danger symbols ............................................................................................................ 2-1
Warning signs and labels ........................................................................................................................... 2-2
Specified precautions ................................................................................................................................. 2-3
Temporary 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
Compressor system maintenance precautions............................................................................................ 2-5
Pressurized air and water precautions ........................................................................................................ 2-5
Fluid precautions........................................................................................................................................ 2-5
Asbestos precautions .................................................................................................................................. 2-6
Pipes, connectors, fittings, lines, tubes and hoses...................................................................................... 2-6
Burn precautions ........................................................................................................................................ 2-7
Coolant Precautions ................................................................................................................................... 2-7
Oil precautions ........................................................................................................................................... 2-7
Fire and explosion precautions................................................................................................................... 2-7
Crushing or Cutting precautions ................................................................................................................ 2-8
Mounting and dismounting precautions..................................................................................................... 2-8
Table of Contents 6/1/04
Cooper Compression Page c

Section 3
Lubrication And Cooling ............................................................................3-1
Compressor frame lubrication specifications .............................................................................................3-1
General specifications.................................................................................................................................3-2
Lubrication system maintenance ................................................................................................................3-2
Compressor Cylinder 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 Compressor Applications...........................................................4-1
General Information....................................................................................................................................4-1
Hazards of Hydrogen Sulfide or "Sour Gas" ..............................................................................................4-1
Concentration Levels ..................................................................................................................................4-2
Trim Requirements .....................................................................................................................................4-2
Hydrogen Sulfide (H 2S) Concentrations Up To 2% By Volume ........................................................4-2
Level 1-11p Trim (H2S) Concentrations of 2% - 5% By Volume.......................................................4-3
Level 2-11 p Trim (H 2S) Concentrations > 5% ...................................................................................4-3
Enhanced H 2S Trim Requirements ......................................................................................................4-4
Section 5
Installation ...................................................................................................5-1
General ........................................................................................................................................................5-1
Preparing The Foundation ..........................................................................................................................5-1
Foundation Bolts ..................................................................................................................................5-2
Placement And Leveling ......................................................................................................................5-3
Coupling Installation And Alignment.........................................................................................................5-5
Rexnord Flexible Coupling Torque Values .........................................................................................5-6
Crankshaft Web Deflection..................................................................................................................5-6
Cylinder Mounting ......................................................................................................................................5-6
Sliding Rod Through Packings ............................................................................................................5-7
Setting Piston End Clearance ...............................................................................................................5-7
Piston Rod Runout ...............................................................................................................................5-8
Vertical runout tolerances ....................................................................................................................5-9
Section 6
OperationStart-up .......................................................................................6-1
Startup .........................................................................................................................................................6-1
Page d Cooper Compression

RAM Compressor Frame Instruction Manual
Preparation for Initial Startup .............................................................................................................. 6-1

Initial Startup ....................................................................................................................................... 6-3
Normal Startup .................................................................................................................................... 6-4
Shutdown.................................................................................................................................................... 6-4
Normal Shutdown................................................................................................................................ 6-4
Emergency Shutdown .......................................................................................................................... 6-5
Recommended Operating Conditions ........................................................................................................ 6-5
Section 7
Maintenance ................................................................................................ 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
Thomas Coupling ................................................................................................................................ 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 ....................................................................... 7-4
Piston-to-Cylinder Bore Clearance ............................................................................................................ 7-5
Valve-in-Head Cylinder Torque Values .................................................................................................... 7-6
Typical Miscellaneous Flanging ................................................................................................................ 7-7
Precautions........................................................................................................................................... 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 for Connecting Rod Components Inspection Purposes Only.......................................... 7-12
Crankshaft.......................................................................................................................................... 7-16
Force-Feed Lubricator ....................................................................................................................... 7-19
Oil Filter ............................................................................................................................................ 7-21
Hand Pump ........................................................................................................................................ 7-23
Measuring Oil Pump Gear Lash ........................................................................................................ 7-26
Crankcase Pressure Relief Valve....................................................................................................... 7-28
Disc Pack Flexible Coupling ............................................................................................................. 7-29
Drive Coupling Hub .......................................................................................................................... 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
Elongation ................................................................................................................................... 7-32
Fatigue Failure ............................................................................................................................ 7-32
Torque Overload (Visible only with strobe light while running) ............................................... 7-32
Table of Contents 6/1/04
Cooper Compression Page e

Cylinder Body ....................................................................................................................................7-33
Cylinder Head ....................................................................................................................................7-33
Piston, Piston Rings And Piston Rod .................................................................................................7-33
Piston Rod Packing ...........................................................................................................................7-33
Valves.................................................................................................................................................7-37
Valve Installation.........................................................................................................................7-37
Valve Replacement ......................................................................................................................7-37
Special Tools.............................................................................................................................................7-39
Alarms And Shutdowns ............................................................................................................................7-40
Recommended Maintenance Schedule .....................................................................................................7-41
Troubleshooting ........................................................................................................................................7-42
Section 8
Frame "as built" Bills of Materials ...........................................................8-1
Section 9
Cylinder "as built" Bills of Materials .......................................................9-1
Page f Cooper Compression

RAM Series Compressor Frame Instruction Manual
Section 1
Introduction to the RAM Series Compressor
and Specifications
About This Manual
Thank you, for purchasing Cooper Energy Services equipment! This Instruction Manual
contains safety, operating and basic maintenance instructions for the Superior® RAM 52 and
RAM54 series compressor frames.
Cooper Energy Services is committed to continuous improvements and design advancements.

Because of this commitment, changes may occur in your compressor frame that may not appear in
this instruction manual. Some photographs or illustrations in this manual show details or options
that may not appear on your compressor frame. Guards, covers or other protective mechanisms
may have been removed for demonstrative or illustrative purposes. Any time a question arises
concerning your compressor or this instruction manual, please contact an authorized Cooper
Energy Services Distributor for the latest available information.
It is very important that Figure 1-1 RAM Compressor

personnel associated with Piston bore
operation maintenance of the ground to micro
finish
RAM series compressor read Rods ground to Compact
variable
this manual and support tight specifications
volume pocket
Standard
documentation. Keep this ASA flange
sizes
manual with related literature High
non-reversible and
non-interchange-able
and compressor information. temperature
O-ring seals
valves
Store it so it is easily found

Valve spacers in all
by maintenance or service cylinders 6-1/2"
diameter and larger
personnel. It is also Air cooled
Packing & wiper
cylinders
important that users carefully rings in same case
study the safety information Internally

drilled Rolled threads
balance
provided in Section 2. lines Carbon filled TFE
piston rings and rider
Always use good safety rings
practices at all times to
prevent injury to personnel or damage to equipment.
This manual contains confidential and proprietary information from the Superior Compressor
Products Group of Cooper Energy Services, a division of Cooper Cameron Corporation. This
manual is given to users for the limited purpose of providing information to facilitate use and
maintenance of RAM series compressor frames purchased from Cooper Energy Services. By
Section 1: Introduction to Servicing the RAM Series Compressor 5/27/03
Cooper Energy Services ■ Superior Compressor Product Group Page 1-1

receiving this document, you agree not to use such confidential information for any purpose
other than limited purpose stated herein and further agree not to disclose such information to
others except in accordance with the limited purpose stated herein.
All specifications and ratings are subject to change without notice. Superior® is a trademark
of Cooper Cameron Corporation.
Identifying Your Compressor Frame and Cylinder
Figure 1-2 Frame Nameplate

Correspondence concerning your
compressor frame must include the
Cooper Energy Services compressor
frame serial number. The compressor
frame serial number applies to the
frame and running gear parts. It is lo-
cated on the frame nameplate which Figure 1-3 Cylinder Nameplate
is attached to the top cover. Each Correspondence concerning your cylinder must in-
compressor frame and cylinder has its clude the Cooper Energy Services cylinder serial
own serial number. number.
Compressor Frame Overview

All Cooper Energy Services compressor frames are engineered for reliable, continuous, heavy
duty and trouble free operation. These ruggedly constructed, balanced-opposed type com-
pressor frames are built with high speed, high precision, high quality and field proven stan-
dards of CES’s Superior® compressors. Easy access to all wearing parts means simplified
maintenance and dependable service. The balance-opposed design, with two crank throws
separated by a crank cheek, is a modern standard for reciprocating compressor frames. This
manual describes the RAM series compressor frame. These compressor frames are designed
for oil and gas production, process, cogeneration and power generation applications.
Precision designed main and connecting rod bearings are thick walled, steel backed and split.
The crankshaft is removed through the top of the base without disturbing the cylinders. The
Page 1-2 Cooper Energy Services ■ Superior Compressor Product Group

lube oil pump and the force feed lubricator are gear or shaft driven and mounted on the
auxiliary end cover. Either may be maintained independently.
Lube Oil is drawn from the sump through a strainer that protects the lube oil pump. A 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 Variable 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 Pockets are furnished as standard

equipment on all cylinder classes.
Crankshaft Rotation
When facing the oil pump end of the frame, Figure 1-6 RAM Cylinder Specifications
the crankshaft rotates in a
counterclockwise direction.
Figure 1-5 RAM Convertible Cylinder
Sizes-4 to 20 inches (101-508mm)

MAWP-D.I. 193 to 2,200 psi (13.3 - 152 bar)
F.S. - 3,850 psi (265.5mm)
Rod Size-2.00 inches (50.8 mm)
Valves-non reversible/non interchangeable
MT Plate Valves

Figure 1-7 General RAM Series Compressor Specifications
Table 1-8 Compressor Specifications

Specification Type Of Unit
RAM52 RAM54
Connecting Rod Length Center to Center-inches (mm) 12.0 (304.8) 12.0 (304.8)
Crosshead Guide Bore Diameter - inches (mm) 9.750 (247.65) 9.75 (247.70)
Crosshead Pin Diameter - inches (mm) 3.5020 (88.95) 3.5020 (88.95)
Crosshead Shoe - Oiling Method External Internal
Maximum Limit for Reciprocating Weights @ 1400 300 lbs 300 lbs
Maximum Limit for Reciprocating Weights @ 1500 262 lbs 262 lbs
* Subject to change without notice.

Compressor System Vibration

Due to the nature of the horizontal compressor design, the reciprocating weights generate some
vibrational forces. Proper balance of reciprocating weights on the opposing throws will minimize
this effect.
Compressor systems (including skids, bottles, piping, valves, and other components) are subject
to vibration. The design goal is to have a system free of vibrations in a normal operating speed
range.
Operators and maintenance personnel should be alert for excessive system vibration that can
cause damage to equipment. Normally, clamping or adding additional support to a vibrating com-
ponent will raise natural frequency and eliminate the vibration problem.
Compressor cylinder mounting can be stiffened, if necessary, by attaching additional supports
directly to the cylinder from the skid or foundation. Most cylinders now have a machined boss
with drilled and tapped holes for attaching an outboard cylinder vibration suppression device.
This is the preferred method of attachment.
Balancing Compressor Frames

Cooper Energy Services manufactures the RAM balanced opposed reciprocating compressor
having one to four cylinders. The cylinders are unique to the RAM compressor in that they are all
air-cooled and range in size from 4.5 to 20.0 inches (114 mm to 508 mm) in diameter and may be
mounted on the frames in various combinations.
CAUTION DANGER
Since the goal is to produce a balanced opposed
compressor, it is necessary to make the
Balancing of the unit is accom- reciprocating weight on each pair of opposing
plished by using both an Failure to verify and correct
appropriate weight crosshead
throws approximately the same.This is quite a
compressor balance can
assembly and piston rod jam task, in view of the large number of cylinder result in excessive mechani-
nut (balance nut) The maxi- sizes and throw location combinations that are cal vibration, frame crack-
mum allowable variation is possible, and because each piston and rod ing, piping vibration,
two pounds (0.90 kg) on the
reciprocating weights and one
assembly (piston, rings, piston rod and cap foundation cracking and
pound (0.45 kg) on the con- screws) has a certain combined weight which other damage to the com-
necting rod weights, but not to will probably be different from the weight of the pressor. It also creates a
exceed one pound net, for each potentially unsafe operating
piston assembly that it will oppose.
pair of opposing throws. condition for the operator.
CAUTION
The crosshead assembly consists of a pair of
shoes, the bolts and nuts to attach the shoes, and the crosshead. There are
When replacing crossheads,
connecting rods, pistons, or
two different weight crossheads available.
changing piston ring material,
the new parts should be
Also available are balance weights in 2.5 and 5-pound increments. Consult
weighed, in order to reaffirm an Authorized Unit Distributor for details concerning the use of the special
the actual unit balance. weights. In addition to the above mentioned balance parts, the connecting
rod weight is also involved in the balance. Connecting rods vary in weight

and when the units are assembled at the factory, care is taken to select the connecting rods so that the
weight variation for opposing throws does not exceed 1 pound (0.45 kg).Every effort should be made
to achieve as near equal balance between opposite throws as possible.This does not apply to
adjacent throw pairs, which sometimes vary by 100 pounds (45 kg) or more, depending on cylinder
sizes.
Figure 1-9 Balance Sheet Example
▼
The estimated balance for the original assembly
of a compressor is recorded on the Compressor
Vent Fill Plug Torsional and Balance Data Sheet. A copy of the
data sheet for each compressor is included in the
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
. from the estimated weights. Also, when
can vary
replacing crossheads, connecting rods, pistons, or
changing piston ring material, the new parts
Drain Plugshould be weighed, in order to reaffirm the actual
00752 unit balance.
Additional Information
Please visit the Cooper Energy Services web site: http://www.cooperenergy.com
Unrestricted copies of Service Bulletins are available at the Cooper Energy Services web site.
You must have Adobe® Acrobat® Reader version 3.0 or later in order to view the bulletins:
http://www.cooperenergy.net
Prerequisites
Personnel using this guide should be familiar with compressor systems, standard mechanical service
tools, and compressor terminology. Service personnel should have adequate experience in good
maintenance and troubleshooting techniques. Cooper Energy Services recommends that all personnel
using this manual should complete CES Superior Reciprocating Compressor Training. Training
includes the following:
• Frame, crosshead guide, and lubrication systems
• Compressor details including: rings, rider bands, pressure packings, valves, and unloaders
• Support systems to include: Coolers, water pumps, and control systems
• Description of installation, inspection, and set up procedures for rod run out, web deflection, cou-
pling alignment
• Description of recommended operational procedures include: startup, normal & emergency shut-
down and compressor performance control
• Description and application of recommended maintenance: maintenance, critical repairs, and trou-
bleshooting
If training is needed, contact the CES Learning Center by calling (713) 354-4062.

How to Use This Manual

Manual Organization
To make finding information as easy as possible, the Superior RAM Instruction Manual is organized
into the following sections:
• Table of Content.
• Section 1: Introduction To RAM series compressor and frame specifications. This section
describes the purpose of the manual and prerequisites. It includes information on how to use the
manual, related publications and important product information.
• Section 2: Safety Precautions and Guidelines. This section explains basic equipment maintenance
safety policies and practices. regarding compressor frame operation and maintenance.
• Section 3: Lubrication and Cooling Specifications. This section is a comprehensive reference
regarding, lubricating and cooling the RAM series compressor frame.
• Section 4: Specifications for sour gas applications.
• Section 5: Installation. This section provides an in-depth functional description of the guidelines
for the foundation, coupling installation, crankshaft web deflection, cylinder mounting, setting pis-
ton end clearance, piston rod run out.
• Section 6: Operation Start-up. This section provides procedure for startup, recommended operat-
ing conditions, and form to request for performance curves.
• Section 7: Maintenance. This section contain precautions, tolerance limits, and recommended
torque values.
• Section 8: Frame "as built" Bills of Materials unique to your compressor. Included are exploded
views of the assemblies.
• Section 9: Cylinder "as built" Bills of Materials unique to your compressor. Included are exploded
views of the assemblies.
Related Publications
The following related publication contain more information about the Superior RAM Series Com-
pressor
•Superior RAM Technical Data Book.
Standards
Cooper Energy Services has developed several standards for our compressor addressing cooling
water quality, lubrication, and packaging. CES recommends that users of Superior compressor under-
stand and follow these standards to get the best performance possible from the equipment. CES also
recommends that oil and gas production service packagers follow the guidelines for prime movers
described in the American Petroleum Institute’s Specification for Packaged Reciprocating Compres-
sors for Oil and Gas Production Services (API Specification 11P). American Petroleum Institute

http://www.api.org will default you to http://www.global.ihs.com 1-800-854-7179 ext 7969 for a
copy of API 11P.
Our Quality Policy

All Cooper Energy Services employees will work to understand and to meet or exceed our customer's
expectations. Customers include purchasers of goods and services, co-workers, other departments
and suppliers. All employees will correctly and efficiently perform their respective functions in
accordance with established requirements, and identify needed changes. Providing goods, services
and communications with ever-increasing quality and value for our customers is a continuous busi-
ness process in our company.
Warranty
The Seller warrants to the Buyer that the equipment to be delivered hereunder will be free from
defects in material, workmanship and title and will be of the kind described in the contract. THE
FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES
WHETHER WRITTEN, ORAL OR IMPLIED (INCLUDING ANY WARRANTY OF MER-
CHANTABILITY OR FITNESS FOR PURPOSE). If it appears within one year from the date the
equipment is placed in service but no later than eighteen (18) months from the date of delivery to the
Buyer, whichever first occurs, that the equipment does not meet the warranty specified above and the
Buyer notifies the Seller promptly, the Seller shall correct any defect, at the Seller's option, either by
repairing any defective part or parts or by making available, at the Seller's factory, a repaired or
replacement part.
The liability of the Seller to the Buyer (except as to title) arising out of the supplying of the equip-
ment, or its use, whether on warranty, contract or negligence, shall not in any case exceed the cost of
correcting defects in the equipment or part thereof and upon expiration of the warranty period all such
liability shall terminate. The foregoing shall constitute the sole remedy of the Buyer and the sole lia-
bility of the Seller.
The preceding paragraph shall not apply and the Seller assumes no liability whatsoever for breach of
warranty when there is evidence that the defect arose as the result of (a) abuse or negligence in the
operation of the equipment, (b) failure to maintain the equipment properly, (c) overloading or over-
speeding, or (d) use of repair parts not approved by Seller.
The warranty given to the Seller by its supplier of special equipment, including but not limited to gen-
erators, is hereby assigned without recourse by the Seller to the Buyer. AS TO THIS SPECIAL
EQUIPMENT, WHICH GENERALLY BEARS THE NAMEPLATE OF THE SELLERS SUP-
PLIER, THE SELLER ASSUMES NO LIABILITY WHATSOEVER FOR BREACH OF WAR-
RANTY, WHETHER WRITTEN, ORAL OR IMPLIED (INCLUDING ANY WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PURPOSE).
Copyright© 2002 Cooper Cameron Corporation. All rights reserved.
Copyright© 2002 Adobe Systems Incorporated. All rights reserved.

Section 2
Safety Precautions and Guidelines
Important Safety Information
DO NOT OPERATE OR ATTEMPT TO REPAIR THIS EQUIPMENT UNLESS YOU
HAVE HAD THE PROPER TRAINING APPROVED BY SUPERIOR. FOR TRAINING
INFORMATION, CONTACT THE COOPER ENERGY SERVICES TRAINING
DEPARTMENT IN HOUSTON, TEXAS, PHONE (713) 354-4062.
Do not operate, work, or perform any lubrication, maintenance or repair on this equipment
unless you have read and understand the operation, lubrication, maintenance and repair
instructions and warnings in this Operations Manual. Failure to follow the instructions or
heed the warnings could result in injury or death. Contact your authorized Cooper Energy
Services Distributor for replacement manuals. Proper care is your responsibility.
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.
Improper operation, lubrication, maintenance or repair of this equipment can be dangerous

and could result in injury or death.
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.
Note, Caution, and Danger Symbols

These safety instructions and procedures are intended to prevent injury in the operation and
maintenance of Cooper Energy Services compressors and auxiliary equipment. These safety
procedures should not be considered as the only precautions to be taken. Good judgement and
careful safety practices should always be used.
Section 2: Safety Precations and Guidelines RAM-5/27/03

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 lubricating
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:
The CAUTION symbol indicates that if the specified precaution is

not heeded, damage to equipment and/or personal injury may result.
The following is an example of a CAUTION:
CAUTION
The DANGER symbol indicates that if the specified warning is not
heeded, there is a substantial risk of serious equipment damage,
personal injury or even death. The following is an example of a D A N GER
DANGER:
Cooper Energy Services cannot anticipate every possible circumstance that might involve a
potential hazard. The warnings in this publication and on the equipment are therefore not all
inclusive. If a tool, procedure, work method or operating technique not specifically
recommended by Cooper Energy Services is used, you must satisfy yourself that it is safe for
you and others. You should also ensure that the equipment will not be damaged or made
unsafe by the operation, lubrication, and maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are presented on the basis
of information available at the time it was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These
changes can affect the service given to the equipment. Obtain the complete and most current
information before starting any job. Authorized Cooper Energy Services Distributors have the
most current information available.
Warning Signs and Labels

There may be several specific safety signs on your equipment. Please take the time to
familiarize yourself with the safety signs.
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 Cooper Energy Services Distributor for new labels.

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.
Temporary Shipping Plugs in Compressor Equipment1
Small diameter threaded connections located on compressor frames,

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
DANGER
Stainless steel plugs are rec-
and storage. The type of plug used is usually a “push-in” insert that ommended. Always verify
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.
Pressurizing the compressor equipment while temporary plugs are in place may result in
serious injury or death and may damage the equipment.
Compressor Frame Crankcase Rapid Pressure Relief Valves2
Cooper Energy Services recommends the installation of Bicera crankcase rapid pressure
relief valve. These valves protect the compressor frame from excessive pressure.
The Bicera valve has a 120o exhaust port opening through which pressure is vented. Due to
the content and high temperature of the vented gas, proper orientation of the exhaust port is
critical for a safe operating environment. Vented gas could be dangerous to both operator and
equipment. The 120o exhaust port must always be directed towards the drive end of the
compressor frame. It must never be directed toward an area where the vented gases could
come into contact with operators or other personnel.
1.Per CES Engineering Service Bulletin SB282

2.Per CES Engineering Service Bulletin SB290

General Precautions
Attach a DO NOT OPERATE or similar warning tag to the start
button or controls before performing maintenance or repairing the
equipment. When appropriate, attach tags at the equipment and at
DANGER
each operator's position and disconnect starting controls.
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.
It is in the best interest of everyone involved in operation and

maintenance of the equipment to observe these additional precautions:
•Always wear safety glasses or goggles, steel-toe safety shoes, hearing protection and protec-
tive head gear. Additional equipment may be required by the job conditions.
•Do not wear loose clothing, neckties, or jewelry that can catch on controls or other parts of
the moving equipment. Keep long hair tied back.
•Make certain all protective guards and covers are secured in place.
•Use only non-flammable, non-toxic cleaning slovents. Never use gasoline or other flamma-
ble products for cleaning purposes.
•Use fans, blowers, etc. during maintenance and clean-up work in enclosed areas to remove
fumes released by cleaning solvents and vented gases.
•Never put maintenance fluids into glass containers;since glass containers break.
•Report all needed repairs.
•When operating this equipment in an enclosed area, vent the exhaust to the outside.
•Keep the area around the unit clean and orderly with ample space to walk safely around the
unit. Clean up spills and leaks quickly to prevent accidents caused by slipping and falling.
General Maintenance Precautions

Unless instructed differently, perform all maintenance as follows:
•Follow all safety and operating procedures put in place by the company that owns and oper-
ates the equipment.
•STOP the equipment. Do not attempt any repairs or adjustments to the equipment while it is
running. Ensure the protective locks or controls are in the applied position. Make sure all
protective guards and covers are installed, if equipment must be started to make adjustments

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 not disable or bypass automatic alarm/shutoff circuits. They are provided to prevent per-
sonal injury and equipment damage.
•Before replacing any studs, measure the stud's height from the machined surface and install
the replacement stud to the identical height.
Compressor System Maintenance Precautions

•Suction and discharge block valves must be closed to prevent gas from flowing into the
compressor system during maintenance.
•Vent all gas pressure from the compressor system and know the piping system associated
with the compressor. Open discharge blowdown and/or bypass valves to vent into the atmo-
sphere.
•Be sure to allow the compressor system to cool for at least 15 minutes before opening suc-
tion or interstage vents. Air may be drawn into the system if a vacuum exists. This can
create an explosive mixture.
•Check local or panel pressure gauges for a zero reading before removing any gas pressure
components such as valves, valve caps, or cylinder heads.
•Unloader control pressure is typically not shown on gauges. Carefully vent unloader con-
trol pressure lines by loosening the control line tubing fitting.
•Remove manual barring devices if used during maintenance before starting the equipment.
•Lock out starting devices and controls
Pressurized Air and Water Precautions

Pressurized air and water can cause debris and/or hot water to be blown and could result in
personal injury. When using pressurized air or water for cleaning, always wear eye/face
protection and protective clothing and shoes. Cooper Energy Services recommends that the
maximum air pressure applied in this type of application must be below 200 kPa (30 psi) for
cleaning purposes.
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
Cooper Energy Services equipment and replacement parts shipped from the factory are
asbestos free. Cooper Energy Services recommends the use of ONLY genuine Superior®
parts. If any replacement parts containing asbestos are used, the following guidelines should
be used in handling these parts and asbestos debris.
Caution should be used to avoid breathing dust when handling components containing
asbestos fibers. If this dust is inhaled, it can be hazardous to your health. The asbestos used in
components is usually bound in a resin or sealed in some way. Normal handling is not
hazardous as long as airborne asbestos dust is not generated.
If dust, which may contain asbestos, is present, there are several common sense guidelines
that should be followed.
•Never use compressed air for cleaning. Avoid areas where airborne asbestos particles may be
present.
•Avoid brushing or grinding of asbestos containing materials.
•For clean up, use wet methods or a vacuum equipped with a high efficiency particulate air
(HEPA) filter.
•Use exhaust ventilation on permanent machining jobs.
•Wear an approved respirator.
•Comply with applicable rules and regulations for the work place. (i.e. U.S.A. OSHA require-
ments 29 CFR 1910.1001).
•Follow environmental rules and regulations for disposal of asbestos.
Pipes, Connectors, Fittings, Lines, Tubes and Hoses

Do not bend or strike any high-pressure connection (i.e. pipes, fittings, connectors, lines,
tubes or hoses). Do not install bent or damaged pipes, connectors, lines, tubes or hoses.
Repair any loose or damaged fuel and oil pipes, fittings, connectors, lines, tubes or hoses.
Leaks can cause fires.
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).
Check for the following:

•End fittings damaged, leaking or displaced.
•Outer coverings chafed or cut and wire reinforcing exposed.
•Outer covering ballooning locally.

•Evidence of kinking or crushing.

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

A flash fire may result in personal injury if crankcase covers are removed within 15 minutes
after an emergency shutdown.

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.
Crushing or Cutting Precautions

Wear protective glasses when striking objects to avoid injury to your eyes.
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.
Mounting and Dismounting Precautions

Do not climb on, or jump off, the equipment or stand on components that cannot support your
weight. When possible use platform steps and handholds (if equipped) when mounting and
dismounting. Clean steps, handholds and platform areas of the equipment you will be working
on or around. Always wear protective head gear when working on the compressor package.

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 for a RAM52 is 10 US gals and
RAM54 is 30 US gals.
Compressor Frame Lubrication:
A gear driven lubricating pump is mounted on the auxiliary end of the frame. The pump delivers the
oil from the frame sump to the bearings, connecting rods and the crosshead guides. An adjustable
pressure relief valve is mounted on the pump for pressure adjustment cold start protection. An off-
mounted shell and tube type oil cooler is provided with connections for water inlet and outlet. Other
features include a connection port for low oil pressure shutdown switch. An oil level sight gage with
low oil indicator is installed on the frame. The oil filter has an indicator to show when to change the
oil filter. The indicator is color coded. Green is okay, red means change filter.
Frame Lubrication Specifications:

A good mineral oil of recommended viscosity, which provides resistance to oxidation, and corrosion
is generally suitable for frame lubrication. A detergent oil if readily available may also be used. To
assure oil suitably, always use a reliable and known brand.
Cooper Compression does not endorse particular brands of oils and does not guarantee the quality or
performance of lubricating oils. Satisfactory oil quality is the responsibility of the refiner, blender or
re-brander. The responsibility for selecting the proper lubricant falls on the user. Use only products
with field proven reliability and merit. Using known and reputed products will provide the best assur-
ance for achieving effective lubrication. Use of such products should always follow the manufac-
turer’s recommendation. Do not permit your compressor to be used as an experimental unit for trying
out new or questionable lubricants.
Compressor design, operating conditions, and the gases being handled all have a significant effect on
how well a lubricant performs in the given application. The following will assist users in selecting the
proper lubricant for each application.
The lubrication of Superior® Compressors requires the use of premium quality, lubricating oils
designed for heavy duty compressor service.
In addition to the above requirement, the frame lubricant must be capable of operating with the type
of gas being handled by the compressor cylinders. For most sweet natural gases and allied gas ser-
vices, a lubricating oil with the minimum quantities specified in ES1002 (Table 2-1 & 3-4) will be
Section 3: Lubrication and Cooling 6/2/04
Cooper Compression Superior Compressors Page 3-1

suitable. In applications where the compressor cylinders are handling corrosive gases such as H2S or
CO 2, 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 3-1 General Specifications
Specification Range Test Procedure
Viscosity: cSt @ 100 oC 12.5 to 16.3 ASTM D 445
Viscosity: cSt @ 40 oC 204 Maximum ASTM D 445
Viscosity Index 70 Minimum ASTM D 2270
Flash Point 400 o F (204o C) Minimum ASTM D 92
Pour Point 15 oF (-9 oC) Maximum ASTM D 97
Table 3-2 Viscosity Information-this information is equivalent to the ranges above and provided for
information only
Specification Range Test Procedure
Viscosity: SUS @ 210oF 75 to 85 ASTM D 88
Viscosity: SUS @ 100oF 1100 Maximum ASTM D 88
Lubrication System Maintenance

I CAUTION
The compressor oil and filters should be changed after the first 500 hours on
a new or overhauled compressor. After the first oil change, the oil and filters Low lube oil pressure alarm
and shut down device(s)
should be changed when visible indicator moves to red or every 2000 hours must monitor compressor
whichever comes first. Cooper 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
should be carefully analyzed and trended. Regular monitoring of the is at driver end of lube oil
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
diagnostic and preventive maintenance tools.
Page 3-2 Cooper Compression Superior Compressors

t
Figure 3-3 The
compressor frame
lubrication system
consists of a gear
driven pump,
pressure relief
valve, check valves,
oil cooler and oil
filter. This Figure
illustrates the
lubrication oil
system flow.
Compressor Cylinder and Packing Lubrication:

Refer to ES1002 for Lubrication of Cylinders & Packing
Lubrication Rate
I CAUTION
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. 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.
Refer to Lubrication Schematic for rate and amount on the compressor.
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
to two drops per minute per inch of bore for very light oils. See section 6-2 thru 6-3 for information
on the sight glass oil level.

The gas being compressed, its cleanliness and Figure 3-4 Force Feed Lubricator
tendencies to act as an oil dilutent, and the type of
the oil being used all influence the lubrication rate
required.
Many applications may require more or less than

the calculated feed rates. To assure that adequate
lubrication is being achieved, a periodic visual
inspection of the cylinder bore and piston rod are
recommended. Initial setting and adjustments to the
feed rate should also be accomplished on a 24-hour
basis since the drop size varies with the viscosity of
the oil.
Pump Per Point System
If a cylinder has more than one feed point, and more than one pump, the requirements for lubrication
must be split evenly. On a normal force feed lubricator (Figure 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 cylinder 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. A shutoff valve is supplied to isolate the external tank and the
lubricator box. The oil flows to the pumps and then pumped to a common manifold feeding the
automatic divisioning system. The automatic divisioning system consists of a rupture indicator (set
for the job), a 10-micron strainer, a digital no-flow and counter, divider blocks and optional pin

indicators (shows which points are over-pressurized and sets accordingly). Each lubrication point
(cylinder and packing case) has a double ball check valve.
The lubricator box uses the same oil as in the frame or external tank to lubricate its cams and bearings.
The right-angle-drive gear on the lubricator box requires a gear oil that meets ISO 680 AGMA-8
(Exxon TK-680 Cylesstic is acceptable).
If a blockage or other anomaly occurs, and the system pressure continues to build up, the safety
rupture relief in the collector manifold bursts, relieving pressure throughout the entire system and
causing the no-flow shutdown to activate and stop the compressor. The protruding pin in the indicator
on the distribution block gives a visual indication of the point where the blockage occurred. Before
restarting, new rupture discs of the same color and thickness as originally installed must be replaced
at the location where rupture occurred. It is the thickness of the “color coded” discs that determine the
rupture pressure. Refer to rupture disc data sheet in Auxiliary Equipment section of this manual.
Figure 3-5 General Cylinder Lubrication
Maintenance
In order to operate properly, the lubrication system must be completely purged of air. This is done by
LOOSENING, BUT NOT REMOVING the nuts of the lube lines at the point of injection to permit
purging of oil and air. The nut at the entry to the distribution block, all pin indicators and 1/8-inch
pipe plugs in the face of the block must be loosened also, for the same reason.

! Caution
High pressure oil streams may puncture skin. Use proper wrench and keep hands away from the immediate
point where the system is purging air.
Loosen the vent screws in the top section of the distribution block. Continue to operate the lubricator
pump manually until clear, air-free oil appears at either of the two loosened vent screws. Retighten
this vent screw and continue pumping until air-free oil emerges at the other vent screw. When this
occurs, retighten second vent screw. Continue to operate the pump manually until air-free oil has
emerged from tubing nuts at every injection point. Then, and only then, tighten the nuts on the tubing
lines, the pin indicators, and pipe plugs.
Note
If distribution block must be disassembled for cleaning, observe the following:
a. Record order of manifold sections and outlet positions in order to facilitate reassembly.
b. Have a clean work area.
c. Avoid vise marks; protect ground surfaces, and NEVER grip the ground mating surfaces in a vise.
d. Pistons are not interchangeable - - each piston is match-honed to its

cylinder. ICAUTION
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 compressed air. Replace •Distribution Block Tie
defective parts, as required. Rod Nuts = 20-25ft.
lbs. (27-34Nm)
•Check Valves = 15-20
h. Use all new gaskets when reassembling manifolds. ft. lbs. (20-27 Nm)
•End Plugs = 15-20
ft.lbs. (20-27 Nm)
•Alternate Outlets and
Proportional Lubrication System Pin indicators = 10-15
ft. lbs. (14-20Nm)
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.

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.
Lubricator Worm And Gear Drive
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
t
Vent Fill Plug Filling Instructions
Upper 1. Remove vent/fill plug.

Plug 2. Loosen
. upper plug.
3. Fill with Exxon TK-680 Cylessic oil
.
(ISO680 Agma-8) until it begins to leak at
upper plug.
4. Tighten upper plug. Install vent/fill plug.
Drain Plug
00752
Compressor Frame Lubrication Oil Cooling

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.

Table 3-7 RAM Compressor Frame Heat Rejection Data
Compressor Heat Rejection
Model RAM 52 RAM 54
@1200 RPM 18,000 BTU/hr (18,990 kj/hr) 36,000 BTU/hr (37,980 kj/hr)
@1500 RPM 26,000 BTU/hr (27,430 kj/hr) 52,000 BTU/hr (54,860 kj/hr)
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 Requirements
I CAUTION
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.
Scales and Sludge

Minerals dissolved in water form scales and sludge. The dissolved minerals tend to come out of
solution when the water is heated. In doing so, the scale is formed on the hot metal surfaces and
impedes good heat transfer. The scales and sludge also interfere with the ability of corrosion
inhibitors to form their protective films.

The most important consideration for the cooling system is good water quality. Table 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 Raw Cooling Water Specifications
Category Standard System Steam System

pH Level 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
Total Dissolved Solids PPM 300.0-400.0 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
compounds from the supplier or manufacturer.

A clean system is a prerequisite for establishing protection of any cooling system. Adequately
protected closed cooling systems seldom, if ever, present problems caused by scaling, corrosion,
deposits or cavitation.
Cooling System
There are three types of cooling systems used for stationary equipment: open, closed and
combination.
Open systems involve cooling towers, spray ponds, etc., and cool the water by evaporation.
Closed systems involve heat rejection through or shell and tube-type or radiator-type heat exchangers.
Combination systems have the engine and compressor 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, Cooper Compression do not recommend using these for this equipment.

Section 4
Sour Gas Compressor
DANGER
Sour gas or hydrogen sul-
fide (H2S) is a highly cor-
Applications rosive and extremely toxic
gas. Every precaution
reguarding life and equip-
This section defines additional compressor hardware and special ment must be taken in a
materials for use when the compressor is applied in sour gas or hydrogen sulfide applica-
corrosive gas service. The requirements listed are based on tion. Read and understand
American Petroleum Institute (API) Production Equipment the United States Depart-
ment of Labor’s Occupa-
Standard 11P, National Association of Corrosion Engineers’ tional Safety and Health
(NACE) Standard MR0175, and Cooper Energy Services Administration (OSHA)
experience. Additional specifications may apply to pulsation regulations for Air Con-
dampers, piping and other equipment used in conjunction with this taminants (standard
compressor. Copies of API 11P and NACE MR0175 can be 1915.1000) and the Con-
purchased on line: fined Space Pre-Entry
Check List (standard
American Petroleum Institute http://www.api.org will default you 1910.146 App D). These
to http://www.global.ihs.com 1-800-854-7179 ext. 7969 for a copy regulations are available
of API 11P. online at the OSHA web-
site:www.osha-slcgov.com
National Association of Corrosion Engineers-A copy of specifi- Cooper Energy Services
cation MR0175 can be purchased online at www.nace.org or by recommends that Superior
calling (281) 228-6200. equipment users and oil
and gas service equipment
These specifications apply to equipment only! Follow safe packagers follow the
operating and maintenance procedures associated with personnel guidelines set forth by the
National Association of
around sour gas machinery as dictated by your company Corrosion Engineers in
procedures. Sour gas is poisonous and attacks the nervous system specification MR0175:
and can cause paralysis, permanent injury or death! Sulfide Stress Cracking
Resistant Metallic Materi-
als for Oilfield Equipment.
Hazards of Hydrogen Sulfide or “Sour Gas”
Caution should be taken when working in or around hydrogen sulfide (H2S). 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 H2S
environment.

Table 4-1 Effects of H2S on the Human Body at Various Concentrations
H2S Concentration Effects
1 ppm (0.0001%) Detectable “rotten eggs” odor.
Protective Equipment Is Recommended For Any Concentrations Over 10 ppm (0.001%)
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.
500 ppm (0.05%) Loss of reasoning ability and sense of balance. Respiratory distur-
bances will occur within 12 to 15 minutes of exposure. Requires
prompt artificial respiration.
700 ppm (0.07%) Rapid loss of consciousness and breathing. Death will result if not re-
moved quickly. Immediate artificial respiration is required.
1,000 ppm (0.10%) Immediate unconsciousness. Permanent brain damage may result if
not rescued immediately.
The equipment specifications are based on three levels of sour gas plus additional National
Association of Corrosion Engineers’ (NACE) requirements as defined by the following
percentages of H2S:
Level I Less than 2% H2S (by volume)

Level 1-11P 2% to 5% H2S (by volume)
Level 2-11P Greater than 5% H2S (by volume)
Enhanced Trim Follow NACE MR0175 Guidelines
Trim Requirements
For Hydrogen Sulfide (H2S) 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 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.

•A complete oil analysis program on the frame lubricant is required to determine proper oil
change intervals as well as to monitor the condition of the lubricant and the unit.
•Compressor cylinder lubricants must adhere to the requirements of Superior Engineering
Standard ES1002. Viscosities are to be on the high side of the pressure conditions normally
required and a 3% to 5% compounding (similar to steam cylinder oils) is also required.
•The compressor cylinder lubricant rate is to be double the normal rate for equivalent non-sour
gas applications.
•All brass, bronze, copper and other copper alloys are to be avoided on hardware for all gas
wetted parts.
•The distance piece is to be properly vented in accordance with local safety standards to 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.
479) can be specified as an option.
Level 1-11P trim (H2S Concentrations of 2% - 5% By Volume) include all of the

requirements applicable to concentrations of less than 2% apply plus the following additional
requirements:
•A suitable corrosion inhibitor should be added to the cylinder lubricating oil.
•Cylinders are to be equipped with a suction flushing system (injection of cylinder lubricating
oil into the suction nozzle of each cylinder). This is in addition to the regular cylinder lubri-
cation. This helps to resist the natural solvent action of the sour gas and insures a thorough
distribution of oil for better lubrication. It also helps to better form a barrier to corrosion by
coating all the valve surfaces with an oil film.
•Oil slingers are to be used on each compressor rod in the distance piece compartment to
insure that none of the H2S contaminated cylinder or packing lubricant works its way back
into the crankcase and contaminates the frame lubricating system.
•Packing and piston ring material shall either be non-metallic or contain no copper bearing
metals.
•Compressor valves will be standard construction and hardness.
•All carbon steel, alloy steel, or 12CR steel parts which are gas wetted (come into contact with
the process gas stream) are to have a maximum hardness of 22 HRC. This is to include all
internal fasteners and V.V. pocket screws as a minimum, but excludes valve fasteners.
•The piston rods are 17-4 pH stainless steel with a hardness of 28 - 33 HRC (Heat Treat Spec
ZA).
•Forged steel cylinder bodies made of AISI 4142 are to have a maximum hardness of 235 HB.
Engineering will evaluate these applications on an individual basis as some cylinder pres-
sure ratings may have to be reduced because of the mechanical properties restrictions.

Level 2-11p Trim (H2S Concentrations > 5%) All of the requirements for H2S
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. H2S). This reduces the pressure differential capability of
any specific valve design and thus the pressure differential capability of the cylinders. Engi-
neering will evaluate these on an individual basis and select appropriate alternative designs
to meet the application requirements.
•This reduced hardness requirement also includes steel valve cages (retainers) when they are
used.
•Compressor valve components may also be made of AISI 416 stainless steel with a maximum
hardness of 22 HRC.
•Valve plates wherever possible are to be plastic to better prevent seat wear against the softer
valves seats.
•When metallic plates are required, 410 stainless steel with a hardness of 17 to 22 HRC will
be used.
•Nimonic 90 valve spring material will be used.
•Two compartment configuration of distance pieces is required. The outer compartment must
be purged with inert gas to a pressure of 3 to 5 inches (7.6 to 12.7 cm) H2O.
•All compressor cylinder and distance piece critical bolting, capscrew, studs, and nuts which
come in contact with the process gas stream shall conform to ASTM A913-B7M (bolts and
studs) and ASTM A194-2HM (nuts).
•All instrumentation that comes into contact with the process stream (liquid level controls,
shutdowns, bourdon tubes, process valving, relief valves, etc.) shall meet the full 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
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

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.

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.
The requirements are as follows:

•A suitable corrosion inhibitor should be added to the cylinder lubricating oil.
•The cylinders are to be equipped with a suction flushing system (injection of cylinder lubri-
cating oil into the suction nozzle of each cylinder).
•Two compartment distance pieces are required. The outer compartment must be purged with
inert gas to a pressure of 3 to 5 inches (7.6 to 12.7 cm) H2O. The inner compartment can
either be separately vented as described previously or purged with inert gas to a pressure of
3 to 5 inches (7.6 to 12.7 cm) H2O.
•Oil slingers are to be used on each compressor rod in the distance piece compartment to
insure that none of the H2S contaminated cylinder or packing lubricant works its way back
into the crankcase and contaminates the frame lubricating system.
•Compressor valve springs are to be Nimonic 90.
•Packing garter springs are to be Inconel.
•The piston rods are stainless steel with a hardness of 28 - 33 HRC (Heat Treat Spec. ZA).
•Tungsten carbide coating is required in the packing travel area of the piston rods.
•The valve components are to be made of carbon steel or AISI 4140 alloy steel with a hardness
of 22 HRC maximum (Heat Treat Spec H2S). This reduces the pressure differential capabil-
ity of any specific valve design and thus the pressure differential capability of the cylinders.
Engineering will evaluate these on an individual basis and select appropriate alternative
valve designs to meet the application requirements. Compressor valve components may
also be made of AISI 416 stainless steel with a maximum hardness of 22 HRC.
•This reduced hardness requirement also includes steel valve cages (retainers) when they are
used.
•Forged steel cylinder bodies are to be made of AISI 4142 with a maximum hardness of 235
HB. Engineering will evaluate these applications on an individual basis as some cylinder
pressure ratings may have to be reduced.
•All steel gas wetted parts are to have a maximum hardness of 22 HRC. This is to include all
internal fasteners and V.V. pocket screws as a minimum.
•Valve plates wherever possible are to be plastic to better prevent seat wear against the softer
valve seats.
•When metal plates are required, 410 stainless steel with a hardness of 17 to 22 HRC shall be
used.
•All compressor cylinder and distance piece critical bolting, capscrews, studs, or nuts which
come into contact with the process gas stream shall conform to ASTM A193-B7M (bolts
and studs) and ASTM A194-2HM (nuts).

Section 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.
Preparing the Foundation
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. CES 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 decrease the soil
Section 5: Installation 5/27/03
Cooper Energy Services ■ Superior Compressors Page 5-1

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) Mounting
Figure 5-1 Base Frame/Skid Mounting
00757
00758
Foundation Bolts
To locate the foundation bolts, make a wooden template to temporarily position the bolts
according to the dimensions given on the foundation plan. Set up the template in the exact
position to be occupied by the compressor, allowing space for the grout as indicated. (Figure
5-3). Fasten the template firmly in position.
The next step is to attach the bolts to the template so that they will extend into the foundation.
There are two important items which should be considered at this point:
a. Make sure the bolts project far enough through the frame hole to allow two full threads
beyond the nut. Allow for thickness of grout, frame, nut, etc.
b. Provide allowance for misalignment. A piece of 2-1/2 to 3-inch (6 to 8 cm) pipe or metal
tube positioned around each bolt (Figure 5-3) will prevent the bolts from being cemented
into a fixed position and thus allow slight movement of the bolts for alignment with the
holes in the frame. Stuff paper or rags around the bolts at the top of the pipe to prevent
cement from entering when the foundation is poured. The length that the bolts extend into
the foundation is indicated on the foundation plans.
5/27/03

Placement and Leveling ▼ Figure 5-3 Foundation Bolt Positioning
After the foundation has been

completed and the concrete has had
ample time to thoroughly set, the
unit is ready to be placed upon the
foundation.
First, remove the template and chip

off the top layer of pure cement and
sand so that the grout will have a
good solid surface for bonding.
Then, clean the top surface of the
foundation thoroughly. Soak the
surface for several hours before
pouring grout, but make sure there is
no standing water. Remove the
stuffing from around the foundation
bolts, but place a dam around the top
00759
of the bolt and extending into the
can, to avoid grout contact with any
part of the bolt. Next, screw each jackscrew through the frame (Figure 5-3) in a manner which
would support the frame approximately 1 to 1.5 inch (2.5 to 3.8 cm) above the foundation.
This provides for leveling, aligning and grouting. (There should be a jackscrew at each
holddown bolt.)
With the compressor resting on the jackscrews, check to see that it is

level. Place level on top side of frame as required to level in both
directions all around. Bring frame to level by adjusting jackscrews.
CAUTION
Keep all jackscrews snug. After levelling, foundation bolt nuts Responsibility for the grout
should be secure but NOT TIGHTENED. It is very important the unit belongs with the customer
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.

Coupling Installation and Alignment
Laminated rings
must be re-assem-
The success of a compressor installation depends greatly upon the bled in the coupling
exactly as received.
construction of the foundation and upon the care used to align the
compressor with its driver. The standard flexible coupling used to
drive the Superior compressor is shown in Figure 5-4. Installation is as follows dial indicator
method:
Figure 5-4 Flexible Coupling Assembly

a. Disassemble the flexible
coupling. Note the
arrangement of bolts,
washer, and nuts. They must
be replaced in their original
position. Tie a string or wire
through one bolt hole of the
laminated rings (A) to retain
the dialed position of
individual discs.
. b. Mount flange (B) on

engine flywheel. Torque
flange screws per Table 7-2
and lockwire together.
Mount hub (C) on
compressor crankshaft. (See
instructions given in Drive
Coupling Hub Page 7-9.)
c. With engine and compressor moved into position, as shown on the outline drawing,
reassemble coupling. Dimension (D) must be maintained during the following alignment
procedure.
▼ Figure 5-5 Dial Indicator Method of Alignment
00761
5/27/03

The recommended procedure for establishing final alignment is called the “indicator method.”
Proper lining up may take a little time, but it is absolutely essential. Flexible couplings should
not be required to compensate for any misalignment that can be eliminated. The closer the
initial alignment, the greater the capacity of the coupling to take care of subsequent
operational misalignment.
d. Attach dial indicator as shown in Figure 5-5 (view B). Rotate coupling 360 degrees to
locate point of minimum reading on dial; adjust indicator to zero.
e. Rotate coupling 360 degrees. Observe misalignment reading.
f. Move engine or compressor, or both, until dial indicator reading

does not exceed 0.0003 inch for each inch of diameter at indicator
stem (0.0003 cm per each cm of diameter at indicator stem). This
Bolt heads
should be held
and locknuts
is approximately 0.006 inch (0.015 cm) at outside diameter of only turned, when tight-
flange B. This corrects angular misalignment. ening coupling bolts.
g. Reset indicator to zero and repeat steps (d), (e), and (f); if either, the engine or
compressor is moved during aligning trials.
h. The coupling should be turned several revolutions to make sure no “end-wise creep” in
the crankshaft is measured.
i. Mount dial indicator (Figure 5-5 (view C)) to check for parallel misalignment. Set
indicator stem on outer diameter surface of flange B and adjust to zero.
j. Rotate coupling 360 degrees. Move and/or shim the units until
the indicator reading comes within the maximum allowable
variation of 0.004 inch (0.010 cm).
Coupling bolts
are tightened at
the factory for
shipping purposes only.
k. Torque all bolts. See Table 7-2 for recommended torque values. When installing cou-
After several hours of operation, recheck both alignment and bolt pling, the below values
apply to bolts and lock-
torque.
nuts as they are received
from the factory. If any
l. When proper alignment is attained within the previously additional lubricant is
specified limits, the laminated rings A must appear vertical and used or if the threads are
wiped dry, these values
undistorted. There must be no end thrust due to poor initial must be modified.
assembly of the coupling.
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.

Table 5-6 Rexnord Flexible Coupling Torque Values
Coupling Size Bolt Size Threads/Inch Torque -- Foot- Dimension D--
in inches Lbs. (N-m) inches (mm) *on
Fig 5-4
500 3/4 16 260 (353) 8-3/4 (222)
550 7/8 14 350 (475) 9-7/8 (2480
600 1 14 490 (529) 10-7/8 (2760
700 1-1/8 12 630 (855) 12-7/16 (316)
750 1-1/4 12 830 (1125) 13-1/2 (343)
800 1-3/8 12 1100 (1492) 14-3/4 (375)
850 1-1/2 12 1400 (1898) 15-3/4 (400)
925 -- -- 1800 (2440) 17-1/4 (438)
Crankshaft Web Deflection Figure 5-7 Crankshaft Web Deflection Mea-

surement
The compressor should be aligned to the
driver according to the instructions given
above. During the alignment procedure, the
crankshaft web deflection should be measured
on the number one throw. (Figure 5-7) The
deflection should not be greater than 0.001
inch (0.025 mm). The deflection should be
periodically checked and should not exceed
0.002 inch (0.051 mm). Note: The deflection
can be measured with #1 connecting rod
removed.
Cylinder Mounting
Cylinders are normally mounted on the

compressor frame when shipped to a location. Sometimes, because of shipping and packaging
restrictions, cylinders may be shipped separately. If that is your case, the cylinder head and the
piston and rod assembly maybe installed prior to shipment.
When reassembling the cylinder to the crosshead guide, use a criss-cross pattern nut
tightening sequence. See Table 7-2 for recommended torque values.
Outer end cylinder supports, if supplied, are intended to support the weight of the cylinder
only. Do not use them to force the cylinder into alignment. If a cylinder cannot be aligned,
check for dirt, burrs, or other irregularities at the mounting surfaces.
5/27/03

Sliding Rod Through Packings
Obtain a piston rod starter tool before attempting to slide the rod through packing. This tool
consists of a split sleeve cone and capscrew. The piston rod should be coated with grease
before and after installing it on the rod. This tool is designed to protect the packing rings from
damage during removal and installation of the rod from the cylinder.
Setting Piston End Clearance Figure 5-8 Piston End Clearance

Check
Piston end clearance is set by screwing the piston and
rod assembly further into or out of the crosshead. With a
cold compressor, the total clearance should be
distributed with two-thirds on the head end and one-
third on the crank end of the cylinder. This allows for
thermal growth of the reciprocating assemblies during
normal operation.
Measure end clearance as follows:
a. Remove a valve from each end of the cylinder.
b. Bar over the compressor, at least one revolution in Figure 5-9 Measuring the Piston
the normal operating direction, to insure all parts are End Clearance
working freely.
c. While barring the compressor over again, head end

clearance is taken by inserting a 1-inch (2.5 cm)
length of soft solder between the approaching piston
and cylinder head. Pistons 10 inches (25 cm) and
larger should use solder inserted from both sides to
keep the piston from cocking and giving a false
reading (Figure 5-8). Measure the crushed solder
wire (Figure 5-9). The head end clearance should be
0.070 to 0.090 inch (1.78 to 2.29 mm) for a cold compressor.
d. Check the crank end using the same method. For a cold compressor, the crank end
clearance should be 0.030 to 0.050 inch (0.76 to 1.27 mm).
e. If any adjustment is needed, loosen the balance nut and screw the piston and rod assembly
in or out of the crosshead. The WG piston rods are threaded with 12 threads per inch. Thus
one complete turn of the piston and rod assembly moves it 0.083 inch (2.11 mm).

f. After adjusting the piston and rod assembly, recheck the head end and crank end clearances.
g. After setting the piston end clearance, re-torque (Table 7-2 torque values) the balance nut.
Piston Rod Runout
Once the piston and rod assembly and cylinder head are assembled, and the piston end
clearances are set, a check can be made for the piston rod runout. Proceed as follows:
a. Bar over the compressor until reaching the crank end dead center position.
b. Place two dial indicators as Figure 5-10 Dial Indicators

close to the packing as
possible. Zero the two dial
indicators. (Figure 5-10).
c. Bar over the compressor

until reaching the head end
dead center position. Record
indicator movement.
d. The horizontal runout must

not exceed +/- 0.0010 inch
(0.025 mm). Allowable
vertical runout tolerances will vary according to the cylinder. Compare the recorded
measurements with the graph in Figure 5-11.
e. If the horizontal run out exceeds acceptable limits, loosen the packing and re-torque. If the
crisscross pattern of torquing is not followed, this may cause the packing case to seat at an
angle, causing the rod to deflect to one side. A second technique would be to loosen the rod-
to-crosshead nut, and rotate the piston one quarter turn before re-torquing. If the runout still
exceeds limitations, contact your Cooper Energy Services Aftermarket facility for assistance.
f. If the vertical runout exceeds acceptable limits, check the packing case as explained for
horizontal runout. Also, check the piping and bottles attached to the cylinder to see if they are
distorting the cylinders. If runout still exceeds limits, loosen the cylinder to crosshead guide
nuts and re-tighten int eh sequence shown in Figure 5-12. If the runout is still beyond
acceptable limits, contact your Cooper Energy Services Aftermarket facility for assistance.
•Vertical run-out should fall within ranges indicated on the curve for the given cylinder diameter in
Figure 5-11
5/27/03

Figure 5-11 Allowable Rod Run-Out Graph
Figure 5-12 Nut Tighting

Sequence

5/27/03

Section 6
Operation Start-up
Complete Superior® Compressor Start-Up Checklist and Report
Control Procedures Engineering Standard ES30 and forward to the
address included in procedure.
Preparation For Initial Startup
Prior to startup, the frame lubrication system should be primed by

CAUTION
using the lube oil hand priming pump or automatic priming pump. Read this manual and famil-
iarize yourself with the
Use of this pump will prevent oil starvation in the bearings during compressor, auxiliary
startup, prolonging compressor life. Compressor design, operating equipment, and your com-
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.
b. Verify the proper torquing of the foundation bolts.
c. Remove the top cover of the base and the covers for the
crossheads and distance pieces on each crosshead guide.
Thoroughly wipe the interior of the compressor with a lint free cloth
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.
DANGER
e. Check the piston rod runout.
f. Remove a valve from each end of every compressor cylinder.

High pressure oil stream may
puncture skin. Use proper
g. Check the piston end clearances on all cylinders, and then replace wrench and keep hands away
the valves. from the immediate point
where connection is purging
air.
h. Add lubricating oil, which meets the proper specifications, to the
base and to the lube oil filter.
Cooper Energy Services ■ Superior Compressos Page 6-1

i. Check the force feed lubricator for cleanliness and fill to the proper level with oil.
j. Adjust all force feed lubricator pumps to full stroke for cylinder and packing break-in.
k. Disconnect ends of force feed lubricator lines as close as possible to cylinders and
crosshead guides. Hand pump the lubricators to fill lines and eliminate air.
l. Connect the force feed lubricator lines and operate pumps ten more strokes to force oil
into cylinders and rod packing.
m. Prime the frame oil system with the lube oil priming pump. Operate the pump a
minimum of 100 strokes or run automatic pre-lube pump. This should fill all empty oil
lines.
n. Hand lubricate the piston rod next to the packing. (This does not
apply to non-lubricated applications.) 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 NOT the level in
the frame 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.
r. Visually verify that all guards are in place.
s. Unload the compressor for startup by placing the bypass line between the first stage
suction and last stage discharge lines.
t. Verify that suction and discharge block valves are open.
The frame lubricant must be capable of operating with the type of gas being handled by the
compressor cylinders. For viscosity requirements see page 3-3 and Table 3-2 & 3-2.
Lube oil header pressure should be 50 psi (345 kPa) and is maintained at this level by the
pressure relief valve. If adjustment is required, it can be done by removing the cap which
provides access to the spring loaded adjusting screw. This should be adjusted while at normal
operating speed and temperature.
5/27/03

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 CAUTION
system (when required). Running compressor at
speeds less than 600 RPM
2. Start up and operate the unit under no-load conditions at for longer than 12 minutes
may result in unusual wear
reduced speed where possible (600 RPM for engine driven units). of the piston rings.
Check the oil pressure. When the compressor is started, an oil
pressure of 20 psi (138 kPa) must be experienced within 5 seconds or the compressor must
be immediately shut down. Do not restart until adequate oil pressure can be assured. The
oil level in the frame is normally at the center of the sight glass.
3. Run compressor for 2 to 5 minutes at 600 RPM. If driver is a constant speed electric
motor run compressor for only 1 to 2 minutes.
4. Shut system down and check all bearings and packings for high temperatures.
5. Remove crosshead guide covers and check all lubricated surfaces for high temperatures.
6. Check piping for oil or water leaks.
7. Start system and compressor up again and run for approximately 20 to 30 minutes. Add
oil to the crankcase to bring the oil level (while running) up to the middle of the sight glass.
Shut down and recheck as above.

DANGER
8. Start unit. Bring unit up to full rated speed. Apply load to
compressor by closing the bypass line between the first stage
Do
suction and last stage discharge lines.
not immediately remove
9. During the initial period of operation, pay close attention to the equipment covers after
the machine for any unusual high temperature, pressure, or the compressor has been
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.
DANGER
2. Operate the force feed lubricator pumps, by hand, for ten
strokes. (Be sure the lubricator tank is kept full.)
3. Hand prime the frame lube oil system by priming 40 strokes Improper setting of variable vol-
with the lube oil hand priming pump or automatic priming pump ume pockets, fixed volume pock-
ets, valve unloaders, or other
(to prevent oil starvation in the bearings for compressor life). unloading devices can result in
damage and/or injury to equip-
4. Turn on cooling water supply. ment and/or personnel.Operating
the system without clearance and
loading information can result in
5. Start the unit. Check frame lube oil pressure. equipment failure due to overload,
excessive rod loads, and high tem-
peratures.
6. Operate at low speed (600 RPM where possible) and no load
for several minutes. Check force feed lubricator sight glasses for
feed (Figure 3-6). Check lube oil for proper level, at sight gauge.
7. Bring up to rated speed and apply load.
Normal Shutdown
1. Decrease speed to 600 RPM (engine driven units only).
2. Unload the compressor by opening the bypass line between the first stage suction and the
last stage discharge lines.
3. Shutdown the compressor driver.
5/27/03

4. Close suction and discharge block valves.
5. Turn off water supply.
6. Relieve pressure by venting compressor cylinders, suction piping, and discharge piping
to remove any remaining gas.
Emergency Shutdown
In an emergency situation, the shutdown devices will shut down the system. In such as case,
the cause of the shutdown must be identified and corrected before restarting the compressor.
Refer to the Troubleshooting Page 7-23 thru 7-31 to troubleshoot compressor.
Recommended Operating Conditions
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. If they have been omitted please fill out the following form and new curves will
be provided to you. If compressor operating conditions change, contact your Cooper Energy Ser-
vices Aftermarket Sales Office.

5/27/03

Fill Out and Return To: Cooper Energy Services

20110 GH Circle
P.O. Box 947
Waller, Tx 77484
Fax:713-890-1399
Unit Serial Number
Model
Compressor Cylinder Sizes
Elevation
Ambient Temperature (°F or °C)
Suction Gas Temperature (°F or °C)
Specific Gravity
“N” Value
Design Suction Pressure
Anticipated Suction Pressure
Design Discharge Pressure
Alternate Discharge Pressure
A complete gas analysis must also be supplied.
Send Performance Curves To:

5/27/03

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.
Acceptable Clearance Values
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. 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).
Table 7-1 Acceptable Tolerance Frame Clearance Values

RAM 52 & RAM 54 Assemblies Clearance range in inches (mm)
Crankshaft - Main Bearing 0.0040 - 0.008 (0.102 - 0.203)
Connecting Rod Bearing 0.0040 - 0.008 (0.102 - 0.203)
Crosshead Pin to Connecting Rod Bushing 0.003 - 0.0045 (0.076 - 0.114)
Crankshaft End Play - Thrust Bearing 0.006 - 0.014 (0.152 - 0.356)
Crankshaft Web Deflection 0.000 - 0.001 (0.000 - 0.025)
Connecting Rod Thrust 0.018 - 0.032 (0.457 -0.813)
Crosshead Pin to Crosshead 0.0015 - 0.0035 (0.038 - 0.088)
Crosshead To Guide 0.008 - 0.014 (0.203 - 0.355)
Crosshead Pin Bushing Interference Fit 0.0035 - 0.006 (0.088 - 0.152)
Stub Shaft Run-out 0.000 - 0.005 (0.0 - 0.127)
Lube Oil Pump Drive Gear Backlash 0.006 - 0.010 (0.152 - 0.356)
Max Backlash Variation 0.004 - (0.102)
Section 7: Maintenance 5/27/03

Table 7-2 Recommended Torques * American measurement (metric measurements)
All torques based on lubricated threads, S.A.E. Grade 5 fasteners or better. Subject to change without notice.
Fastener (S.A.E.) Grade 5 or Better) SIZE TORQUE Ft.-Lbs. (N-m)*
SPECIFIC TORQUE VALUES
Main Bearing Cap Bolt 1"-8 350 (475)
Connecting Rod Bolt 1"-14 460 (623)
Piston Rod/Crosshead Nut 2"-8 1100 (1491)
Crosshead Shoe Capscrew 1/2"-20 20 (25)
Spacer Bar Nut 7/8" - 9 300 (407)
Crankshaft Drive Gear Cap screw 5/16"-18 15 (20)
Cylinder/Crosshead Guide Cap Screw 7/8" - 9 200 (271)
Balance Weight Capscrew 5/8"-11 62 (84)
Distribution Block Tie Rod Nuts 1/2" NPT 20 - 25 (27 - 33)
Check Valves 1/4" NPT 15 - 20 (20 - 27)
Pin Indicators 1/8"-BSP 10 - 15 (13 - 20)
Packing Case Cap Screw (15" & larger cylinders) 5/8" - 11 62 (84)
Packing Case Cap Screw (less than15" cylinders) 3/4" - 10 110 (149)
VVP Bonnet Cap Screw 7/8" - 9 180 (244)
Valve Cap Retaining Cap Screw 7/8" - 9 200 (271)
Cylinder/Crosshead Guide Nut 7/8" - 9 200 (271)
Handwheel Nut 7/8" - 14 180 (244)
Piston Nut 1-1/2"-12 1200 (1627)
End Plugs 1/4" NPTF 15 - 20 (20 - 27)
Inspection door covers 3/8" 12 - 18 (16 - 24)
Foundation Bolt Touque to packager’s recommended value
GENERAL TORQUE VALUES1 1
To be used if not specified otherwise.
All Fasteners Size in Inches Torque Ft.-Lbs. (N-m)*
1/4 4-6 (5-8)
3/8 12-18 (16-24)
1/2 35-45 (47-61)
5/8 60-70 (81-95)
3/4 120-140 (163-190)
7/8 200-220 (271-298)
1 260-290 (353-393)
1-1/8 370-410 (502-556)
1-1/4 520-570 (705-773)
1-3/8 700-770 (949-1044)
1-1/2 930-1030 (1261-1397)
2
THOMAS COUPLING Use when coupling furnished by Superior. All other Thomas recommendations take precedence if
specified otherwise. Refer to Service Bulletin #149 for additional information.
Coupling Sizer Size in Inches Torque Ft.-Lbs. (N-m)*
500 3/4 - 16 265 (359)
550 7/8 - 14 350 (474)
600 1 - 14 490 (664)
Hoerbiger Valve "CT" Series Capscrew Torque2 See Table 7-4
3 - 1/4" - 4 - 3/8" CT Valves 3/8-24" UNF 17 - 21 (23 - 28.4)
4 - 7/8" - 8" CT Valves 7/16" -20 UNF 25 - 30 (33.8 - 40.6)
.
Page 7-2 Cooper Energy Services ■ Superior Compressors

Table 7-3 Acceptable Tolerance Cylinder Clearance Values

Assemblies* Clearance range in inches (mm)
Cylinder head - end clearance 0.070 - 0.090 (1.77 - 2.28)(cold)
Cylinder crank - end clearance 0.030 - 0.050 (0.762 - 1.27)(cold)
Packing case - rod clearance 0.005 - 0.010 (0.127 - 0.254)
Typical packing side clearance 0.017 - 0.024 (0.431 - 0.609)
Maximum cylinder wear1 0.030 (.762)
Maximum rod wear2 0.010 (0.254)

Side clearance-all VVP piston rings 0.008 (0.203)
1
Maximum cylinder wear factor is a general figure for Superior ductile iron cylinders. Beyond this point of wear the
cylinder may become unsafe for operation. Consult with an authorized Superior machine shop for reconditioning
information.
2Maximum rod wear generally is found in the packing areas. The wear is a general figure that indicates a point at which
the packing will no longer seal and leakage or "blow-by" will occur.
Table 7-4 "CT" Valves

Valve Valve Type Seat Seat Profile Pin Height Counter Center Stud
Diameter Dimension Retirem Land Depth(P.D.) (P.H.)Recess Bore Guide and Torque
(inches) ent Widths (inches) Dia.1 Ring (ft-lbs)
(inches) (inches)
3 -1/4 " 75CFT 1.060 .060 .020 .335 .512/.516 3/8-24(17-21)
4" 90CFT 1.060 .060 .020 .335 .512/.516 3/8-24(17-21)
4-3/8" 102CFT 1.060 .060 .020 .335 .512/.516 3/8-24(17-21)
4-7/8" 116CGT 1.060 .060 .020 .315 .670/.673 7/16-20(25-30)
5-1/4" 127CGT 1.060 .060 .020 .315 .670/.673 7/16-20(25-30)
5-3/4" 137CHT 1.060 .060 .020 .315 .670/.673 7/16-20(25-30)
6-1/2" 158CJT .870 .060 .020 .315 .670/.673 7/16-20(25-30)
7" 169CJT .870 .060 .020 .315 .670/.673 7/16-20(25-30)
8" 190CKT .870 .060 .020 .315 .670/.673 7/16-20(25-30)
Torque Recommendations
To insure satisfactory compressor performance and to minimize costly

CAUTION
When tightening nuts and bolts
failures, it is extremely important to tighten all nuts and bolts to the on compressor valve caps, bot-
recommended torque values specified in this section. Additional information tles, and flanges care must be
taken to avoid excessive tighten-
is given in Service Bulletins SB168, SB175, and SB253. Follow the ing. Over-tightening can result in
following general recommendations. unnecessary stress in the cylin-
• Torque wrenches should not be used to “break loose” fasteners. Use an der body and, in the case of valve
caps, can result in valve seat dis-
appropriate wrench or breaker bar. tortion.Inadequately torqued
bolts can damage crankshafts,
• Hand position is critical. Only pull from the hand hold to assure accuracy. frames and rods.
• Occasionally clean and lubricate the ratcheting head with light oil, NOT
GREASE.
• Periodic calibration is essential to ensure accuracy.

Figure 7-5 Diagram and Torque for Proportional Lubrication System

Table 7-6 Piston-to-Cylinder Bore Clearance, Ring End Gap and Side Clearance Values
*RC-rider/compression ring: R - rider ring; C - compression ring
Cylinder Diameter (inches) Piston to Cylinder Ring End Gap Side Clearance inches
Bore Clearance Type* (inches)
4-1/2 0.040 - 0.046 RC 0.095 - 0.105 0.009 - 0.014
5 0.040 - 0.046 RC 0.106 - 0.116 0.009 - 0.014
5-1/2 0.040 - 0.044 RC 0.127 - 0.137 0.009 - 0.013
6 0.050 - 0.054 RC 0.139 - 0.149 0.009 - 0.013
6-1/2 0.050 - 0.054 RC 0.139 - 0.149 0.008 - 0.012
7 0.050 - 0.054 RC 0.151 - 0.161 0.009 - 0.014
7-3/4 0.048 - 0.055 RC 0.168 - 0.178 0.005 - 0.010
8 - 1/4 0.048 - 0.055 RC 0.179 - 0.189 0.005 - 0.010
9 0.050 - 0.053 RC 0.202 - 0.212 0.008 - 0.013
9 - 1/2 0.050 - 0.053 RC 0.213 - 0.223 0.008 - 0.013
10 - 1/2 0.094 - 0.098 R 0.293 - 0.313 0.017 - 0.025

C 0.178 - 0.198 0.009 - 0.013
11 0.094 - 0.098 R 0.307 - 0.327 0.017 - 0.025

C 0.188 - 0.208 0.009 - 0.013
12 0.094 - 0.098 R 0.328 - 0.348 0.013 - 0.022

C 0.268 - 0.288 0.009 -0.017
12 - 1/2 0.094 - 0.098 R 0.341 - 0.361 0.017 - 0.022

C 0.279 - 0.299 0.009 -0.017
13 - 1/2 0.094 - 0.098 R 0.368 - 0.388 0.013 - 0.022

C 0.301 - 0.321 0.009 - 0.017
14 0.094 - 0.098 R 0.382 - 0.402 0.013 - 0.022

C 0.312 - 0.332 0.009 - 0.017
15 - 1/2 0.094 - 0.097 R 0.432 - 0.452 0.015 - 0.023

C 0.353 - 0.373 0.009 - 0.017
16 0.094 - 0.097 R 0.446 - 0.466 0.015 - 0.023

C 0.364 - 0.384 0.009 - 0.017
17 - 1/2 0.110 - 0.113 R 0.486 - 0.506 0.015 - 0.024

C 0.396 - 0.416 0.010 - 0.017
18 0.110 - 0.113 R 0.499 - 0.519 0.015 - 0.024

C 0.408 - 0.428 0.010 - 0.017
19 - 1/2 0.110 - 0.113 R 0.532 - 0.552 0.015 - 0.024

C 0.434 - 0.454 0.010 - 0.017
20 0.110 - 0.113 R 0.546 - 0.566 0.015 - 0.024

C 0.445 - 0.465 0.010 - 0.017

Valve-in-Head Cylinders Figure 7-8 Torquing Sequence for Valve-in-Head Cylinder
Table 7-7 Valve-in-Head Cylinder

Torque Values
Cylinder Class Fastener Torque
Size Size
14.00" 438 DC 1" - 8 290 ft-lb*
14.75" 437 DC 1" - 8 290 ft-lb*
15.50" 436 CC 1" - 8 290 ft-lb*
15.50" 417 CC 7/8" - 9 300 ft-lb*
16.00" 418 CC 7/8" - 9 300 ft-lb*
17.50" 419 CC 1" - 8 375 ft-lb*
18.00" 420 CC 1" - 8 375 ft-lb*
19.50" 421 CC 1" - 8 375 ft-lb*
20.00" 422 CC 1" - 8 375 ft-lb*
Follow these steps to properly

torque valve-in-head cylinders
(Figure 7-8).
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.
Step 3. Check all critical torque values according to the following schedule:
It is critical that the following preventative maintenance schedule be followed to prevent major
damage to your compressor (SB168).Check all critical bolt torques on components as follows:
• One (1) month after unit is placed in service
• Six (6) months after unit is placed in service.
• Every twelve (12) months thereafter.
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 7-9) or cross pattern sequence for all bolting except for the valve-in-head(Table 7-7
& Figure 7-8).

Typical Miscellaneous Flanging

Figure 7-9 Diagonal Torque Sequence
(Typical for miscellaneous flanging)
DANGER
When work is being done
on the compressor, the
driving unit must be block-
ed in such a way that the
compressor cannot turn
over. Block valves must be
closed on the suction and
discharge lines. Air or gas
must be bled off from the
cylinders. Precaution must
be taken to prevent the
opening of any valve which
would release pressure
against a piston, causing it
Precautions to rotate the unit at a criti-
cal moment.
Follow the precautions listed below when any maintenance is performed. Damage to the
equipment, personal injury or death may result if these precautions are not followed.
a. Block the flywheel to prevent rotation of the compressor and driver.
b. Remove all gas by unloading, venting, and then “blinding” the compressor. Blinding means to shut
off all block valves so there can be no process gas flow to the compressor.
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.
j. Do not refinish worn valve plates.
k. When reassembling parts during maintenance, replace all worn or damaged gaskets and seals.
l. Always install new cotter pins or lock wire.

m. Check and clean all lubricating oil passages when the unit is down for repair or normal maintenance.
n. After a long period of shutdown or a major overhaul, frequently check the unit during the first 300
hours of operation.
o. After completing maintenance, remove any locking or blocking devices before attempting to rotate
the equipment.
Maintenance Figure 7-10 Compressor Running Gear

The compressor frame is rigidly
constructed and precision bored to
house the main bearings,
crankshaft, and crosshead
assemblies. The lower part of the
frame provides an oil sump and
main oil header. The differences
between the two- and four-throw
compressor frames are few. The
four-throw compressor frame has
the additional size and running
gear parts to accommodate the
addition of two more throws. The
parts of the running gear are the frame, crankshaft, main bearings, connecting rods, and the crossheads
(Figure 7-10).
Main and Connecting Rod Bearings Figure 7-11 Crankshaft Showing Main/
The main and connecting rod bearings are of the Connecting Rod Bearing
removable "tang" type, with the bottom half of the
main bearing fitting into the saddle of the frame, and
the top half fitting into the bearing cap(Figure 7-11).

Figure 7-12 Connecting Rod and Bearings

The precision tri-metal bearing
shell is constructed of a steel-
backed bronze with a babitt
overlay and needs no shimming
or scraping to be installed with
the correct clearance. The
connecting rod bearing and frame
main bearing use the same
bearing shell to minimize parts
inventory. The rod bearing is
cradled inside the crank-end bore
of the connecting rod with one
half of the shell against the rod
cap and the other against the rod
itself (Figure 7-12).
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 access to the Figure 7-13 Dial Indicator
bearings and crankshaft.
b.Use a magnetic base to secure the dial indicator

(Figure 7-13) to the bearing cap. Mount the indicator
so the button contacts the crankshaft at its highest
point. Depress the button until the dial makes one
complete revolution, then set the pointer to zero.
c. Use a suitable hydraulic jack that will fit between the

crankshaft and frame bottom (about 4"-102mm).
Position it as close as possible to the bearing being
checked.
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. If the clearance reading
exceeds the maximum limit, replace the bearing with two new bearing shells.

Changing Main/Connecting Rod Bearings
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 CES distributor representative for trained field assistance.
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-
CAUTION
The main bearing and connect-
lb (Table 7-2). This helps support the crankshaft and facilitates easy removal ing rod cap bolts must be prop-
of the other bearing sets since the crankshaft has a tendency to sit on its erly torqued and maintained at all
heavy driven end and rise on the lube oil pump end. times. Under no circumstances
should the compressor be
allowed to run without the proper
To change the main bearings, follow these steps: torque applied to these critical
components.
a. Remove a bearing shell by inserting the neck of the main bearing removal Figure 7-14
tool (Figure 7-14) into the oil passage hole in the crankshaft journal. Main Bearing
When the unit is rolled over, the tool pushes the shell out from underneath 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. This offers easy access to the rear cap bolts. Support 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 cap back into position and tightening the two bolts to their proper
The caps and rods are
numbered by throw
and have their weights
torque as stated in Table 7-2. stamped on them. Always install
rods with this information dis-
played up.

Connecting Rods Figure 7-15 Connecting Rod and Bearings
Each connecting rod is a typical forged

design (Figure 7-15). A hole is rifle-
drilled from the crank end through the
length of the rod to the crosshead end.
This allows lubrication of the two pin
bushings, which are pressed into the
crosshead eye end of the rod. The
pressurized oil is forced through the
connecting rod eye to lubricate the top
and bottom crosshead shoes.
Procedures for removing, inspecting
and reinstalling the connecting rods are
found below.
Connecting rod removal process steps:

*See the RAM 52 & 54 frame bills of material for complete parts identification
a. Shut down the driver and compressor, and Figure 7-16 Top Cover Assembly
isolate it from the power source.
b. Relieve pressure in the cylinders.
c. Drain oil from the frame base sump.
d. Refer to and remove screws (4), washers (2)

and (3), and top cover (1) (Figure 7-16).
e. Remove the breather (9) from the top cover.
f. Remove screws (13), washers (11) and (12),

crosshead cover (10) and O-ring (9)
(Figure 7-17).
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)
CAUTION
Take extreme caution to adequat-
(Figure 7-29). edly support the connecting rod.
If care is not taken during the
bearing removal prcess, personal
i. Remove dowel pins (4) and bearings (8) from the rod caps. injury and equipment damage
could result.
j. Bar the compressor over until the crosshead pin is accessible through the
crosshead cover opening.

k. Refer to Figure 7-19 and remove the snap Figure 7-17 Frame, covers & components
rings (5) and the crosshead pin (4).
l. Bar the compressor over to achieve maximum

clearance between the crankshaft and
connecting rod, remove the rod.
m. Refer to (Figure 7-15) and remove bearing

(8) from the connecting rod (3).
n. Repeat steps g - m for the remaining installed

connecting rods.
Inspection
Inspect the connecting rod and compare the

results to the data in Table 7-18 to assure that parts have not exceeded
maximum wear limitations. If you discover the crosshead pin bushings need
CAUTION
If you need to change the cross-
changed or the rod needs re-bored to restore proper running clearance, send head pin bushings, contact your
the rod to the nearest CES 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
Connecting Rod Eye Bore Diameter 3.7485 - 3.7490 (95.212 - 95.224) an authorized machine shop.
Maximum Eye out-of-roundness .0005 (0.0127)

Rod-to-bushing interference fit 0.0035 - 0.006 (0.088 - 0.152)
Bushing ID after assembly 3.5015 - 3.5020 (88.93 - 88.95)
Crosshead pin diameter 3.4985 - 3.4980 (88.86 - 88.84)
Operating Clearance 0.003 - 0.004 (0.076 -0.101)
To complete the connecting rod inspection, follow these steps:

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 replace the
bearings if you notice cuts or grooves parallel to bearing rotation.
6. Refer to Table 7-1 to check important clearances.

Installation
Press-fitting bushings into the connecting rod assembly is sufficient in most cases. But we
recommend that you shrink-fit the bushings by freezing the bushings in dry ice for 30 minutes.
During this time, preheat the eye of the rod to 300-350 °F. When the rod is preheated, lay it flat on a
smooth surface. This allows the edge of the bushing to fit flush with the edge of the eye of the rod.
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:
CAUTION
The complete bearing set (two
halves) must be replaced as a set.
a. Have bushings (1) (Figure 7-15) installed into connecting rod (3) at a Replacement of only one bearing
CES authorized distributor. half may cause serious damage to
the connecting rod and/or crank-
shaft.
b. Install bearing (8) into connecting rod (3).
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). CAUTION
The main bearing and connecting
e. Secure the connecting rod to the crosshead with crosshead pin (4) and snap rod cap bolts must be properly
rings (5) (Figure 7-19). torqued and maintained at all
times. Under no circumstances
should the compressor be allow-
f. Install the connecting rod into the proper position against the crankshaft. ed to run without the proper
torque applied to these critical
components. Damage to equip-
g. Install the dowel pins (4) and bearing (8) in rod cap (5) (Figure 7-15). ment may result if the torque
specification on any item is
h. Secure rod cap (5) to connecting rod (3) with bolts (2), washers (6) and ignored.
nuts (7). Refer to Table 7-2 for correct torque.
i. Inspect and install the crosshead as described under the next corrective
maintenance topic, Crosshead and Crosshead Pin. Loctite grade 515 is
the required sealant
for the top cover.The
correct application of
j. Install the crosshead cover (10) and O-ring (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).
k. Apply sealant to the top opening of the frame.

l. Install the top cover (1) using screws (4) and washers (2) and (3) (Figure 7-16).
Crosshead and Crosshead Pin Figure 7-19 Crosshead Assembly
The crosshead (Figure 7-19) is made of ductile iron

and is machined to accept two aluminum shoes. 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.
The crosshead pin is a full-floating design. It is secured

within the crosshead and the eye of the connecting rod
by two snap rings.
*See the RAM 52 & 54 frame bills of material for complete parts identification
To remove a crosshead proceed as follows:

a. Vent compressor clearance bottles, unloaders and all associated gas piping to atmospheric pressure.
b. Bar over the compressor so piston is in the outer most position.
c. Remove screws (13). washers(11) and (12), crosshead cover (10) and O-
CAUTION
Do not place any wrenches
ring(9) (Figure 7-17). directly on the piston rod surface.
Damage to the rod surface, which
d. Bar the compressor over so the crosshead pin (4) in Figure 7-19 is contacts the rod packing, may
result in a bad seal.
accessible through the crosshead cover opening.
e. Remove snap rings (5) and crosshead pin (4).
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.

h. Remove the cylinder head . Figure 7-20 Special RAM Tools

Item Name
1 Valve removal bracket
2 Valve removal tool
3 Main bearing removal tool
4 Crankshaft seal expander
5 Rod insertion tool
6 Auxiliary lube drive shaft seal installer
7 Crosshead tool handle
8 Crankshaft seal installer
9 Crosshead tool
10 Spanner wrench
11 Jam nut wrench
i. Turn the piston and rod assembly out of the crosshead using the spanner wrench (Figure 7-20).
j. Position the crosshead as nearly aligned with the crosshead cover opening as possible
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)
m. Remove screws (8) and balance weight(s)(6).
Inspection
Complete your crosshead inspection by following these steps:

d. Refer to Table 7-1 check important clearances.
Installation
The following procedure describes how to reinstall the crosshead components:

a. Install the balance weight(s)(6) onto the crosshead (3) and secure with screws (8) (Figure 7-15).
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.

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
securing with screws (13) and washers (11) and (12). be replaced accordingly.
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. 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
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 components
the opposite end of the oil pump. A hub
mounted on this extension allows the
compressor to be coupled with the driver.
At the point where the crankshaft extends
beyond the frame wall, a seal prohibits oil
leakage. This seal allows removal and
maintenance using special tools (Figure 7-
20). Remove the crankshaft to replace this
seal. We recommend crankshaft removal be
performed by authorized CES distributor.
The crankshaft seal should be changed
whenever you detect leakage. The steps for
removal, inspection, and installation are
presented in the following procedures.

Removal of Crankshaft (Figure 7-21):

a. Shutdown the driver and compressor, and isolate it from the power source.
b. Relieve pressure in the cylinders.
c. Disconnect coupling (5) between the driver and frame and remove any
DANGER
Take extreme caution to ade-
coupling components from the drive end of the crankshaft (7). quately support the rod. If care
is not taken during the bearing
d.Drain the oil from the frame sump. removal process, personal
injury and equipment damage
could result.
e.Referring to Figure 7-16, remove screws (4), washers (2) and (3), and top cover (1).
f. Referring to Figure 7-17, remove screws (1), lockwashers (2) and drive-end cover (3).
g. Again referring to Figure 7-17, remove spacer bar nuts (7) and o-rings (6).
h.While holding the spacer bar (4) with one hand, withdraw the spacer bar stud (5) and remove both
the bar and stud.
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).
j. Bar the compressor over to separate the crankshaft from the connecting rod, carefully laying the rod
end in the bottom of the base sump.
k. Referring to Figure 7-21, remove bolts (1), washers (2) and main bearing caps (3).
l. Remove bearing shells (4) from the bearing caps.
m. Remove the force-feed lubricator as described later in this section.
n. Remove the lube oil pump as described later in this section.
o. Referring to Figure 7-22, remove screw (10), lockwashers (9) and auxiliary end cover (7).
p. Remove screws (4) and stub shaft gear assembly (1).
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.

Inspection
Follow these steps to complete crankshaft inspection:

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.
f. Check gears for wear that prevents correct meshing.
g. Refer to Table 7-1 to check important clearances.

CAUTION
The complete bearing set (two
Installation halves) must be replaced as a
set. Replacement of only one
bearing half will cause serious
The following procedure guides you through reinstallation of the crankshaft damage to the crankshaft.
and related components:
a. Install bearing shells (4) and thrust bearings (8) into the base (Figure 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.
d. Assembly gear (2) onto stub shaft (3) (Figure 7-22).

Loctite grade 515 is th
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).
h. Inspect and install the lube oil pump (Figure 7-28).
i. Inspect and install the force-feed lubricator (Figure 7-22).
j. Install the bottom four lockwashers (9) and screws (10) to the auxiliary end cover (7) (Figure 7-22).

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.
n. Referring to Figure 7-17, install spacer bar (4) and spacer bar studs (5). Secure with nuts (7) and
O-rings (6). Refer to Table 7-2 for correct torque.
o. Apply sealant to the drive-end opening of the base.
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.
r. Apply sealant to the top opening of the frame.
s. Install the top cover (1), securing with screws (4) and washers (2) and (3) (Figure 7-16).
t. Refill the frame oil sump.
u. Referring to Figure 7-21, reconnect coupling (5) between the driver and frame.
Force-Feed Lubricator Figure 7-22 Force-Feed Lubricator
The RAM compressor cylinders are lub-

ricated with a force-feed lubricator (Figure
7-22). It is driven directly by a coupling off
the crankshaft drive gear. During periodic
overhauls, check the coupling for wear.
Refer to ES1002 for the amount of cylinder
oil required by a particular packing case or
cylinder. A gradual pressure loss or leaking
O-ring seals requires that the lubricating
pump be rebuilt.
Removal
Steps to remove the force-feed lubricator:

b. Place a suitable container under the lubricator and remove drain plug to drain the oil. Dispose of
the oil according to local or offshore regulations.

c. Disconnect and remove the oil lines. Figure7-23 Coupling and stub shaft
d. Remove the two screws and
lockwashers, which hold the coupling
guard. Remove the coupling guard.
e. Remove the screws, lockwashers and

shim washers from the lubricator bracket.
Remove the lubricator while pulling apart
the coupling.
f. Remove the setscrew from the coupling

half attached to the lubricator. Remove
the coupling shock absorber, coupling
half and key from the lubricator shaft
(Figure 7-23).
g. Remove the setscrew from the coupling half attached to the frame. Remove the coupling half and
key from the stub shaft. Then remove the stub shaft seal.
h. Remove the remaining screws and lockwashers from the lubricator bracket.

Inspection The stub shaft/gear
assembly is shrink
fitted. The avail-
Follow these steps for inspecting the lubricator: able interference
assembly fit of the stub
a. Clean all parts before inspecting. shaft into the drive gear is
0.0005-0.0020 inch
b. Check for physical distortion, wear, cracks, and pitting. (0.013-0.051 mm).
c. Check sealing surfaces for nicks, burrs, and scratches, which may damage the seal.
d. Examine sediment adhering to the drain plug (Figure 7-24) for accumulations of grit or fine metal
particles. They may indicate actual or potential component failure.
e. Examine tubing for kinks or leaks. Inspect fitting threads for damage.
CAUTION
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
a. Install the lubricator bracket with screws and lockwashers. prevent burns.
b. Heat the drive gear to between 470 °F and 600 °F (243 °C and 316 °C). Install the gear onto the
stub shaft.

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.
e. Install the coupling shock absorber onto Figure7-24 Lubricator worm and gear drive
the coupling half. Tap the shock absorber
oil filter
with a wooden mallet to assure a snug fit.
f. Place the lubricator onto its bracket base

with the shim washers properly aligned
under the lubricator. Be sure the coupling
halves and shock absorber fit together
snugly. Secure the lubricator to its
bracket with lockwashers and screws.
g. Install the coupling guard with the two

screws and lockwashers.
h. Reconnect the oil lines.
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.
Oil Filter Figure7-25 Oil filter & related components

Before the oil travels to the main gallery, it
passes through the oil filter (Figure 7-25).
This filter contains paper elements which
you must change regularly in accordance
with the maintenance schedule in Section 3 .
Follow the steps below for removal,
inspection, and installation.
*See the RAM 52 & 54 frame bills of

material for complete parts
identificationRemoval
Steps to remove the oil filter:

b. Disconnect the tubing from the reducer bushing (2).
c. Remove the threaded nipple (9) and pipe coupling (10).

d. Remove screws (15), lockwashers (7) and oil header flange (14).
e. Remove the reducer bushing (2) from the reducing tee (1).
f. Remove the reducing tee and close nipple (3).
g. Remove the elbow fitting (8) and nipple (9).
h. Unscrew the filter housing (18) from the filter head (4).
i. Remove the filter element (19) and O-ring (20) from the housing.
j. Remove the oil filter head (4) from the bracket (5) by removing screws (6) and lockwashers (7).
k. Remove the bracket (5) by removing screws (6) and lockwashers (7) that secure it to the base.
Inspection
Follow these steps to inspect the oil filter:
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.
d. Inspect fitting threads for damage. Figure7-26 Pump assembly strainer

e. Also examine the pump strainer element
(Figure 7-26) for debris whenever you replace the
filter element.
Installation
Once you've completed inspecting the oil filter,

again refer to Figure 7-26 as you follow these steps
to reinstall the oil filter:
*See the RAM 52 & 54 frame bills of material for

complete parts identification
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)

c. Attach the filter housing to the filter head (4).
d. Install the oil filter head (4) onto bracket (5) with screws (6) and lockwashers (7).
e. Install elbow fitting (8).

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.
i. Install coupling (12).
j. Reconnect the tubing to the reducer bushing (2).
Hand Pump 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
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.
See the RAM 52 & 54 frame bills of

material for complete parts identification
Removal
Steps to disassemble the hand pump:

a. Shut down the compressor.
b. Disconnect fittings and remove the tubing (3 and 8).
c. Remove elbows (2 and 9) and nipple (10).
d. Remove elbow (2) and bushing (1).
e. Remove screws (6), lockwashers (7) and hand pump (4).

f. Remove screws (6), lockwashers (7) and bracket (5).
Inspection
Steps through the hand pump inspection process:

c. Examine tubing for kinks or leaks.
d. Inspect fitting threads for damage.
Installation
To reinstall the hand pump, simply reverse the steps for Removal.
Lube Oil Pump Figure7-28 Lube oil pump & components

Both the RAM 52 and 54 series
compressors use the same lube oil pump.
Figure 7-28 shows the pump assembly and
related components. Only the driven gear is
different to accommodate the increased
lubrication needs of the RAM 54. The
crankshaft/lubricator driving gear directly
drives the lube oil pump.
The system applies lubricating oil in the

frame under positive pressure. First it goes
to the lube oil manifold cast in the bottom of
the frame. Then it lubricates the main and
rod bearings, crosshead pin bushings, and
the crosshead shoes. The following information describes removal, inspection, and installation
procedures for the lube oil pump.
See the RAM 52 & 54 frame bills of material for complete parts identification
Removal
Steps for removing the lube oil pump (Figure 7-27&28).

b. Disconnect the fittings to remove tubing (3) and (8) (Figure 7-27).


c. Remove coupling (20) (Figure 7-28). You can leave these
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).
g. Remove screws (5) and lockwashers (6).
h. Carefully pull pump (2) and gear (4). Leave adapter (9) doweled in place.
i. Pry gear (4) from the pump shaft.
j. Remove bushing (13), magnetic plug (14) and strainer screen (12) from strainer (11).
Inspection
Steps for inspecting the lube oil pump.

a. Examine the strainer screen (12) and magnetic plug (14) for debris. If you discover debris, inspect
the oil filter housing and element (see parts 18 and 19 in Figure 7-25). Check the frame for source of
the debris.
b. Clean all other parts before inspecting.
c. Check all parts for physical distortion, wear, cracks, and pitting.
d. Check sealing surfaces for nicks, burrs, and scratches which may damage seal.

e. Examine tubing for kinks or leaks. Loctite grade 515 is
the required seal-
ant for the auxiliary
f. Inspect fitting threads for damage. end and lube oil
pump flange. The correct
application of this sealant
g. Check gears for wear that prevents correct meshing. to mating surfaces, as
described in the manufac-
turer’s instructions, is
Installation essential to prevent oil
leakage.
Steps for reinstallation of the lube oil pump (Figure 7-28).
a. Check Superior service for instructions if the gear on the pump needs to be replaced. It is
recommended to change the whole assembly.
b. Apply sealant to the pump flange (2).

c. Install the pump to the adapter plate (9) with screws (5) and lockwashers (6).
d. Apply sealant to the auxiliary drive opening of the base.
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).
h. Install bushing (24) and nipple (23).
i. Install threaded tee (21), nipple (15), elbow (18) and nipple (19).
j. Install nipple (10), strainer (11), nipple (15), check valve (16), nipple (17), elbow (18) and nipple
(19) - if these components were removed.
k. Refer to Figure 7-27 and install tubing (3) and (8).
l. Install coupling (20). Figure 7-29 Top cover assembly

Measuring Oil Pump Gear Lash
You should periodically check backlash

clearance of the gears to monitor wear on the
mating teeth. The following steps guide you
through this process:

a. To optimize your time and effort, we Figure7-30 Position of guide bracket

recommend obtaining all the parts need
beforehand. These include measuring rod,
guide bracket and dial indicator.
b. Refer to Figure 7-29 and remove screws

(4), washers (2) and (3), and top cover (1).
.c. Position the guide bracket and measuring

rod as shown in Figure 7-30.

d. Take care to position the flat end of the Figure7-31 Measuring rod & dial 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.
e. Locate the dial indicator as shown in

Figure 7-31. Note the positions 1 - 4 on the
oil pump gear face. These positions are
important for completing the next step.
f. You can manually rotate the pump gear

through the suction or discharge ports, or through the top cover opening.
Rotate the pump shaft clockwise until it stops.
CAUTION
If the spacer plate and/or end
plate are adjusted, you must
g. Set the dial indicator to zero. re-dowel pin them before
operating the compressor.
If you change the pump gear,
h. Manually rotate the pump shaft counterclockwise until it stops. Note the it must be heated to 470ºF -
dial indicator reading. This amount of movement of the measuring rod - 600ºF and shrunk fit onto
measured by the dial indicator - is the backlash between the teeth of the oil the oil pump gear shaft
for an interference fit of
pump gear and the drive gear. 0.0001 to 0.0025 inch.
Do not adjust the backlash to
less than 0.0006 inch.

The correct sequence for measuring the oil pump gear backlash on a RAM 54 The overall diame-
ter of the oil pump
compressor frame is 2, 1, 4 and 3. Since the oil pump gear on a RAM 52 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
components con-
positions as prescribed for each RAM model. nected if you are
inspecting the pump
j. If backlash is more than .014 on a new and over .020 on an old compressor with the strainer in place.
change the parts. Repeat the backlash process after parts are replaced. The
readings should be .010 to .014 with a variation of .004.

Crankcase Pressure Relief Valve Figure 7-32 Pressure Relief Valve
We recommend that you service the Bicera

pressure relief valve at least once a year. This
service includes visual inspection to assure
the valve is operating normally and that the
cover is properly secured. Also replace O-
rings and gaskets at this time (Figure 7-32).

Follow these steps for servicing the valve:

a. Shut down the compressor and allow it to
cool until you can touch it with your bare
hands.
b. Remove the valve and adapter plate from

the compressor.
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).
i. Place seal retainer (10) over the O-rings.
j. Place spring, with spring caps on each end, over the

spindle so the bottom cap sits over the seal retainer.

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.
door gaskets as needed. Reinstall the inspection door.
Disc Pack Flexible Coupling
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.
Drive Coupling Hub Figure 7-34 Removing Crankshaft Coupling Hub
The main drive coupling hub has a

shrink taper fit on the compressor
crankshaft. Additionally, the hub is held
in place by a round locknut which
threads onto the end of the crankshaft
and is locked in place by “Nylock”
setscrews.
The coupling hub is removed as follows

(Figure 7-34):
a. Loosen lock nut (E), after first
unlocking its setscrews, until there is
1/8" (3mm) of space at dimension (X).

b. Mount steel bar (G) in the manner illustrated. Putting a 1-1/2-6 UNC tapped hole at its midpoint will
permit a standard 1-1/2 UNC cap screw to be used as a jackscrew.
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).
g. Remove the jackscrew and bar arrangement.
h. Remove nut (E); the hub can then be lifted off by crane or by hand.
If the proper equipment is not available, the most practical method of removing the coupling hub
from the crankshaft is by first removing the crankshaft from the base. The crankshaft and drive end
cover plate may now be taken to a suitable work area where the locknut is removed, the hub heated
and pressed off the crankshaft.
Install the coupling hub onto the crankshaft as follows:

a. When at room temperature, push the hub on the crankshaft taper as far as possible.
b. Push the crankshaft all the way to one side to take up any thrust clearance that may be present.
c. Use gage blocks and shims to fill the space between the coupling and the compressor end cover.
d. Remove the amount of shims needed to provide an advance of the hub on shaft of 0.050" (1.27 mm).
e. Heat the coupling hub and slide it on the shaft until it engages the gage block (with the reduced
amount of shims as defined in item d above).
f. Hold hub in position until it is cool enough to engage the crankshaft.
g. When hub has cooled to room temperature, install lock nuts and Nylock setscrews.
Flexible Drive Coupling
Obtain the most recent version of Service Bulletin SB149 for detailed information on flexible drive
couplings. The flexible drive coupling will give you relatively trouble-free service and long life if
installed and maintained properly. The coupling was selected based on known loads and operating
conditions of the driver and driven equipment.
Initial alignment is one of the most critical factors affecting coupling performance.It should be re-
membered that the couplings are basically in-line devices which are intended to compensate for small
amounts of shaft misalignment caused by bearing wear, foundation settling, thermal growth, etc.

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.
Troubleshooting Rexnord Couplings
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.
Figure 7-35 Elongated Bolt Hole-Disc had broken

▼
through bolt hole. Indicates loose coupling bolts. Replace

disc pack and tighten bolts to specified torque value.
00767
Figure 7-36 Scored Body Bolt-Discs embedded into bolt body.

Usually a result of a loose bolt. This may also be caused by turning
the bolt during installation. Replace the bolt and tighten locknut to
00768 proper torque. Do not turn the bolt during locknut tightening process.
Figure 7-37 Misalignment failure-Disc is broken adjacent to

washer face. Usually indicates excessive shaft misalignment during
operation. This type of disc failure usually starts in the outer discs in
00769 the pack and progresses through the disc pack. Realign equipment and
replace disc pack. Make HOT check of alignment to assure it is within
coupling misalignment capacity.

Figure 7-38 Compression-Disc pack is wavy and dimension between
flange faces is smaller that indicated on installation instructions. This
means that the coupling was installed in a compressed condition or
equipment has shifted axially during operation. Check for thermal
growth. If the application is a bearing motor, verify that the operating
center line of the motor rotor is properly positioned.
t Figure 7-39 Elongation-Disc pack is wavy and dimension between

o flange faces is larger than specified on installation instructions or appli-
r cable assembly drawing. The coupling has been installed in an elongated
q position or equipment has shifted axially during operation. Realign posi-
u tion of equipment so coupling operates with a neutral flat disc pack. If
e sleeve bearing motor, make sure operating centering on motor rotor is in
proper position.
O
v
Figure 7-40 Fatigue Failure-Disc is broken adjacent to the wash-

er face with heavy corrosion along area of break. This failure is typi-
cal of discs that have been in service for years or have been operating
00770 in an offshore environment. Breaks will first appear in the outer discs
and will progress into the disc pack. If excessive corrosion exists, they
should be replaced with stainless steel plating.
▼
! Caution
Figure 7-41 Torque Overload If bulged or bowed condition
only appears in one chordal section there may be a loose bolt on
one side of the distortion. Loosen coupling locknuts and turn bolt
slightly to remove friction. Bulge should flatten out. Re-torque
locknuts. If distortion does not disappear, replace disc pack.

Torque Overload (Visible only with strobe light while running)
The disc pack has a bulge near the center or is bowed toward one flange in every other chord position
Figure 7-41. 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
CAUTION
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 the piston rod through the piston rod packing, prepare the rod as described in
Section 5.

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.
Piston Rod Packing

Figure 7-42Typical Lubricated Wiper Packing Case
Piston rod packing comes in many
different arrangements and designs.
This manual will not explain each
individual design, but should contain
enough detail to allow you to success-
fully remove, maintain and install the
piston rod packing on your compressor.
There are two different types of

packing; lubricated and non-lubricated.
The RAM compressor uses both
designs, depending upon the type of
cylinder. Typically, the cylinders
ranging from 4.5" - 14" (114 - 356 mm)
bore have lubricated packing case(s),
and all otheres are non-lubricated.
Oil is fed directly to lubricated packing

cases by a force-feed lubricator pump
driven by the crankshaft gear. A system
of strainers, distribution blocks, and
check valves deposits a predetermined
amount of lubrication in the packing case and/ or cylinders. Refer to the lubrication schematic in the
frame bills of materials section for further information.
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 distributor.
Ordinarily, packing cases (cups and

glands) are not severely worn.
Therefore, it is possible to repair piston
rod packings by replacing the packing
rings only. It is good practice to keep a
complete set of packing rings on hand
for the packing assemblies of all your
cylinders.
In order to remove a packing case ▼ 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.
Before disassembling a packing case,

note all identification marks to ensure
components are reassembled
properly. If components are not
marked, identify each cup’s position
relative to the adjacent cup or flange
by numbering or marking them
together. While disassembling a
packing, record the position of each
ring and the direction each ring faces
for proper reassembly.
Refer to Figure 7-45 for aid in

identifying packing rings. Knowing
your packing rings is very helpful when ordering new ones.

▼ Figure 7-45 Typical Packing Configurations
00776

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
CAUTION
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.
for burrs. If found, burrs should be removed. Also, replace the o-ring in the
outside diameter of the wiper packing flange with a new one.
A new metallic gasket should be placed in the groove of the pressure

packing nose cup. Remove the old metallic gasket with a sharp tool; take The rings must be
placed in the packing
care not to damage the groove. Clean the groove thoroughly and install a cups in the 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 Installation
Suction and discharge valves must be installed in the proper direction. This can be determined by first
inspecting the valve to see which direction the valve plates move while opening or compressing the
springs. Gas will flow in that same direction (Figure 7-45).
Valve Replacement
Proceed with valve removal in the following manner(Figure 7-46):

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.
c. Loosen set screw in valve retainer

(bottom valves only). Insert threaded
puller into valve retainer and remove.
d. Using threaded valve puller, remove

valve from seat in cylinder.
e. Remove, inspect and replace gaskets as

needed.
f. Clean all gasket surfaces on valve and in

valve pocket, and on valve retainer and on
valve cap.
g. Install new gasket in valve pocket.

Place valve in pocket FACING
PROPER DIRECTION.

h. Install the retainer on top of the valve. Install new gasket in place on 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. 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. Place valve on top of retainer with valve 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.

Figure 7-47 Valve Replacement

Alarms and Shutdowns
Each unit is equipped with a specified complement of electrically or pneumatically operated

alarm and/or shutdown devices. These devices are designed to protect the unit in the event of any
abnormal operation or any malfunction which may occur. Each device should be checked and
reset after each shutdown, or at least once every six months - whichever is sooner, 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 distributor.
Table 7-48 Recommended Alarm Set point
Alarm/Shutdown Normal Condition Alarm Point Shutdown Point
Oil Pressure in Header 45-55 psig (310-380 kPag) 25 psig (173 kPag) 20 psig (138 kPag)
Oil Temperature out of 160-180°F (71-82°C) Out 185°F (85°C) Out 190°F (88°C) Out
the Frame
Vibration Nominal 1/4-3/8 turn from normal 3/8 - 1/2 turn from normal
condition condition
Gas Temperature Suction (TS) or Discharge 20°F (11°C) above TS or 25°F (14°C) above TS or
(TD) TD TD
Water Temperature Tin or Tout 20°F (11°C) above T out or 25°F (14°C) above Tout or
Tin Tin
Gas Pressure Suction (PS) or Discharge 5% below PS 10% below PS

(PD) 5% above PD 10% above PD

System Recommended Maintenance Schedule
Adhering to Table 7-49 will result in less equipment down time and less operating costs.
Table 7-49 SYSTEM Recommended Maintenance Schedule
CONTROLS Daily Weekly Monthly Semi-Annually Annually
or as
Needed
Perform safety shutdown system tests. X
Note and record panel gauge readings. X
Check calibration of all themometers and pressure gauges. X
LUBRICATION SYSTEM
Check oil levels, oil level regulator, and oil sight level. X
Check lubricator line connections for leakage. X
Inspect frame, lubricator, and packing cases for leakage. X
Clean and/or replace crankcase breather(s). X
Check compressor force feed lubricator pump(s) for proper output rate. X
Collect a compressor oil sample for analysis. X
Change compressor oil and filters elements after the first 400 hours of compressor operation. Oil and filter change periods can then
be extended out to 2000 hours of operation. Change lube oil filters when differential pressure reaches 12 to 15 psi.
Replace O-rings. X
MECHANICAL/OPERATING SYSTEM - CYLINDERS
Note and record inlet temperatures. X
Check for loose cylinder fasteners. X
Note and record cylinder discharge temperatures. X
Hand check suction valve covers from coolness. X
Listen for unusual noises. X
Check temperatures of coolant to and from cylinders, lube oil cooler, and X
packings.
Check one compressor valve on each stage. Inspect for broken plates, bro- X
ken springs, and trapped solids or liquids.
Remove the distance piece cover from the crosshead guide and inspect the X
packing area on each piston rod.
Remove head and piston of the first stage cylinder. Check cylinder bore, X
piston rings, packing rings, piston, and rod bearing.
MECHANICAL /OPERATING SYSTEM - FRAME
Check crosshead clearances. X
Check crosshead guide for wear metals. X
Check foundation bolt torques.
Check compressor coupling for proper alignment. X
Visually inspect frame interior for bearing material in frame, gear tooth X
condition, crosshead shoe and guide condition.
Roll out compressor thrust main lower shell for inspection. X
Check compressor accessory drive gear lash and general condition. X

Troubleshooting
Troubleshooting is the process of finding operational problems. This section describes the difficulties
which may arise during operation of a compressor, the typical origins or sources of these problems
and suggestions on how to repair the trouble. The following steps should be followed in all
troubleshooting activities:
a. Determine what general area is affected - frame, cylinders, lubricating system, etc.
b. Analyze the symptoms (clues) to pinpoint the exact location of the problem valves, bearings, etc.
c. Replace all defective or damaged parts.
d. Return the unit to service and verify that normal operation is resumed.
Tables 7-50 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
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 Defective shutdown device. Check the control system and device for proper operation.
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 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
nuts or crossheads to obtain this balance.
Worn bearings. Possible broken frame, Verify crankshaft alignment, piston rod runout, and
connecting rods, crankshaft, or bearing clearances. Replace bearings as needed.
piston rods. Reverify alignment and runout.
Improper Foundation damage, Realign the compressor per Section 5.
compressor foundation bolt failure, grout
installation and cracking, or broken frame and
alignment. crankshaft.
Gas pulsation. Excessive vibration causing Analyze compressor with a vibration or indicator analyzer.
cracked welds, foundations, Install orifices at the cylinder flange, change piping,
grout, and parts. Also possible change cylinder operating configuration, or change
foundation bolt breakage. operating speed.
Loose valves. Valve seat damage, broken Remove valve and retainer. Replace broken parts. Dye
valve bodies, or broken valve check the cylinder valve seat for cracks. Install new valves
retainers. and tighten to proper torque.

Table7-51 Oil System Troubleshooting

No lube oil Lack of oil Scored bearings, crankshaft, Check all lubricated surfaces and replace parts as
pressure crosshead shoes and pins. required. Fill with oil to the proper level.
Possible seizure of
compressor.
Clogged strainer or Same as above. Check all lubricated surfaces and replace parts as
filters. needed. Replace filter element and/or strainer.
Lube oil pump or drive Same as above. Check mating gears and replace if needed. Check
gear. pump end clearances.
Air leak in suction piping. Same as above. Repair leaks as needed.
Low lube oil Low oil level. Scored bearings, crankshaft, Check all lubricated surfaces. Fill with oil to the
pressure crosshead shoes, and pins. proper level.
Seizure of compressor is
possible.
Clogged or dirty filters. Same as above. Check all lubricated surfaces and replace parts as
needed. Replace filter element and/or strainer.
Air leak on suction side Same as above. Find and stop leak.
of pump.
Sticking or maladjusted Same as above. Free or adjust valve.
pressure relief valve.
Excessive main and Same as above. Replace defective bearings.
connecting rod bearing
clearance.
High lube oil Lube oil cooler clogged Reduce viscosity resulting in Clean cooler.
temperature or dirty. lower lubrication and filtration.
.
Insufficient warm cooling Same as above. Correct water flow problem or temperature.
water through cooler.
Table 7-52 Cylinder Area Troubleshooting

Failure to deliver gas Restricted 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 or any other worn, broken, and
pressure between stages with insufficient rod defective parts.
reversal, resulting in pin failure
Deposits on Possible broken plate valves or springs. Clean and replace any defective
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 bore overheating Replace with new rings
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 parts
as damage to the piston rods, crossheads,
crosshead guides, and connecting rods.
Collateral damage from broken parts
entering the cylinder bore
Open or Same as above If damaged, repair or replace
defective fixed/ defective parts
variable pocket
head

Table 7-52 Cylinder Area Troubleshooting (Continued)
Low compressor cylinder Loose valve(s) Same as above. Also, check for valve seat Remove valve and retainer;
discharge pressure damage, broken valve bodies and retainers replace any broken parts. Dye
(Continued) check the cylinder valve seat.
Install new valves and properly
torque down valve caps
High compressor Improper setting High rod loads, insufficient rod load reversal, Increase setting of variable
cylinder discharge of volume or discharge temperatures exceeding the volume pocket(s) or open fixed
pressure. pockets. maximum working pressure. volume pocket(s) until discharge
pressure decrease to a proper
level. Unload the crank ends if this
does not reduce pressure. Open
all pockets before starting. Always
follow performance curves
provided with your compressor.
Improper Same as above. Open valve.
positioning in
piping
downstream of
the compressor.
Clogged cooler. Same as above. Clean coolers.
Insufficient capacity Dirty suction Possible cylinder heat buildup. Clean scrubber.
scrubber.
Worn piston Piston, rings, and bore overheating. Replace rings.
rings.
Restricted Clogged suction screens. Clean suction line and screen, if
suction line or dirty. Replace screen if damaged.
filter screens.
Defective or Insufficient rod load reversal. This can cause Replace plates, springs, or other
missing valves. damage to the crankshaft from excessive worn or broken parts.
heating, seizure of the crosshead pin, as well
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 valves. Same as above. Possible damage to valve Remove valve and retainer.
seat, valve bodies or retainers. Replace any broken parts. Dye
check the cylinder valve seat.
High interstage pressure Improper Rod load exceeding the design M.W.P. of 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 high-
er stage cylinder
Defective relief Same as above Repair or replace defective valve
valve parts

Table 7-52 Cylinder Area Troubleshooting (Continued)

High gas discharge Defective Damaged gaskets, damaged O-rings, and Replace defective parts
temperature discharge valves cylinder overheating
High discharge Rod load exceeding design. Insufficient rod Increase setting of variable
pressure load reversal exceeding the M.W.P. of the volume pocket(s) or open fixed
cylinder. High discharge temperature volume pocket(s) until discharge
pressure decrease to a proper
level. Unload the crank ends if this
does not reduce pressure. Open
all pockets before starting. Always
follow performance curves
provided with your compressor.
Low suction Insufficient rod load reversal which can lead Try corrective measures listed for
pressure to damage to the crankshaft from excessive Low Compressor Cylinder
heating, seizure of the crosshead pin, as well Discharge symptom.
High suction Leaking suction valves causing suction valve Replace springs or plates.
pressure damage. Overheating of compressor
cylinder.
Improper water Breakdown in cylinder lubrication causing Check pump for proper flow, heat
cooling overheating, cylinder scoring, and valve exchanger condition for proper
damage. cooling, and water supply for
proper level. Repair or clean
cooling system, or add water as
required.
Table 7-53 Troubleshooting Abnormal Noises

Growling in lube oil Suction side air leak. Pump rotor and drive gear Find and stop leak in line.
pump damage and lubricated part
damage.
Chatter in relief valve Air in oil lines. Damage to relief valve and Find and stop leak in line.
lubricated parts damage.
Knock in cylinder area Foreign material in cylinder Cylinder scoring, valve damage, Remove foreign material from
(including water). scored or bent rods and cylinder. If condensation is in gas,
crankshafts. Blown off cylinder use separators and check dump
head. valve operation.
Piston-to-cylinder end Bent rods and crankshaft. Set end clearance to proper value.
clearance set incorrectly.
Improperly installed valve. Piston, rod, pin, crosshead rod, Replace damaged parts.
or crankshaft damage.
Loose valve. Seat damage on cylinder and Remove valve and retainer. Dye
broken valve bodies and check valve seat.
retainers.
Loose piston nut. Head, piston, crosshead, or Replace damaged parts.
cylinder damage.
Incorrect piston to head Failure of piston and/or piston Reset clearance. Check for
clearance. rod. Damage to crosshead. stretched piston rod and/or rod
studs. Check for loose crosshead
nuts.
Scored piston or cylinder. Piston seizure. Find and eliminate reason for
scoring.
Loose valve assembly. Damaged seating surfaces in Tighten assembly and check
cylinder or on valve. gaskets.
Loose packing assembly. Damaged seating surfaces on Tighten assembly and check
packing case. gaskets.
Loose piston. Scoured piston or cylinder. Tighten piston rod nuts. Check for
stretching of studs.
Excess carbon deposits. Same as above Remove carbon.
Foreign object in cylinder Same as above Remove any objects and repair da-
mage.Check separation equipment

Table 7-53 Troubleshooting Abnormal Noises (Continued)
Knock in cylinder area Loose cylinder head. Damage to gasket seal surface Tighten head.
(continued)
Loose variable volume pocket Damage to gasket seal surface. Tighten variable volume pocket.
unloader.
Whine in auxiliary end Worn, broken, or chipped gear Gear damage. Replace gear.
gear teeth.
Improper backlash setting. Gear damage. Reset gear lash.
Table 7-54 General Troubleshooting

Vibration Piping system improperly Potential failure of piping Install proper piping support to raise
supported. system. the frequency of the vibrations.
Loose piston or piston rod. Piston seizure, contact between Replace all damaged components.
piston and cylinder heads, bent Tighten components properly.
piston rods, or failure of running
gear.
Loose nuts on cylinder to Same as above. Tighten nuts.
frame mounting studs.
Unit loose on foundation or Piping strain. Tighten.
rails.
Low capacity Excessive pressure drop in Loss of production. Properly design piping system.
piping system.
Gas measurement Apparent production loss. Use correct measurement
techniques are not correct. techniques.
Poor mechanical condition of Failure of individual Restore to proper mechanical
unit. components. condition.
Gas pulsation in vicinity of Causes abnormal cylinder Modify piping to eliminate pulsation.
cylinders. capacity performance.
High load Excessive capacity being Overload. Determine cause and correct.
delivered.
Poor mechanical condition of Distortion of compression cycle Correct mechanical problems.
unit. resulting in excess load.
Gas pulsation in vicinity of Abnormal cylinder horsepower Modify piping to eliminate
cylinders. performance. pulsations.
Lubricator does not Feeds not vented of air. Overheated and/or damaged Prime lubricator pump to insure oil
discharge oil packing. Scored cylinder walls. passage to the pump.
Low oil level. Same as above. Add oil to proper level.
Plugged vent in lubricator Same as above. Unplug vent.
tank.
Line leaking or kinked. Same as above. Unkink or replace line.
Oil check valve on cylinder Same as above. Replace oil check valve.
faulty.
Incorrect adjustment of pump Same as above. Readjust pump stroke.
stroke.
Leak in line or fitting. Same as above. Retighten fitting or replace line as
needed.
High cooler pressure Faulty suction valves in high Damage to cooler. Replace faulty compressor valves.
stage cylinder.
Defective gauge. Improper operation of the Replace gauge.
compressor.
High discharge Faulty valves. Cracked or broken cylinder, Replace valves.
temperature bent rod, or worn piston rings or
packing.
Scored piston or liner. Same as above. Repair damage and replace
damaged parts.

Table 7-54 General Troubleshooting

High discharge Insufficient lubrication Same as above. Increase lubrication.
temperature (lubricated cylinder only).
(continued)
Packing too tight. Same as above. Check rings for proper clearance
and packing case for clearance
around rod.
High suction gas Same as above. Check valves, coolers, and
temperature. process.
High discharge pressure. Same as above. Check valves and/or process
condition. On multistage units
check suction valves of next higher
stage.
Low suction pressure. Same as above. Check proceeding stages of
process.
Liquid in cylinder Condensate caused by cold Broken or bent rod. Cracked Raise cooling water temperature.
interstage piping. cylinder.
Liquids in process are not Same as above. Check process operating
removed from the gas stream conditions. Check operation of
by separation equipment. separation equipment and dump
valves.
Broken valve and Dirty gas or foreign matter in High gas temperatures. Clean up gas by proper separation
springs gas stream. Possible piston and cylinder and/or filtration.
damage.
Liquid in cylinder. Same as above. Find source of liquid and correct.
Excessive lubrication. Same as above. Reduce lubrication.
Carbon deposits. Same as above. Reduce lubrication. Change to
lubricant which forms less carbon.
Improper assembly. Same as above. Reassemble properly.
Insufficient control. Pressure Same as above. Check for possible control pressure
or leaking seal in variable leak.
volume pocket unloader.
Rupture disk ruptures Disk rating incorrect. Overheated and/or damaged Trace line from designated rupture
packing. Scored cylinder walls. disk and fix malfunctions.
Clogged filter. Same as above. Replace filter.
Blocked main line. Same as above. Unblock line.
Blocked secondary line. Same as above. Unblock line.
Divider block does not cycle. Same as above. Clean divider block interior.

RAM Series Comrpessor Frame Instruction Manual
Frame "as Built" Bill of Materials and Illustrations
ICAUTION
Proper length of
studs and bolts is
important for
proper thread
engagement.
Before removing
any studs, mea-
sure stud height
from machined
surface and posi-
tion replacement
stud to same
height.
Section 8: Frame "as Built" Bill of Materials and Illustrations RAM-6/1/04
Cooper Compression Superior Compressor Product Group Page 8-1

RAM54
Illustration Item# Material Material Description Qty UOM
LSB-04R1340 ZLSB-04R1340 LUBE SCHEMATIC 1 EA
5500-000 Z5500-COMA-004 COMMON PARTS 1 EA
1 Z11TB1210MA BUSHING PIPE REDN 3 EA
2 Z03PP1000CA PLUG PIPE 1 EA
4 Z620-155-001 NAMEPLATE 1 EA
5 Z00FW0616P0 WASHER PLAIN 32 EA
6 Z01LW0600P0 LOCKWASHER SPLIT 32 EA
7 Z01CS0610PC BOLT HEX HEAD 32 EA
9 Z904-181 BREATHER 2 EA
10 Z914-176-001 PLATE WARNING 1 EA
11 Z01VS0604C0 SCREW DRIVE 4 EA
12 Z600-055 NUT 8 EA
13 Z900-835-070 SEAL O RING 8 EA
14 Z600-054 STUD DOUBLE END 4 EA
25 Z04SS1228PC SCREW SET 6 EA
29 Z600-062 GAUGE 1 EA
30 Z600-053 SPACER SLEEVE 4 EA
42 Z600-037 GEAR 1 EA
43 Z04CS0508PC SCREW SOCKET HD 3 EA
67 Z02PP0600SP PLUG PIPE 4 EA
Z5500-T01A-004 FRAME 1 EA
26 Z600-372 FRAME COMPRESSOR 1 EA
Z5500-T02A-004 CRANKSHAFT 1 EA
39 Z600-328 CRANKSHAFT COMPRESSOR 1 EA
Z5500-T03A-004 MAIN BEARINGS 1 EA
40 Z600-520-001 SHELL BEARING 4 EA
41 Z600-006 BEARING THRUST 2 EA
Z5500-T04A-004 TOP COVER 1 EA
3 Z600-466-001 COVER RECP COMPR 1 EA
15 Z625-500-001 HANDLE 2 EA
16 Z02MS5206PC SCREW MACHINE 8 EA
Z5500-T05A-000 END COVERS - RAM52/4 1 EA
18 Z600-533-001 COVER 1 EA
19 Z01RP241600 PIN ROLL 2 EA
22 Z600-044-001 SEAL 1 EA
31 Z600-028 COVER RECP COMPR 1 EA
34 Z01DP041200 PIN DOWEL 2 EA
44 Z600-044-002 SEAL 1 EA
Z5500-T07B-000 SPECIAL TOOLS - RAM 1 EA
46 ZBM-10046 FITTING GREASE 1 EA
47 Z600-123 WRENCH OPEN END 1 EA
48 Z600-329-001 ADAPTER TOOL 1 EA
49 Z620-116-004 PROTECTOR 1 EA
50 Z600-121 TOOL 1 EA
51 Z600-122 TOOL 1 EA
52 Z600-124 WRENCH SPANNER 1 EA
53 Z600-318 TOOL 1 EA
54 Z600-187 TOOL 1 EA
55 Z600-306 TOOL VALVE PL 1 EA
56 Z600-307 BRACKET 1 EA
62 Z600-460-001 TOOL 1 EA
65 Z620-199-001 GAUGE 1 EA
66 Z620-200-001 GUIDE 1 EA
68 Z620-203-001 PULLER 1 EA
69 Z600-557-001 WRENCH OPEN END 1 EA
1 Z625-434-004 SCREW SOCKET HD 16 EA
2 Z600-018-001 SHOE CROSSHEAD 8 EA
4 Z600-017 PIN CROSSHEAD 4 EA
5 Z024-876 RING RETAINING 8 EA
11 Z029-281 NAMEPLATE 4 EA
12 Z01VS0808P0 SCREW DRIVE 8 EA
13 Z600-034 COVERDOOR CROSSHEAD 4 EA
14 Z900-835-071 SEAL O RING 4 EA
Z5501-T01A-000 CONNECTING RODS 4 EA
18 Z600-520-001 SHELL BEARING 4 EA
19 Z600-524-001 CONN ROD MAST COMPR 4 EA
Z5501-T02B-000 CROSSHEAD - HEAVY - 95 LB. 2 EA
3 Z600-016 CROSSHEAD 2 EA
Z5501-T02A-000 CROSSHEAD - LIGHT - 57 LB. 2 EA
3 Z600-014 CROSSHEAD 2 EA
5502-000 Z5502-T01A-004 LUBE OIL PUMP - RAM54 1 EA
1 Z600-474-004 PUMP ASSY LUBE OIL - RAM54 1 EA
Z5502-T02A-000 LO PIPING - UPSTREAM - STL 1 EA
10 Z028-026-03 PIPE STEEL 1 EA
11 Z600-049 STRAINER OIL 1 EA
15 Z11TN1013SP NIPPLE PIPE 1 EA
16 Z600-335 VALVE CHECK 1 EA
18 Z11TE1000MA ELBOW PIPE THDED 1 EA
19 Z028-006-29 NIPPLE PIPE 1 EA
20 Z031-863-006 JOINT 1 EA
21 Z028-006-29 NIPPLE PIPE 1 EA
24 Z11TT1000MA TEE PIPE THDED 1 EA
26 Z11TB1210SP BUSHING PIPE REDN 1 EA
29 Z12TT1006MA TEE PIPE THDED 1 EA
Z5502-T03A-000 LUBE OIL FILTER - MOUNTED 1 EA
34 Z600-338 BRACKET -FILTER 1 EA
37 Z600-346-001 FILTER OIL 1 EA
38 Z758-220 CARTRIDGE FILTER 1 EA
Z5502-T04A-000 PIPING DWNSTRM OF MTD FLTR-STL
1 EA
ZBM-11959-10 TEE PIPE THDED 1 EA
43 Z031-863-006 JOINT 1 EA
50 Z600-334 FLANGE FF SQ 1 EA
Z620-228-001 ELBOW TUBE COMPN 1 EA
Z900-902 ORIFICE PLATE 1 EA
Z061-397-008 ELBOW TUBE COMPN 1 EA
Z620-227-001 ADAPTER TUBE COMPN 1 EA
Z11TB0403SP BUSHING PIPE REDN 1 EA
Z12TN0112SP NIPPLE PIPE 1 EA
Z061-652-035 FITTING 1 EA
Z11TN1013SP NIPPLE PIPE 1 EA
Z11TB1004SP BUSHING PIPE REDN 1 EA
Z5502-T06B-000 LOW L O PRESS S/D-ELEC-MURPHY1 EA
70 Z600-275 SWITCH 1 EA
73 Z061-385-008 ELBOW TUBE COMPN 1 EA
74 Z04TU070240 TUBING STAINLESS 6 FT
76 Z11TB0802MA BUSHING PIPE REDN 1 EA
77 Z600-059 FLANGE FF SQ 1 EA
Z5502-T07A-000 L. O. LEVEL REGULATOR - NONE 1 EA
Z5502-T08A-000 PLUG - L O HEATER OPENING 1 EA
Z5502-T10A-000 LUBRICATOR BRACKET AND DRIVE1 EA
103 Z033-218-004 SHIM LAMINATED 2 EA
104 Z033-219-004 SHIM STEEL 2 EA
105 Z600-042 SUPPORT 1 EA
133 Z025-100-004 KEY SQUARE 1 EA
134 Z909-524-004 COUPLING FLEXIBLE 1 EA
135 Z600-337 GUARD COUPLING 1 EA
136 Z600-063 PLATE MOUNTING 1 EA
138 Z03MS5020PC SCREW MACHINE 2 EA
Z5502-T11A-000 FF LUBR OIL SUPPLY-FROM BASE 1 EA
117 Z061-652-015 FITTING 1 EA
119 Z061-369-023 CONNECTOR TUBE COMPN 1 EA
122 Z061-538-004 ELBOW PIPE THDED 1 EA
131 Z061-625 ELBOW TUBE COMPN 1 EA
Z5502-T12A-004 CYLINDER LUBE TUBING 1 EA
149 Z061-053-002 REDUCER 6 EA
151 Z060-079 CLIP TUBING 4 EA
152 Z061-581-005 UNION TUBE COMPN 4 EA
154 Z061-454 CLAMP TUBING 2 EA
155 Z061-532 CLIP TUBING 2 EA
156 Z061-581-005 UNION TUBE COMPN 8 EA
Z620-159-001 NAMEPLATE - CYCLE TIME 1 EA
1 Z600-400 HUB COUPLING 1 EA
2 Z600-401 NUT 1 EA
3 Z09SS1008PF SCREW SET 2 EA
Below for blank throw
Z5503-004-000 ADAPTER-HUB TO COUPLING 1 EA
4 Z600-412 PLATE ADAPTER 1 EA
5504-000 Z5504-T03B-000 BLANK THROW CLOSURE 1 EA
3 Z600-277 ROD 1 EA
4 Z600-011 COVER 1 EA
5 Z900-835-071 SEAL O RING 1 EA
7 Z01HN1400PC NUT PLAIN HEX 8 EA
C15I 15.5" 417CC 01c1250
illustration Item Material Material Description Qty UOM
valves Z600-500-602 Suction valve assy 4 ea
sa Z757-831-072 Suction seat 1 ea
sb Z758-134-343 Suction guard 1 ea
sc Z757-135-001 Locating pin 2 ea
sd Z757-136-011 12 pt cap screw 1 ea
se Z757-828-127 Valve plate 1 ea
sf Z757-832-078 Guide ring 1 ea
sg Z757-833-008 Closing spring 18 ea
sh Z758-145-002 Threaded washer 1 ea
si Z753-138-002 Wafer Spring 1 ea
valves Z600-501-602 Discharge valve assy 4 ea
da Z757-831-074 Discharge seat 1 ea
db Z758-134-348 Discharge guard 1 ea
dc Z757-135-001 Location pin 2 ea
dd Z757-136-004 12 pt cap screw 1 ea
de Z757-828-127 Valve plate 1 ea
df Z757-832-078 Guide ring 1 ea
dg Z757-833-044 Closing spring 18 ea
dh Z758-145-002 Threaded washer 1 ea
di Z753-138-002 Wafer Spring 1 ea
C15I-0000 ZC15I-COMA-0000-0 COMMON PARTS 1 EA
2 937-206-006 NUT 4 EA
3 01CS1420PC BOLT HEX HEAD 4 EA
4 900-835-071 SEAL O RING 1 EA
5 914-175-001 NAMEPLATE 1 EA
6 620-154-003 NAMEPLATE 1 EA
7 907-004-001 TACK METAL 8 EA
23 900-838-021 SEAL O RING 1 EA
43 620-174-001 NUT 1 EA
45 03CS1028MC SCREW SOCKET HD 4 EA
46 600-126 NUT JAM 1 EA
88 620-173-001 WASHER 1 EA
62 04TU040240 TUBING STAINLESS 2 FT
63 061-397-008 ELBOW TUBE COMPN 2 EA
64 901-312 VALVE CHECK 2 EA
65 061-538-002 ELBOW PIPE THDED 2 EA
66 061-638-002 REDUCER PIPE THDED 2 EA
ZC15I-T01A-0000-0 CYL BODY15.5" DIA CONVERIBLE1 EA
1 600-143-003 BODY COMPR CYL 1 EA
8 600-144-003 BODY COMPR CYL 1 EA
9 600-113 GASKET FLAT RD 1 EA
10 01HN1400PC NUT PLAIN HEX 6 EA
12 03CS1422PC SCREW SOCKET HD 6 EA
ZC15I-T03A-0000-0 HEAD END HEAD - VV POCKET EA
21 600-242-001 HEAD COMPRESSOR 1 EA
24 600-128-002 PISTON/ROD ADJ CLEAR 1 EA
25 600-077-003 RING 1 EA
26 900-838-029 SEAL O RING 1 EA
27 926-404-001 RING BACK UP 2 EA
28 01EN1400PF NUT PLAIN HEX 1 EA
29 03PP0100SP PLUG PIPE 1 EA
30 902-042 HANDLE 1 EA
31 Z904-463-001 NUT 1 EA
32 06WK140011 KEY WOODRUFF 1 EA
ZC15I-T04A-1475-0 ALUMINUM PISTON / CFT RINGS EA
40 620-183-001 PISTON END 2 EA
42 903-108-046 RIDER RING 1 EA
44 600-129-001 RING COMPN 2 EA
48 620-172-001 WASHER 1 EA
89 620-193-001 CARRIER RING 1 EA
ZC15I-T05A-0000-0 PISTON ROD - LONG EA
49 600-469-006 ROD COMPR PSTN 1 EA
ZC15I-T06A-0000-0 RETAINER/CAP/GSKTS-SUC 4 EA
51 909-981-201 GASKET FLAT RD 8 EA
52 600-103-001 RETAINER VALVE 4 EA
53 600-105-001 CAP COMPR VLV 4 EA
54 900-838-011 SEAL O RING 4 EA
58 901-687-012 SPACER VALVE 4 EA
ZC15I-T07A-0000-0 RETAINER/CAP/GSKTS-DIS 4 EA
53 600-105-001 CAP COMPR VLV 4 EA
54 900-838-011 SEAL O RING 4 EA
56 04SS0410PC SCREW SET 4 EA
58 901-687-011 SPACER VALVE 4 EA
ZC15I-T08A-0000-0 DISTANCE PIECE / SPACER EA
71 600-317 PIECE DISTANCE 1 EA
72 900-838-034 SEAL O RING 1 EA
75 600-312 COVERDOOR 1 EA
76 900-838-053 SEAL O RING 1 EA
78 01LW0600P0 LOCKWASHER SPLIT 6 EA
79 03PP0600CA PLUG PIPE 4 EA
ZC15I-T10A-0000-0 PRESSURE PACKING - STD EA
47 Z600-249-001 PACKING COMPR ROD 1 EA
47 Z908-822-009 Gskt-wire 1 ea
47 Z600-089-001 Ring double acting type"BT" 3 ea
47 Z600-087-002 Ring double acting type"BD" 1 ea
47 Z900-838-050 O-Ring-Viton 1 ea
48 Z600-088-001 Oil Scraper type "3RWS" 1 ea
C15E-0000 9.5" 410CC 04c1339,04c1232,04c1343,04c1345
illustration Item Material Material Description Qty UOM
Valves Z600-496-603 Suction valve assy 2 ea
Valves Z600-497-603 Discharge valve assy 2 ea
C15E-0000 ZC15E-COMA-0000-0COMMON PARTS EA
2 Z937-206-006 NUT 4 EA
4 Z900-835-071 SEAL O RING 1 EA
7 Z01VS0604C0 SCREW DRIVE 8 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
45 Z03CS1232MC SCREW SOCKET HD 6 EA
46 Z600-126 NUT JAM 1 EA
64 Z901-312 VALVE CHECK 2 EA
65 Z061-538-002 ELBOW PIPE THDED 2 EA
66 Z061-638-002 REDUCER PIPE THDED 2 EA
ZC15E-T01A-0950 CYINDER BODY EA
1 Z600-207-007 BODY COMPR CYL 1 EA
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
30 Z902-042 HANDLE 1 EA
31 Z904-463-002 NUT 1 EA
32 Z06WK140011 KEY WOODRUFF 1 EA
ZC15E-T03A-0950-0 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 WASHER 1 EA
88 Z620-173-001 WASHER 1 EA
89 Z620-189-002 CARRIER RING 1 EA
ZC15E-T04B-0000-0 PISTON ROD - LONG 0 EA
49 Z600-469-012 ROD COMPR PSTN 1 EA
ZC15E-T05A-0000-0 RETAINER/CAP/GSKTS-SUCTION
0 EA
51 Z909-981-199 GASKET FLAT RD 4 EA
52 Z600-079-001 RETAINER VALVE 2 EA
53 Z600-173-001 CAP COMPR VLV 2 EA
54 Z900-838-031 SEAL O RING 2 EA
58 Z901-686-015 SPACER COMPR VLV 2 EA
ZC15E-T06A-0000-0 RETAINER/CAP/GSKTS-DISCHARGE
4 EA
51 Z909-981-199 GASKET FLAT RD 8 EA
52 Z600-079-001 RETAINER VALVE 4 EA
53 Z600-173-001 CAP COMPR VLV 4 EA
54 Z900-838-031 SEAL O RING 4 EA
58 Z901-686-016 SPACER COMPR VLV 4 EA
ZC15E-T07B-0000-0 DISTANCE PIECE / SPACER 1 EA
71 Z600-317 PIECE DISTANCE 1 EA
72 Z900-838-034 SEAL O RING 1 EA
74 Z01HN1400PC NUT PLAIN HEX 4 EA
75 Z600-312 COVERDOOR 1 EA
76 Z900-838-053 SEAL O RING 1 EA
ZC15E-T09A-0000 PRESSURE PACKING - STANDARD EA
pa Z908-822-009 Gskt-wire 1 EA
pb Z600-085-001 Ring double acting type"P" 1 EA
pc Z600-086-001 Ring double acting type"TR" 3 EA
pd Z600-087-001 Ring double acting type"BD"1 EA
pe Z600-088-001 Oil Scraper type "3RWS" 1 EA
pf z900-838-051 o-ring 2 ea
pg c02-500802 retaining assy 1 ea
C15C-0000 6.5" 01C1304, 01C1305, 01C1306, 01C1307
UO
Illustration Item Part Number Description Qty M
Valves Z600-492-602 Suction valve assy 2 ea
Valves Z600-493-602 Discharge valve assy 2 ea
C15E-0000 1 600-358-001 BODY COMPR CYL 1 EA
2 937-206-006 NUT 4 EA
4 900-835-071 SEAL O RING 1 EA
5 914-175-001 NAMEPLATE 1 EA
6 620-154-003 NAMEPLATE 1 EA
7 907-004-001 TACK METAL 8 EA
21 600-233-005 HEAD COMPRESSOR 1 EA
23 900-838-011 SEAL O RING 1 EA
24 600-128-008 PISTON/ROD COMPRESSOR 1 EA
25 600-077-008 RING COMPN 1 EA
26 900-838-029 SEAL O RING 1 EA
27 926-404-001 RING BACK UP 2 EA
28 01EN1400PF NUT PLAIN HEX 1 EA
30 902-042 HANDLE 1 EA
31 Z904-463-001 NUT 1 EA
32 06WK140011 KEY WOODRUFF 1 EA
33 900-838-001 SEAL O RING 1 EA
40 600-134-003 PISTON COMPRESSOR 1 EA
43 600-073 NUT PISTON ROD 1 EA
44 903-118-004 RING COMPN 4 EA
46 600-126 NUT JAM 1 EA
49 600-071-006 ROD COMPR PSTN 1 EA
53 600-120-002 CAP COMPR VLV 4 EA
54 900-838-015 SEAL O RING 4 EA
58 600-361-001 SPACER COMPR VLV 2 EA
63 061-369-009 CONNECTOR TUBE COMPN 2 EA
64 901-312 VALVE CHECK 2 EA
65 061-538-002 ELBOW PIPE THDED 2 EA
66 061-638-002 REDUCER PIPE THDED 2 EA
71 600-317 PIECE DISTANCE 1 EA
72 900-838-034 SEAL O RING 1 EA
75 600-312 COVERDOOR 1 EA
76 900-838-053 SEAL O RING 1 EA
78 01LW0600P0 LOCKWASHER SPLIT 6 EA
79 03PP0600CA PLUG PIPE 2 EA
pa Z908-822-009 Gskt-wire 1 EA
pb Z600-085-001 Ring double acting type"P" 1 EA
pc Z600-086-001 Ring double acting type"TR" 3 EA
pd Z600-087-001 Ring double acting type"BD" 1 EA
pe Z600-088-001 Oil Scraper type "3RWS" 1 EA
pf z900-838-051 o-ring 2 ea
pg c02-500802 retaining assy 1 ea
Z04TU070240 1TUBING STAINLESS 3 FT
Z904-463-001 NUT 1 EA

Ram 54

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Ram 54

Uploaded by

Copyright:

Available Formats

RAM Instruction Manual

Customer: Valerus Compression Services

RAM Instruction Manual

Table of Contents 6/1/04

Cooper Compression Page c

Page d Cooper Compression

Preparation for Initial Startup .............................................................................................................. 6-1

Table of Contents 6/1/04

Cooper Compression Page e

Page f Cooper Compression

Cooper Energy Services is committed to continuous improvements and design advancements.

It is very important that Figure 1-1 RAM Compressor

Store it so it is easily found

study the safety information Internally

Section 1: Introduction to Servicing the RAM Series Compressor 5/27/03

Cooper Energy Services ■ Superior Compressor Product Group Page 1-1

Identifying Your Compressor Frame and Cylinder

Figure 1-2 Frame Nameplate

Compressor Frame Overview

Page 1-2 Cooper Energy Services ■ Superior Compressor Product Group

Although piston and rod lengths may vary according

Variable Volume Pockets are furnished as standard

Sizes-4 to 20 inches (101-508mm)

Section 1: Introduction to Servicing the RAM Series Compressor 5/27/03

Cooper Energy Services ■ Superior Compressor Product Group Page 1-3

Table 1-8 Compressor Specifications

Page 1-4 Cooper Energy Services ■ Superior Compressor Product Group

Compressor System Vibration

Balancing Compressor Frames

Section 1: Introduction to Servicing the RAM Series Compressor 5/27/03

Cooper Energy Services ■ Superior Compressor Product Group Page 1-5

Page 1-6 Cooper Energy Services ■ Superior Compressor Product Group

How to Use This Manual

Section 1: Introduction to Servicing the RAM Series Compressor 5/27/03

Cooper Energy Services ■ Superior Compressor Product Group Page 1-7

Our Quality Policy

Page 1-8 Cooper Energy Services ■ Superior Compressor Product Group

Improper operation, lubrication, maintenance or repair of this equipment can be dangerous

Note, Caution, and Danger Symbols

Section 2: Safety Precations and Guidelines RAM-5/27/03

Cooper Energy Services ■ Superior Compressor Product Group Page 2-1

The CAUTION symbol indicates that if the specified precaution is

Warning Signs and Labels

Page 2-2 Cooper Energy Services ■ Superior Compressor Product Group

Temporary Shipping Plugs in Compressor Equipment1

Small diameter threaded connections located on compressor frames,

Compressor Frame Crankcase Rapid Pressure Relief Valves2

1.Per CES Engineering Service Bulletin SB282

Section 2: Safety Precations and Guidelines RAM-5/27/03

Cooper Energy Services ■ Superior Compressor Product Group Page 2-3

It is in the best interest of everyone involved in operation and

General Maintenance Precautions

Page 2-4 Cooper Energy Services ■ Superior Compressor Product Group

Compressor System Maintenance Precautions

Pressurized Air and Water Precautions

Section 2: Safety Precations and Guidelines RAM-5/27/03

Cooper Energy Services ■ Superior Compressor Product Group Page 2-5

Pipes, Connectors, Fittings, Lines, Tubes and Hoses

Check for the following:

Page 2-6 Cooper Energy Services ■ Superior Compressor Product Group

•Evidence of kinking or crushing.

Fire and Explosion Precautions

Section 2: Safety Precations and Guidelines RAM-5/27/03