K102A&B

g GE Oil & Gas Nuovo Pignone
Operation & Maintenance

Manual
Reciprocating Compressor Type 6SHM/3
ABB SpA – Process Automation Division
PROJET RECUPERATION DES GAZ TORCHES & REINSTRUMENTATION

DES CENTRES DE PRODUCTION DE LA REGION DE HAOUD BERKAOUI
Catègorie Doc.
LOGO ET NOM DU FORNISSEUR
Nuovo Pignone N. FORNISSEUR
FIRENZE
Echelle
TITLE
Format OPERATION AND MAINENANCE MANUAL
A4
Projet Numero MR Numero Ordre Feuille Rév.

20027 20027-0100-M32-MR-52210 4580016320 1/355 00
Customer: ABB FOR SONATRACH

Service: FLARE GAS RECOVERY
Plant Location: ALGERIA
Plant: HAOUDBERKAOUI
Manufacturer:g GE Oil & Gas

Via Felice Matteucci, 2
50127 Florence, Italy
T +39 055 423 211
F +39 055 423 2800
12-2010 1003084

Manual

Plant: HAOUD BERKAOUI
Manufacturer: g GE Oil & Gas

Via Felice Matteucci, 2
50127 Florence, Italy
T +39 055 423 211
F +39 055 423 2800
1003084
12-2010
OPERATION AND MAINTENANCE MANUAL
Revision and Status Description
ORIGINAL INSTRUCTIONS
Revision Status Date Prepared Checked Approved Revision Description
00 23.12.10 ISSELnord L. Davini L. Petruzzi AS SHIPPED MANUAL
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1.1 AFTER SALES SERVICE
1.1.1 GE OIL & GAS TECHNICAL COMMUNICATION

Service Bulletins represent the official means used by GE Oil & Gas to communicate our latest
technologies and to provide customer’s service personnel with technical recommendations and
solutions to known fleet issues as well as better maintenance practices and upgrades for optimizing
existing equipment.
GE Oil & Gas publishes two kinds of documents:
- Service Bulletin “NIC”[Customer Information Note] informs Customers about modifications
and upgrades that may impact the operation of the unit or maintenance performance.
- Service Letterinforms Customers of changes to standard inspection procedures or
maintenance policies.
An application called the Technical Updates Portal is available on the official GE Oil & Gas web site
to enable faster and simpler delivery of all Technical Bulletins. After registering, customers can log
in anytime to easily access and download all bulletins relating to their specific GE equipment. Queries
can be made by technology type, equipment serial number, bulletin number, title/keyword, issue
date and category.
Additional key features are:
- implementation status by units
- customer feedback form
There is even an option for receiving automatic email notifications of bulletins relating to the
customer’s equipment without having to log in to the Portal.There is even an option for receiving
automatic email notifications of bulletins relating to the customer’s equipment without having to
log in to the Portal.
To register and get started, simply go to http://www.geoilandgas.com/ and select Technical Bulletins
from the Online Tools menu at the left side of the page. Click GO and you're on your way.
All the instructions for obtaining access to thisTechnical Updates Portal, for subscribing to
automatic mail notification, and for any additional information relevant to the application have been
provided in the:TECHNICAL UPDATES PORTAL LAUNCH (NIC 07.37.SL)
1.1.2 CUSTOMER SERVICE CENTER

Customers can call our CSC 7x24 or find the appropriate Expert for an issue on Support Central –
CCM – in the Technical Assistance Community. The Expert will take ownership of the case ID until a
solution is found. The CSC Team collects Customer’s issues, and records and tracks them using
Customer Claim Management – or supports the Customer in doing so – thus streamlining the process.
CSC- Technical Assistance Form
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The following information is needed by the Customer Service Center at the time that a technical
assistance request is submitted. Missing information can delay the process. The Customer Service
Center is available 24/7 to receive the form and to help you with a rapid response.
- Serial number of the unit (for auxiliaries and associated equipment always include the machine
serial #.)
- Machine fired hours
- Number of starts
- Current machine status
- Last intervention type and date
- Alarm and trip log
- Is machine covered by remote monitoring & diagnostics (Y/N)
- Description of the event
- Is the event recurrent (Y/N)
If Applicable
- Vibration and axial displacement values with respective
- GE tag number
- Bearing temperature values with respective GE tag number
Phone: +39-055-427 2500
Fax: +39-055-423 2800
e-mail: customer.service.center@ge.com
1.1.3 REMOTE MONITORING & DIAGNOSTICS (RM&D)

Machinery and peripheral equipment for oil and gas applications must operate within specified
parameters in order to achieve the desired performance, production targets and operating costs.
Traditional monitoring methods require on-site personnel and analysis, with periodic OEM
engineering support. GE’s RM&D service offers the superior alternative of continuous monitoring by
expert engineers with significantly enhanced response times – and without additional on-site
staffing costs or logistics.
1.1.4 HOW IT WORKS

Our standard monitoring instruments (for temperature, pressure, vibration, etc.) are supplemented
with a Site Connectivity Kit so that operating data can be securely transferred from the site to the
GE Oil & Gas RM&D Center. The M&D system is linked to our Florence headquarters where a dedicated
team of diagnostic engineers evaluates the actual and target parameters as well as correlations
between components to continuously monitor the performance and health status of components.
They then work with your staff to support onsite activities – ranging from detailed optimization plans
to immediate emergency procedures. The diagram below shows the overall architecture of the
RM&D system:
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Figure 0
The system is used to enhance machine protection as well as performance and for this purpose, a
set of diagnostic thresholds are implemented in the central system. In addition, the system facilitates
technical assistance activities and Customer support.
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Figure 0
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Figure 0
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g GE Oil & Gas Volume 0 Nuovo Pignone
PAGE INTENTIONALLY LEFT BLANK

g GE Oil & Gas Index Nuovo Pignone
INDEX OF VOLUMES
Volume 1 - COMPRESSOR INSTRUCTIONS 1

Volume 2 - COMPRESSOR PART LIST 1
Volume 3 - AUXILIARY EQUIPMENT AND INSTRUMENTATION 1
Volume 4 - UNIT CONTROL SYSTEM 1
Volume 5 - REFERENCE DRAWINGS OF THE JOB 1
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Manual
Volume 1
COMPRESSOR INSTRUCTIONS

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TABLE OF CONTENT
Section1 - GENERAL INFORMATION

1 DEFINITIONS 9
2 SYMBOLS IN THE MANUAL 11
3 INTRODUCTION 12
4 IDENTIFICATION OF HAZARDOUS AREAS 14
5 GUARDS (SAFETY DEVICES AND SHROUDS) AND STOP DEVICES 16
6 RESIDUAL RISKS 17
6.1 General residual risks 17
6.2 Mechanical residual risks 20
6.3 Electric residual risks 22
6.4 Thermal residual risks 23
6.5 Residual risks due to noise 24
6.6 Residual risks due to materials and substances 24
7 HAZARDS INFORMATION IN CASE OF FAILURE 26
8 FORESEEN USE OF THE MACHINE 27
9 GENERAL WARNINGS 28
Section2 - MOVING, HANDLING, STORAGE
1 Moving and handling 32
2 Storage 34
3 SKID-MOUNTED UNITS 40
Section3 - INSTALLATION
1 SAFETY PRECAUTIONS - PROCEDURES PRECEDING GROUTING OF EQUIPMENT 43
1.1 Safety precautions 43
1.2 Installation site 44
1.3 Foundation check 45
1.4 Foundation cleaning 45
2 POSITIONING SKID ALIGNMENT CHECK 47
2.1 Positioning 47
2.2 Alignment check 47
2.2.1 Procedure 48
2.2.2 Definitions 49
2.2.3 Taking alignment data 50
2.3 Checks on assembled unit 52
2.3.1 Taking alignment data 52
2.3.2 Recording data 52
3 SKID ANCHORING 67
4 CONNECTING CYLINDERS TO FRAME, RUN-OUT 72
4.1 Installation 72
4.1.1 Vertical cylinders to be connected onsite 72
4.1.2 Horizontal cylinders to be connected onsite 73
4.1.3 Horizontal cylinders already connected in the shop 74
4.2 Run-out 74
5 AUXILIARIES SKIDS POSITIONING AND ANCHORING 77
5.1 Positioning 77
5.2 Anchoring 77
Section4 - OPERATION
1 GENERAL INFORMATION 79
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1.1 Operating schematics 79
1.1.1 PROCESS GAS P&I Diagram 79
1.1.2 LUBE OIL P&I Diagrams 79
1.1.3 COOLING SYSTEM P&I Diagram 80
1.1.4 CAPACITY CONTROL P&I Diagram 80
1.1.5 Engine air, fuel and exhaust P&I Diagram 81
1.2 Procedures preliminary to setting at work 81
1.3 Safety precautions preliminary to putting into operation 81
1.4 Procedures 82
1.5 Auxiliaries 83
1.6 Operation defects 83
2 ANNEX A - COOLING WATER ACCEPTABILITY LIMITS 83
2.1 Introduction 83
2.2 Antifreeze 83
2.3 Water Treatment 84
3 SAFETY PRECAUTIONS 86
4 PREPARING COMPRESSOR FOR STARTUP 90
4.1 General information 90
4.2 Coolant preheating procedure 94
4.2.1 Closed loop with coolant to water heat exchanger 94
4.2.2 Closed loop with partial main water circulation 94
5 NO-LOAD RUNNING-IN 97
5.2 Complete running-in 98
5.3 Running-in for piston rings plus rider rings and/or packing seals 99
6 PIPING CLEANING, PICKLING, FLUSHING, BLOWING OUT, PURGING 100
6.1 Process gas system 100
6.2 Lube oil system 102
7 START UP AND LOAD-TAKING RUNNING-IN UNDER LOAD 105
7.2 Start-up and load-taking 105
7.3 Running-in under load 107
8 CAPACITY CONTROL 110
9 COMPRESSOR SUPERVISION 111
10 COMPRESSOR SHUT DOWN 114
10.1 Temporary shut down 114
10.2 Shut down for maintenance 114
10.3 Shut down for plant inactivity 115
Section5 - TROUBLESHOOTING
1 TROUBLES, CAUSES, CORRECTIVE ACTIONS 117
Section6 - MAINTENANCE
1 MAINTENANCE INFORMATION 127
1.1 GE Oil & Gas Technical Communication 127
1.2 RM&D for New Equipment 128
1.3 RM&D Service 129
2 SAFETY PRECAUTIONS MAINTENANCE PROGRAM 132
2.2 Safety precautions 134
2.3 Checks and procedures to be carried out after first start-up or after complete overhaul 139
2.3.1 After 30 to 60 hours of operation 139
2.3.2 After 500 hours of operation 139
2.3.3 After 1,000 hours of operation 142
2.4 Checks and procedures to be carried out for periodic maintenance 142
2.4.1 Every 4,000 hours of operation 142
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2.4.2 Every 8,000 hours of operation for non-lubr. cylinder compressors, 12,000 for lubricated 142
cylinder compressors
2.4.3 Every 24,000 hours of operation 143
3 TORQUE WRENCH SETTING AND HYDRAULIC TIGHTENING PRESSURE 145
4 CLEARANCES, WEAR, OVALIZATION 148
4.1 Shaft and crank gear 148
4.2 Cylinders 148
4.3 Piston rods 148
4.4 Miscellaneous 148
Section7 - FRAME AND CRANKGEAR
1 SAFETY PRECAUTIONS - GENERAL INFORMATION 151
2 FRAME 153
2.2 Balancing reciprocating masses 153
2.3 Assembling the reinforcing beams 154
3 SHAFT AND MAIN BEARINGS 155
3.1 Shaft 155
3.1.1 General information 155
3.1.2 Disassembly and reassembly 155
3.2 Main bearings 155
3.2.2 Clearance check 155
3.2.3 Replacement 156
3.3 Shaft axial positioning 157
4 CONNECTING ROD AND BEARINGS 160
4.2 Connecting rod 160
4.2.1 Disassembly 160
4.2.2 Assembly 160
4.3 Big end bearing 161
4.4 Small end bush 162
5 CROSSHEAD 166
5.2 Disassembly 166
5.3 Assembly 166
5.4 Shoes 166
5.5 Rod crosshead connection 167
5.5.1 Assembly 167
6 PARTITION COVER 174
6.2 Maintenance 174
6.2.2 Assembly 174
7 INTERMEDIATE PARTITION PACKING 175
7.2 Maintenance 175
7.2.2 Assembly 175
8 BARRING GEAR 177
9 FLYWHEEL 179
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9.2 Flanged shaft end, coupled connection 179
9.2.2 Assembly 179
9.3 Flanged shaft end, coupling with single journal driver 179
9.4 Parallel shaft end 180
9.4.2 Assembly 180
Section8 - CYLINDER ASSEMBLY
2 CYLINDER BODIES 189
2.1 Components data 189
2.2 Cylinder removal and reassembly 189
2.3 Cooling jackets maintenance 189
2.4 Wear, ovalization and reboring 190
2.4.1 Wear M: 191
2.4.2 Relative wear R: 191
2.4.3 Ovalization P: 191
2.4.4 Reboring 191
2.5 Liner removal and assembly procedure 192
2.5.1 Liner fitted without interference 192
2.5.2 Liner fitted with interference 193
2.6 Instructions for hydraulic tightening of tie rods on head 195
2.6.1 Assembly 195
3 PISTONS - PISTON RODS 203
3.2 Pistons maintenance 203
3.3 Piston rod disassembly and reassembly 203
3.3.2 Reassembly 204
3.3.3 Rod-Spacer Ring polishing 204
3.4 Assembling piston with piston rod 204
3.5 Rider ring wear - Run-out 206
3.5.1 Rider ring wear 206
3.5.2 Run-out 207
3.6 Procedure for applying white metal coating 207
3.6.1 Coating applied with oxyacetylene torch 207
3.6.2 Coating applied with spray gun 209
3.6.3 Finishing 210
3.7 Piston rings 210
3.8 Wear on piston rods - Grinding 210
3.8.1 Wear 210
3.8.2 Grinding 211
4 PISTON ROD PACKING 215
4.2 Maintenance 215
4.2.2 Assembly 216
5 VALVES 218
5.1 Description 218
5.1.1 Operation 218
5.1.2 Components 218
5.1.3 Types 219
5.2 Maintenance 219
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5.2.2 Valve assembly preliminary check 220
5.2.3 Checking and restoring valve components 220
5.2.4 Checks on assembled valves prior to installation 222
5.2.5 Nut tightening and loosening equipment 223
5.3 Disassembly from cylinder and reassembly 223
5.3.2 Reassembly 224
6 REVERSE-ACTION GAS OPERATED DEVICE FOR VALVE UNLOADER CONTROL 239
6.1 Operation 239
6.2 Maintenance 239
7 DIRECT-ACTION GAS OPERATED DEVICE FOR CLEARANCE POCKET VALVE CONTROL 241
7.1 Operation 241
7.2 Maintenance 241
8 CHECKING PISTON ROD OSCILLATION SAFETY DEVICES FOR WEAR OF PISTON RIDER RINGS 243
8.2 Piston rod oscillation check 243
8.3 Safety devices for rider rings wear 243
8.3.1 Magnetic induction proximity probe 243
8.3.2 Melting or rolling device 245
Section9 - LUBRICATION
1 CRANK GEAR LUBRICATION 249
1.1 Safety precautions - General information 249
1.2 Lubrication system 249
1.2.1 Pumps 249
1.2.2 Coolers 250
1.2.3 Filters 250
1.3 Omponents description, usage and maintenance 251
1.3.1 Pumps 251
1.3.2 Lube oil pressure control 252
1.3.3 Cooler 253
1.3.4 Filter 253
1.3.5 Lube oil 254
2 CYLINDERS AND PISTON ROD PACKING LUBRICATION 260
2.1 Safety precautions - General information 260
2.2 Lubricator 260
2.3 Lube oil 260
2.3.1 General information and specifications 260
2.3.2 Lube oil rate 261
3 LUBRICATION OF AUXILIARIES 262
Section10 - PROTECTION DURING IDLENESS - PUTTING OUT OF SERVICE, DISMANTELLING,
SCRAPPING
2 IDLENESS NOT EXCEEDING 1 MONTH 266
3 IDLENESS FROM 1 TO 6 MONTHS 267
3.2 Compressors with lubricated cylinders 267
3.2.1 Frame 267
3.2.2 Cylinders 267
3.2.3 Valves 268
3.2.4 Piping, equipment 268
3.2.5 Instrumentation 268
3.2.6 Auxiliary drivers 269
3.2.7 Non-painted machined parts 269
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3.3 Compressors with non-lubricated cylinders 269
3.3.1 Frame 269
3.3.2 Cylinders 269
3.3.3 Valves 269
3.3.4 Piston rods and packings 270
3.3.5 Piston rings, rider rings, seal rings 270
3.3.6 Piping, equipment, instrumentation, auxiliary drivers 270
4 IDLENESS EXCEEDING 6 MONTHS 271
4.2 Compressors with lubricated cylinders 271
4.2.1 Frame 271
4.2.2 Cylinders 272
4.2.3 Valves 272
4.2.4 Piston rods and packings 272
4.2.6 Lubricators and relevant tubing 273
4.2.8 Safety valves 273
4.3 Compressors with non-lubricated cylinders 273
4.3.1 Frame 273
4.3.2 Cylinders 273
4.3.3 Valves, piston rods and packings 274
4.3.6 Safety valves 274
5 RECOMMENDED PROTECTIVE AGENTS 276
5.1 Oils 276
5.2 Dehydrating products 276
5.3 Solvents 276
6 PROCEDURES FOR RESTARTING 277
7 DECOMMISSIONING - DISMANTLING - SCRAPPING 278
7.1 Decommissioning 278
7.2 Dismantling 278
7.3 Scrapping 278
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1 - GENERAL INFORMATION
1 DEFINITIONS .....................................................................................................................................................9 1-9

2 SYMBOLS IN THE MANUAL .........................................................................................................................11 1-11
3 INTRODUCTION ...............................................................................................................................................12 1-12
4 IDENTIFICATION OF HAZARDOUS AREAS ............................................................................................14 1-14
5 GUARDS (SAFETY DEVICES AND SHROUDS) AND STOP DEVICES ..............................................16 1-16
6 RESIDUAL RISKS ..............................................................................................................................................17 1-17
6.1 General residual risks ..................................................................................................................................17 1-17
6.2 Mechanical residual risks ..........................................................................................................................20 1-20
6.3 Electric residual risks ...................................................................................................................................22 1-22
6.4 Thermal residual risks .................................................................................................................................23 1-23
6.5 Residual risks due to noise .......................................................................................................................24 1-24
6.6 Residual risks due to materials and substances ............................................................................24 1-24
7 HAZARDS INFORMATION IN CASE OF FAILURE .................................................................................26 1-26
8 FORESEEN USE OF THE MACHINE ...........................................................................................................27 1-27
9 GENERAL WARNINGS ...................................................................................................................................28 1-28
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1.1 DEFINITIONS
OPERATOR
Person or people in charge of machine installation, operation, adjustment, maintenance, cleaning,
repair or transportation.
HAZARDOUS AREA
Any area inside and/or near a machine which may be hazardous for the people involved in its
operation (injuries or health problems).
NOTE
- THE HAZARD LEADING TO THE RISK MENTIONED IN THIS DEFINITION:

- IS PRESENT IN A PERMANENT WAY DURING THE FORESEEN USE OF THE MACHINE
(MOVEMENT OF HAZARDOUS MOBILE ELEMENTS, ELECTRIC ARC DURING WELDING, ETC.),
OR CAN OCCUR IN AN UNEXPECTED WAY (UNFORESEEN/UNEXPECTED STARTUP, ETC.).
HAZARD
Source of injuries or health problems.
NOTE
THE TERM "HAZARD" IS GENERALLY USED TOGETHER WITH OTHER WORDS THAT DEFINE ITS
ORIGIN OR THE NATURE OF ANY FORESEEN INJURIES OR HEALTH PROBLEMS: ELECTROCUTION,
CRASHING, SHEARING, POISONING, ETC. HAZARD.
RISK
A combination of probabilities and gravity of possible injuries or health problems due to an hazardous
situation.
RESIDUAL RISK
Risk which is still present even after adopting specific safety measures.
GUARDS
Safety measures consisting in the adoption of specific technical means called guards (shields and
safety devices) aimed at protecting people from any hazard which cannot be reasonably eliminated
or sufficiently limited during the planning stage.
SAFETY DEVICE
Device (different from a shield) able to eliminate or reduce any risk, by itself or together with a shield.
SHROUD
Element of a machine specifically used to ensure protection by means of a physical barrier.
Depending on its frame, a shroud can be called casing, cover, screen, door, enclosure, etc.
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NOTE
A SHROUD CAN ACT:

- INDEPENDENTLY; IT IS THEREFORE EFFECTIVE ONLY WHEN IT IS CLOSED;
- TOGETHER WITH AN INTERLOCKING DEVICE WITH OR WITHOUT SHROUD LOCK; IN THIS
CASE, PROTECTION IS ENSURED NOTWITHSTANDING THE SHROUD POSITION. (WHEN A
FIXED SHROUD IS "CLOSED", IT MEANS THAT IT IS "KEPT IN PLACE ").
FORESEEN USE OF THE MACHINE

The task to be performed by the machine in compliance with the indications supplied by the
manufacturer or that is considered as standard relating to the machine's design, construction and
function.
The foreseen use also implies the compliance with the technical instructions available in the
instruction manual. Furthermore, it is necessary to familiarize with any deviations from proper
operation.
NOTE
AS FAR AS THE FORESEEABLE WRONG USE IS CONCERNED, THE FOLLOWING BEHAVIOURS

SHOULD BE TAKEN INTO CONSIDERATION WHILE EVALUATING THE RISKS:
- ANY FORESEEABLE WRONG BEHAVIOUR RESULTING FROM NORMAL CARELESSNESS AND
NOT FROM THE DELIBERATE INTENTION TO USE THE MACHINE IN AN IMPROPER WAY;
- ANY INSTINCTIVE REACTION BY A PERSON DURING OPERATION, IN CASE OF FAILURES,
INCIDENTS, DAMAGES, ETC.
- ANY BEHAVIOUR ARISING FROM THE "LEAST RESISTANT LINE" WHILE PERFORMING A TASK
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1.2 SYMBOLS IN THE MANUAL

General information
These warnings have been divided into three categories according to the kind of information given
and the type of problem faced with. In particular:
DEFINITIONS
WARNING
THIS SYMBOL INDICATES A PROCEDURE, A PRECAUTION OR A CONDITION THAT, IF NOT

OBSERVED, CAN LEAD TO SERIOUS INJURIES, EVEN DEATH. THE TERM "OPERATOR" REFERS TO A
PERSON OR TO THE PEOPLE RESPONSIBLE FOR THE MACHINE OR ITS AUXILIARY EQUIPMENT
INSTALLATION, OPERATION, ADJUSTMENT, MAINTENANCE, CLEANING OR REPAIR.
CAUTION
THIS SYMBOL INDICATES A PROCEDURE, A PRECAUTION OR A CONDITION THAT, IF NOT

OBSERVED, CAN SERIOUSLY DAMAGE THE EQUIPMENT.
NOTE
THIS SYMBOL INDICATES ANY INFORMATION THAT MAY BE NECESSARY FOR THE PERSONNEL IN
ORDER TO CARRY OUT ANY OPERATING PROCEDURES OR MAINTENANCE OPERATIONS.
These symbols have been adopted all through the manual. the following sub-paragraphs contain a
list of general information relating to WARNINGS and CAUTIONS that the operator has always to
keep in mind before operating the machine.
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1.3 INTRODUCTION
In compliance with any applicable directives and regulations, this section contains important
information whose knowledge is essential for the operator in order to work safely.
All the staff working on the system has to know, in every moment, that transporting, installing,
operating, maintaining and preserving the compression unit and its auxiliaries can give rise to certain
risks that must not be ignored or underestimated. Furthermore, they must be aware that in order to
minimize such risks, there are certain precautions to be adopted and followed while performing
theirs tasks.
Operators must be aware of the proper operation of the system and have carefully read this manual,
complying with all dispositions contained in it and with the instructions supplied by the manufacturer.
Operators must also have been properly trained for the tasks they will have to carry out. In particular:
- they must know all accident-prevention standards, rules and regulations
- they must be aware of first aid measures and know the location of local first aid centers
- they must be equipped with accident-preventing means well suited for the tasks they have to
perform
- other specific warnings relating to personnel requirements are to be found in the relevant
manual's sections: TRANSPORTATION AND HANDLING, STORAGE, INSTALLATION, OPERATION,
MAINTENANCE.
For this reason the operator must be properly trained by the GE Oil & Gas Nuovo Pignone training
service (for instance, by attending an initial training course). For any situations that may not be
present in this manual and wherever specifically mentioned, it is necessary to contact the Nuovo
Pignone Support Center. Updated contacts are available in our Web site www.gepower.com.
Before starting any activity, operators will have to take note of particular safety prescriptions
supplied by the manufacturers of each assembly. Such prescriptions are listed in the manuals
relating to auxiliary equipment and instruments. All the safety prescriptions contained in this manual
will have to be followed while operating the system.
Safety managers shall to make sure that the staff involved in the operation is able to perform the
tasks they have been assigned, authorize any interventions which may be requested, provide any
safety means that may be deemed necessary.
The machine and its auxiliary equipment are designed and manufactured so as to minimize risks
for the operators. Any residual risks and relevant precautions are mentioned both in this section,
although in a general way, and in the sections relating to the different tasks to be performed and to
any risks connected to them that may cause injuries and damages to the machine.
Failure to comply with these precautions or safety regulations and/or removing or changing any
safety guards, as well as the expiration of the manufacturer's warranty and the adoption of full
liability on the part of the user, can cause incidents, even serious.
All the manuals supplied by GE Oil & Gas Nuovo Pignone have to be made available to staff and
operators. Safety managers shall check and make sure that this condition is applied. In order to
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make reference easier, we recommend to find an easily accessible place that is well known to all
users involved.
Operators must constantly keep the log book updated. This is useful for carrying out periodical
examinations, in order to find out whether there are any failures in the system. Such failures must
be solved as soon as they arises. This will help preventing hazardous situations or serious damages.
Users shall be made aware of any indications necessary to establish whether the machine is to be
sent to the production or to the maintenance departments.
Users are responsible for the conservation and preservation of materials over time. Any complaints
will be considered by GE Oil & Gas Nuovo Pignone only if they are reported when the materials are
received.
GE Oil & Gas Nuovo Pignone cannot be held responsible for any injury or damage due to:
- improper installation (if not carried out by GE Oil & Gas Nuovo Pignone)
- non-compliance with the instructions given
- improper use of the compressor and its accessories
- use not complying with any applicable regulations
- any improper behavior by unskilled personnel
- feed defects
- lack of maintenance
- use of non-original spare parts
- changes and interventions that have not been authorized by GE Oil & Gas Nuovo Pignone
- exceptional events
Users will have to consider the machine normal wear and deterioration.
If the machine is not operated and maintained in compliance with the instructions supplied, GE Oil
& Gas Nuovo Pignone could decide to adopt any useful measures following to damage to its good
name.
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1.4 IDENTIFICATION OF HAZARDOUS AREAS

During installation and maintenance on the compressor and its auxiliaries, the risks linked to the
specific tasks performed have to be considered. The safety warnings connected to such hazards are
shown in the relevant sections in the manual.
During normal operation of the compressor and its accessories, hazards may be due to:
- presence of gas or high pressure air in the process circuits and in the auxiliary systems;
- presence of high pressure fluids in the adjustment, lubrication and control circuits;
- use of medium and high voltage in the auxiliary and control systems (average voltage);
- presence of very hot or cold surfaces on the compressor and in its auxiliary systems;
- presence of noise;
- presence of hazardous gas (flammable, explosive or toxic). The effects of these hazardous
situations can be seen even far away from the machine.
- presence of slippery surfaces around the machine and its auxiliary systems.
Cover or acoustic hood on the compressor and its auxiliaries
If a cover or acoustic hood is assembled, both the hazards shown in the previous paragraph and
the hazards deriving from the presence of the firefighting system (gas that may cause asphyxia, lack
of oxygen, etc.) are present in its inner part. Therefore the area inside the cover (or hood) must be
always considered an hazardous area and as such it must not be accessed.
Access is allowed only when the machine is switched off and after the completion of the cool down
period (about 1 hour). Of course it must be kept in mind that, even if the machine is switched off
during the cool down period, some of the above mentioned hazards may still be present.
If it is necessary to enter the enclosure (or hood), adopt a specific procedure. Among the minimum
requirements, it is necessary to include the presence of at least two people in the area (one of them
must wait outside and stay in touch with the operator entering the machine).
Operators will have to be properly trained and equipped with suitable personal protection
equipment.
Operators must stay inside the machine as little as possible. This procedure must consider any
operations to be performed on the firefighting system so as to eliminate all the risks for the operators.
WARNING
IF THERE IS A PRESSURIZED COVER OR ACOUSTIC HOOD, ACCESS DOORS CAN LEAD TO SHEARING
HAZARD. OF COURSE, VENTILATION EXERTS SOME PRESSURE ON THE DOOR, CAUSING IT TO MOVE.
SECURING THE MACHINE BEFORE CARRYING OUT MAINTENANCE

Maintenance operations on the compressor and its auxiliaries described in the section
“Maintenance” has to be carried out only after the cool down period has elapsed. Maintenance
operations are statistically the most dangerous.
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In order to carry out any maintenance operations inside the cover or the acoustic hood, it is necessary
to intercept the discharge pipes of the firefighting system (by locking the valves). In this way, the risk
of accidental discharge can be eliminated. Furthermore, all the fire extinguishers have to be easily
accessible.
Before working on the compressor and its auxiliaries, it is indispensable to secure them. In order to
do so, it is necessary to:
- eventually restrict the area with special tape and prohibit access to the area by means of
suitable signs
- insulate the devices from any external energy sources (electric, pneumatic and hydraulic
supply, etc.) so that they cannot be accidentally reactivated after intervention (Lock-out)
- signal by means of suitable signs placed on the switches, on the control panel, on the
interception means, that the energy source must not be restarted (Tag-out)
- discharge any inner energy sources (such as springs, pressurized containers, electric
capacitor, electric and pneumatic accumulators, etc.)
- after maintenance has been completed and before restarting any feed, it is necessary to check
(twice) that all removed guards have been replaced and that all the components of the
hydraulic and pneumatic lines are correctly tightened (in compliance with the seal check
procedure).
The above mentioned prescriptions must be incorporated in the Lock-out and Tag-out
procedures issued by the system manager.
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1.5 GUARDS (SAFETY DEVICES AND SHROUDS) AND STOP DEVICES

Shrouds and safety devices are installed on the compressor and its auxiliary systems. These devices
must not be removed or excluded during operation. They must instead be maintained and checked
periodically in order to make sure they operate efficiently.
Shrouds are mechanical and fixed devices and are mainly composed of: boxes, coupling guards and
shields that prevent access to hazardous areas (moving mechanical parts, hot surfaces, energized
parts).
Safety devices are both mechanical and electronic and are driven by the machine or by the station
control system.
The mechanical safety devices installed on the compressor, on its auxiliaries and on the process
pipes, are mainly composed of pressure trip valves and check valves, if available (see process gas
P&ID).
Other mechanical safety devices are available on the driving machine (gas engine, electric motor,
steam turbine, etc.) in order to stop the entire train.
Please see the relevant manuals for further information on these devices.
The electronic safety devices are divided according to the alarm and lock functions.
Generally, an alarm indicates that the machine and its auxiliaries do not run correctly. However, this
failure is not likely to cause an immediate danger. Such failure has to be eliminated as soon as
possible.
The electronic lock systems, on the contrary, stop the machine train (acting on the driving machine)
in order to protect the machine against any damages which may be hazardous for the operators.
The lock systems installed on the compressor and its auxiliaries are mainly:
- systems for detecting the process gas temperature and pressure;
- systems for detecting the lubrication oil pressure.
The complete list of these devices is available in the "Instrument List" document enclosed to this
manual.
All electronic safety devices with a locking function act on the driving machine in order to stop the
entire train in the safest way as possible.
Furthermore, manual emergency stop devices, composed of pushbuttons, send the command to
the control system.
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1.6 RESIDUAL RISKS

Preamble
The purpose of this section is to show any general residual risks and to provide any warnings required
to minimize such risks.
Other warnings on specific residual risks are shown in the relevant sections of this manual.
Failure to comply with these warnings can lead to injuries, even death.
1.6.1 General residual risks
WARNING
THE AREA SURROUNDING THE COMPRESSOR OR THE ACOUSTIC HOOD ( PARAGRAPH 4 ), IS AN

HAZARDOUS AREA. THE PRESENCE OF PERSONNEL IN THIS AREA SHOULD BE LIMITED AS MUCH
AS POSSIBLE.
FORESEE AN ADEQUATE SUPERVISION IN ORDER TO PREVENT ACCESS TO UNAUTHORISED
PEOPLE.
WARNING
ANY INTERVENTIONS ON THE MACHINES AND THEIR AUXILIARIES MUST BE CARRIED OUT BY
PROPERLY TRAINED OPERATORS.
WARNING
DO NOT PERFORM THE FIRST STARTUP OF THE COMPRESSOR AND ITS AUXILIARIES UNLESS ALL
OPERATORS HAVE BEEN PROPERLY TRAINED. THEY MUST ALSO BE GIVEN ALL THE INSTRUCTIONS
AND INFORMATION ABOUT SAFETY DEVICES AND PROCEDURES.
WARNING
THE USE OF NON-ORIGINAL SPARE PARTS DURING REPLACEMENT CAUSES THE WARRANTY TO
EXPIRE AND CAN GIVE RISE TO HAZARDOUS SITUATIONS. SPARE PARTS THAT HAVE NOT BEEN
INSPECTED, CHECKED AND TESTED BY GE OIL & GAS NUOVO PIGNONE CAN HAVE CHEMICAL-
PHYSICAL, MECHANICAL AND DIMENSIONAL CHARACTERISTICS THAT DO NOT MATCH EXACTLY
THOSE ESTABLISHED BY THE DESIGNER. THEREFORE THEIR USE CAN CAUSE FAILURES AND
DAMAGES TO THE CONNECTED PARTS, WHOSE CONSEQUENCES MAY SOMETIMES BE VERY
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SERIOUS. THE MANUFACTURER CANNOT BE HELD RESPONSIBLE FOR ANY INJURIES AND/OR
DAMAGES ARISING FROM THE USE OF NON-ORIGINAL SPARE PARTS.
WARNING
DURING OPERATION, ALL EQUIPMENT PARTS MUST BE PERFECTLY RUNNING; THE EQUIPMENT
MUST NOT BE STARTED IF DEFECTS OR ANOMALIES HAVE BEEN FOUND.
WARNING
IN GENERAL, OPERATORS WILL HAVE TO USE PERSONAL PROTECTION EQUIPMENT ACCORDING

TO THE HAZARDS PRESENT IN THE AREAS THEY HAVE ENTERED AND TO THE TASKS TO BE
PERFORMED.
THE IDENTIFICATION OF SPECIFIC PERSONAL PROTECTION EQUIPMENT MUST BE PERFORMED BY
THE SYSTEM MANAGER, CONSIDERING THE INFORMATION SHOWN IN THIS MANUAL.
THE OPERATORS' CLOTHING MUST BE APPROPRIATE FOR THE RELEVANT HAZARDS. IN
PARTICULAR, TRY TO AVOID ANY HAZARD CAUSED BY ENTANGLEMENT.
WARNING
AS THE TYPE OF OPERATION AND OF THE ENVIRONMENT IN WHICH THE MACHINE RUNS
(PRESENCE OF GAS, HIGH PRESSURE, ETC.) IS HIGHLY HAZARDOUS, USERS MUST NOT PERFORM
ANY TASKS THAT ARE NOT FORESEEN IN THIS MANUAL (EVEN IF THE SYSTEM IS SWITCHED OFF).
FOR SUCH OPERATIONS, ALWAYS CONTACT THE GE OIL & GAS NUOVO PIGNONE SERVICE CENTRE.
WARNING
BEFORE MAINTAINING THE COMPRESSOR OR ITS LINES, SECURE THE MACHINE AND ITS
AUXILIARIES OR THE LINE BY INSULATING IT FROM ANY EXTERNAL ENERGY SOURCE (ELECTRIC,
PNEUMATIC AND HYDRAULIC SUPPLY, ETC) AND DISCHARGING ANY INTERNAL ENERGY SOURCES
(SUCH AS SPRINGS, PRESSURISED CONTAINERS, CAPACITORS, ETC.). CAREFULLY LOCK ANY
EXTERNAL ENERGY SOURCES SO THAT THEY CANNOT BE ACCIDENTALLY RESTARTED DURING
MAINTENANCE. PLEASE FOLLOW A SPECIFIC PROCEDURE ISSUED BY THE SYSTEM MANAGER (
PARAGRAPH 3 ).
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WARNING
ONLY THE OPERATORS THAT HAVE BEEN AUTHORIZED BY THE SYSTEM MANAGER CAN PERFORM
ANY CONTROL AND ADJUSTMENT OPERATIONS ON THE COMPRESSOR AND ITS AUXILIARIES. THE
MACHINES MUST BE SWITCHED OFF.
THIS IS NOT ALLOWED DURING NORMAL OPERATION.
ANY ADJUSTMENT AND CONTROL OPERATIONS FOR WHICH IT IS INDISPENSABLE TO LET THE
COMPRESSOR AND ITS AUXILIARIES RUNNING, MUST BE LIMITED AND AUTHORIZED BEFOREHAND
BY THE SYSTEM MANAGER.
WARNING
ANY CHANGES THAT HAVE NOT BEEN AUTHORIZED BY GE OIL & GAS NUOVO PIGNONE CAN CAUSE
UNBEARABLE STRESS AND THEREFORE ENDANGER SAFETY.
THEREFORE, USERS ARE NOT ALLOWED TO CHANGE THE EQUIPMENT OPERATING PARAMETERS
OR THE INSTRUMENTS AND EQUIPMENT CALIBRATION. THIS MAY LEAD TO HAZARDOUS
SITUATIONS.
WARNING
THE EQUIPMENT MUST BE INSTALLED AND STARTED UNDER THE SUPERVISION OF NUOVO
PIGNONE STAFF.
WARNING
ALL CONTROL AND SAFETY DEVICES MUST BE CHECKED, CALIBRATED AND TESTED PERIODICALLY
WARNING
DO NOT EXCLUDE OR REMOVE THE SAFETY DEVICES AND SHROUDS INSTALLED ON THE
EQUIPMENT.
WARNING
IN CASE OF LONGER STANDSTILL, ADOPT A SUITABLE GUARD IN ORDER TO PRESERVE THE

MACHINE AND ITS AUXILIARIES IN COMPLIANCE WITH THE INSTRUCTIONS SHOWN IN THE
RELEVANT SECTION OF THE MANUAL.
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WARNING
THE MACHINE MUST BE EQUIPPED WITH A WARNING SIGN IF IT CAN BE STARTED BY MEANS OF
A REMOTE CONTROL. IF THE INSTALLATION OCCURS IN AN EU COUNTRY, IT IS COMPULSORY TO
PLACE THIS SIGN IN COMPLIANCE WITH ISO 7000-0017 REGULATIONS. PLEASE REFER TO THE
LOGICAL FUNCTIONAL DIAGRAM AND/OR THE CONTROL PANEL START UP/STOPPING SEQUENCE
IN THE RELEVANT SECTION OF THE MANUAL, IN ORDER TO FIND OUT WHETHER THE MACHINE
HAS THIS FEATURE. THE WARNING SIGN MUST BE CONVENIENTLY PLACED IN A VISIBLE POSITION,
KEPT INTEGER AND BE ALWAYS READABLE.
WARNING
FOR INSTALLATIONS IN WHICH GAS MAY DECOMPOSE OR EXPLODE DUE TO ITS NATURE, THE
USER MUST CLEARLY IDENTIFY THE AREA CONNECTED TO THE COMPRESSION SYSTEM AS AN
"HAZARDOUS AREA".
1.6.2 Mechanical residual risks
WARNING
IT IS FORBIDDEN TO START THE EQUIPMENT WITHOUT PREVIOUSLY INSTALLING THE FORESEEN

SHROUDS. IT IS FURTHERMORE FORBIDDEN TO REMOVE THEM DURING OPERATION.
WARNING
IT IS FORBIDDEN TO USE HOME-BUILT EQUIPMENT (SUPPORTS, BRACKETS, TOOLS, ETC.) THAT

HAVE NOT BEEN EXPLICITLY AUTHORIZED BY THE TECHNICAL OFFICE OF GE OIL & GAS NUOVO
PIGNONE.
WARNING
HOT (OR COLD) AND/OR PRESSURIZED FLUIDS ARE PRESENT IN THE COMPRESSOR AND IN SOME
AUXILIARY SYSTEMS (LUBRICATION OIL, COOLING WATER, STEAM SYSTEMS).
SPECIAL CARE HAS TO BE ADOPTED WHILE OPERATING THE VENT AND BLEED VALVES OF THE
CIRCUITS IN QUESTION.
BEFORE STARTING ANY MAINTENANCE OPERATIONS REQUIRING DISASSEMBLY, MAKE SURE THAT
THE INNER FLUID HAS COOLED DOWN AND THAT IT IS NOT PRESSURISED.
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WARNING
DO NOT STAND NEAR THE MACHINE DURING STARTUP AND AVOID ENTERING THE NEARBY AREA
WHILE IT IS RUNNING.
WARNING
IN ORDER TO AVOID SKIDDING, IMMEDIATELY CLEAN ANY OIL AND REMOVE THE CAUSE OF OIL
LEAKAGE AS SOON AS POSSIBLE.
WARNING
BEFORE LIFTING THE EQUIPMENT, CHECK THE POSITIONS AND THE CAPACITIES OF THE LIFTING
POINTS SHOWN IN THE LIFTING DRAWINGS.
DO NOT USE THE LIFTING POINTS RELATING TO THE MACHINE FOR LIFTING THE MACHINE AND
ITS BASE.
WARNING
IF THERE ARE ANY UNBALANCED LOADS, USE ADDITIONAL ROPES IN ORDER TO PREVENT
TURNOVER DURING LIFTING.
FAILURE TO COMPLY WITH THESE PRECAUTIONS CAN LEAD TO SERIOUS INJURIES. LIFTING AND
HANDLING OPERATIONS MUST BE CARRIED OUT ONLY BY PROPERLY TRAINED PERSONNEL.
WARNING
EACH PART OF THE PRESSURIZED SYSTEM MUST BE PROTECTED AGAINST OVERPRESSURE, FOR
INSTANCE BY MEANS OF RUPTURE DISKS OR SAFETY RELIEF VALVES. NO ISOLATION DEVICES MUST
BE INSTALLED BETWEEN THE COMPRESSOR CYLINDERS AND THE SAFETY RELIEF VALVES (OR
RUPTURE DISKS).
SIMILARLY, NO ISOLATION VALVES OR EQUIVALENT DEVICES MUST BE INSTALLED AT THE OUTLET
OF THE SAFETY VALVES (OR RUPTURE DISK).
WARNING
USE ANY AVAILABLE SERVICE DEVICES (SUCH AS STAIRS, GANGWAYS, GRATINGS, TUNNELS, ETC.)
CORRECTLY (FOR INSTANCE, DO NOT OVERLOAD THEM).
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1.6.3 Electric residual risks
WARNING
MAINTENANCE ON THE ELECTRIC DEVICES MUST BE PERFORMED BY QUALIFIED AND AUTHORIZED

PERSONNEL. PLEASE REMIND THAT IN THE CIRCUITS IN WHICH CAPACITORS ARE INSTALLED,
VOLTAGE CAN STILL BE PRESENT FOR SOME TIME EVEN AFTER THE POWER SUPPLY HAS BEEN
SECTIONED.
WARNING
IF THEY ARE NOT SUPPLIED BY GE OIL & GAS NUOVO PIGNONE, THE USER MUST PROVIDE ANY
ELECTRIC EQUIPMENT WITH SUITABLE OVERCURRENT GUARDS AND ISOLATION SWITCHES.
WARNING
HAZARDOUS VOLTAGES ARE PRESENT INSIDE THE SWITCHBOARDS AND NEAR THE ELECTRIC
DEVICES INSTALLED ON THE MACHINE AND ON ITS AUXILIARIES.
DO NOT REMOVE THE GUARDS UNLESS THE EQUIPMENT HAS BEEN PREVIOUSLY SECURED.
REPLACE THE GUARDS BEFORE SUPPLYING THE EQUIPMENT AGAIN.
WARNING
NEVER WORK ALONE ON ELECTRIC EQUIPMENT. MAKE SURE THAT THE PERSONNEL INVOLVED IS
AWARE OF ANY FIRST AID PROCEDURES TO BE ADOPTED IN CASE OF ELECTRIC SHOCK.
WARNING
DO NOT STAND ON ELECTRIC DUCTS OR JUNCTION BOXES, NOR USE THEM AS SUPPORTS.
WARNING
ALWAYS INSTALL THE EQUIPMENT GROUND LEADS AS SHOWN IN THE DRAWINGS.

IN PARTICULAR, GROUND THE COMPRESSOR BY USING AT LEAST ONE OF THE TWO M12
THREADED HOLES ON TWO CORNERS OF THE FRAME BASE.
NEVER REMOVE SUCH CONNECTIONS.
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WARNING
DO NOT USE WATER TO EXTINGUISH A FIRE WHEN THE EQUIPMENT IS PRESSURIZED.

FIRE EXTINGUISHERS MUST BE WELL SUITED FOR THE EQUIPMENT IN USE AND FOR THE TYPE OF
FIRE.
WARNING
USERS MUST BE AWARE OF THE ELECTRIC CLASSIFICATION AREA FOR WHICH THE UNIT HAS BEEN
DESIGNED (COMPRESSOR, AUXILIARIES, INSTRUMENTS). THIS INDICATION IS SHOWN IN THE
COMPRESSOR SUPPLY SPECIFICATION (DATA SHEET) ENCLOSED TO THIS MANUAL.
1.6.4 Thermal residual risks
WARNING
DURING OPERATION, SOME PARTS OF THE COMPRESSOR AND OF ITS AUXILIARY SYSTEMS REACH
HIGH TEMPERATURES. ACCIDENTAL CONTACT WITH HOT SURFACES CAN CAUSE SERIOUS BURNS.
BEFORE CARRYING OUT ANY INSPECTION OR MAINTENANCE, MAKE SURE THAT THESE PARTS
HAVE COOLED DOWN.
WARNING
EACH PART OF THE COMPRESSOR AND OF THE SYSTEM THAT DURING OPERATION REACHES A
TEMPERATURE HIGHER THAN 70°C OR LOWER THAN -10°C AND THAT, DUE TO ITS POSITION, CAN
BE ACCIDENTALLY TOUCHED BY THE OPERATORS, MUST BE PROPERLY INSULATED OR
PROTECTED, OR SIGNALLED BY MEANS OF WARNING SIGNS. IF INSTALLATION OCCURS IN AN EU
COUNTRY, IF THERE ARE NO GUARDS OR INSULATION AVAILABLE, IT IS COMPULSORY TO ATTACH
SUCH SIGNS. THESE MUST COMPLY WITH 417-IEC-5041 (HIGH TEMPERATURE SIGNALLING) AND
EN 50 099 (LOW TEMPERATURE SIGNALLING) STANDARDS.
THEREFORE, REFER TO THE FUNCTIONAL DIAGRAMS OF THE COMPRESSOR AND ITS AUXILIARIES
(SEE THE SPECIFICATIONS AND DIAGRAMS SECTION), WHERE THE SYSTEM COMPONENTS ARE
SHOWN. WARNING SIGNS MUST BE PLACED IN A WELL VISIBLE POSITION, KEPT INTEGER AND BE
ALWAYS READABLE.
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1.6.5 Residual risks due to noise
WARNING
DURING OPERATION NEAR THE COMPRESSOR, PROCESS PIPES AND ANY RECYCLE VALVES, THERE
ARE HIGH LEVELS OF NOISE THAT MAY CAUSE TEMPORARY OR PERMANENT DAMAGES TO
HEARING, UNLESS SUITABLE PROTECTION MEANS ARE USED. ANY PERSONNEL WORKING FOR
ANY REASONS, EVEN FOR A SHORT PERIOD OF TIME, NEAR THIS EQUIPMENT WHEN THE UNIT IS
RUNNING MUST WEAR HEARING PROTECTION MEANS ( PARAGRAPH 4 ).
1.6.6 Residual risks due to materials and substances
WARNING
IF A CARBON DIOXIDE FIREFIGHTING SYSTEM IS USED, DISCHARGE INSIDE A PROTECTED ROOM

CAUSES A GREAT DECREASE IN TEMPERATURE AND IN VISIBILITY, AS WELL AS A GREAT REDUCTION
IN OXYGEN CONCENTRATION. THIS MAY LEAD TO ASPHYXIA FOR THE PEOPLE THAT MAY
ACCIDENTALLY BE INSIDE THE ROOM. BEFORE ENTERING THIS ROOM, INHIBIT THE AUTOMATIC
DISCHARGE SYSTEM AND LOCK THE VALVES ON ALL THE DISCHARGE PIPES. A SPECIFIC
PROCEDURE MUST BE ISSUED BY THE SYSTEM MANAGER.
WARNING
IF A WATER MIST SYSTEM IS USED, THE DISCHARGE INSIDE THE PROTECTED ROOM CAUSES A
GREAT DECREASE IN VISIBILITY AND BREATHING MAY BECOME VERY DIFFICULT.
BEFORE ENTERING THIS ROOM, INHIBIT THE AUTOMATIC DISCHARGE SYSTEM AND LOCK THE
VALVES ON ALL THE DISCHARGE PIPES. A SPECIFIC PROCEDURE MUST BE ISSUED BY THE SYSTEM
MANAGER.
WARNING
WHEN THE FIREFIGHTING SYSTEM IS OPERATED, THE DISCHARGE IS ANNOUNCED BY AN

ACOUSTIC SIGNAL INSIDE AND NEAR THE PROTECTED AREA.
WHEN HEARING SUCH SIGNAL, ANY PEOPLE PRESENT IN THE ROOM MUST IMMEDIATELY
LEAVE THE ROOM AND SHUT THE DOOR.
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BEFORE ENTERING THE ROOM AGAIN AFTER THE DISCHARGE, MAKE SURE THAT THE FIRE HAS
BEEN COMPLETELY EXTINGUISHED AND THAT IT CANNOT BE TRIGGERED AGAIN. AFTERWARDS,
AERATE THE ENVIRONMENT BEFORE ENTERING.
WARNING
VENTS, DISCHARGES AND DRAINS CAN LEAD TO POISONING, FIRE AND EXPLOSION HAZARDS.
THEREFORE THEY MUST BE PROPERLY PIPED. THESE PIPES MUST COMPLY WITH INFORMATION
SHOWN IN RELEVANT DIAGRAMS (SEE THE SPECIFICATIONS AND DIAGRAMS SECTION).
VENTS AND DRAINS MUST BE PROPERLY TREATED AND PLACED IN A SAFE PLACE AS THEY ARE
HIGHLY POLLUTANT AND HAZARDOUS FOR PEOPLE AND OBJECTS.
APART FROM GASES THEMSELVES (MORE OR LESS HAZARDOUS), GASEOUS FRACTIONS CAN ALSO
CONTAIN OTHER REAGENTS TREATED BY THE COMPRESSOR.
DISCHARGES AND DRAINS CARRY LUBRICANT OIL AND CONTAIN THE SAME GASES MENTIONED
ABOVE (DISSOLVED OR COMBINED) THAT GET OUT OF THE FLUID MORE OR LESS RAPIDLY.
WARNING
DO NOT USE ANY FLAMMABLE PRODUCTS TO CLEAN THE MACHINE COMPONENTS.

PLEASE REFER TO THE USAGE PRESCRIPTIONS SHOWN IN THE PRODUCT SAFETY SHEET.
WARNING
IN HAZARDOUS AREAS, USERS ARE NOT ALLOWED TO SMOKE, WELD, USE OPEN FLAMES OR
DEVICES WHICH MAY BE IGNIFEROUS.
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1.7 HAZARDS INFORMATION IN CASE OF FAILURE

The machine and its auxiliaries are designed according to a "Fail safe" philosophy. In case of failure
of the electric, hydraulic or pneumatic circuits, the assembly is stopped under safety conditions both
for the machine and for the operators.
Also the control system is designed according to a "Fail safe" philosophy. Any failure of the control
system is detected by means of self-diagnostic programs that determine the positioning of output
signals corresponding to safety conditions.
In case of failure of the devices containing pressurized and/or hazardous fluids or of a wrong
assembly/disassembly of the circuit components containing pressurized fluids, hazardous situations
may arise, such as the presence of hazardous gases, high pressure or high temperature fluid
projection. For these hazards, please refer to the paragraph relating to mechanical risks and risks
due to materials and substances.
In case of failure due to some parts of the machine breaking down during operation, there may be
projections (event though the probability is very low) of parts. Please refer to the paragraph relating
to the residual risks due to mechanical dangers.
Machine start up occurs only after confirming the command on the unit control panel (or DCS).
Therefore it is unlikely that the machine can be started up accidentally. However, if the station is
controlled by means of a remote control, it is necessary to issue a notification procedure for the
personnel working on the station to be adopted before startup. This procedure must be carried out
by the system manager.
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1.8 FORESEEN USE OF THE MACHINE

The foreseen operational conditions and the data relating to the machine and its auxiliaries design
are shown in the COMPRESSOR SUPPLY SPECIFICATION included in the SPECIFICATIONS AND
DIAGRAMS section of the manual. Additional information is shown in the diagrams. In particular:
- gas pressure and temperature in the compressor's circuit: see "PROCESS GAS DIAGRAM"
- capacity adjustment: see the relevant DIAGRAM.
Refer also to the relevant paragraph in the "OPERATION" section.
- service and/or phases arrangement on the compressor: see "LAYOUT OF THE COMPRESSOR
SYSTEM ".
The use with different pressure, temperature, capacity and number of revolutions, can lead to
situations that may damage the machine and/or injure the operators.
Operating the machine in such conditions, as well as removing any guards, are not to be considered
proper use.
The characteristics of treated gas must comply with the compositions shown in the above mentioned
data sheets.
The presence of fluids or solid particles in the treated gas can damage the machine or erode its inner
parts.
It may be dangerous to operate the machine at its critical speed, unless this has been previously
approved by the GE Oil & gas NP technical department. These conditions are shown in the "torsional
analysis" enclosed to this manual).
Any changes to the machine or its control system that have not been previously approved by GE Oil
& Gas Nuovo Pignone can be hazardous for the personnel and/or for the machine.
GE Oil & Gas Nuovo Pignone cannot be held responsible for any consequences arising from an
improper or unforeseen use of the machine or of its auxiliaries.
WARNING
ALWAYS CHECK THE OPERATIONAL CHARACTERISTICS AND THE SAFETY DEVICES BEFORE
STARTING THE COMPRESSOR.
THE CUSTOMER WILL BE HELD RESPONSIBLE FOR ANY DAMAGE OR INJURY ARISING FROM
OPERATING CONDITIONS DIFFERENT FROM THOSE SPECIFIED OR NOT REASONABLY
FORESEEABLE, FROM WRONG OPERATIONS OR PROCEDURES, OF IMPROPER MAINTENANCE OR
CORROSION, EROSION, DEPOSITS OR GRADUAL WEAR.
WARNING
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THE COMPRESSOR CANNOT BE USED TO COMPRESS DIFFERENT TYPES OF GAS. IT CANNOT BE

OPERATED IN AN ATMOSPHERE DIFFERENT FROM THE ONE SPECIFIED IN THE DRAWINGS.
1.9 GENERAL WARNINGS

The following precautions refer to the compressor and must be complied with during all service
procedures.
Failure to comply with one of these precautions can cause damages or destroy the machine.
Precautions are not listed in order, from most important to least.
CAUTION
ALL THAT REFERS TO THE MACHINE AND TO THE SYSTEM INTO WHICH THE MACHINE IS INSTALLED
MUST BE MANUFACTURED AND PERFORMED IN COMPLIANCE WITH LOCAL SAFETY AND
ANTIPOLLUTION REGULATIONS (ELECTRIC, FIRE PREVENTION, FACTORY, ETC.).
CAUTION
PAY ATTENTION AND AVOID ANY COLLISION WHILE MOVING THE MACHINE AND ITS
COMPONENTS.
CAUTION
BEFORE STARTING THE MACHINE, MAKE SURE THAT ALL INLET, DISCHARGE AND VENT COVERS
HAVE BEEN REMOVED AND THAT THEY ARE NOT CLOGGED.
CAUTION
AT STARTUP, PLACE A TEMPORARY FILTER ON THE SUCTION PIPING NEAR THE COMPRESSOR; THIS
FILTER CAN BE REMOVED WHEN PIPING IS CLEAN.
CAUTION
CAREFULLY OBSERVE ALL THE INDICATIONS ON THE MONITORS AND ON THE INSTRUMENTS
BEFORE STARTUP AND DURING OPERATION. PRESSURE AND TEMPERATURE MEASURED VALUES
ARE THE BEST INDICATORS OF THE MACHINE PROPER OPERATION.
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CAUTION
IN CASE OF STOP OR FAILURE, DO NOT TRY TO START THE MACHINE AGAIN, UNLESS THE CAUSE
HAS BEEN FOUND AND CORRECTED.
CAUTION
AS A SAFETY MEASURE, CLOSE ALL THE OPEN DUCTS DURING MAINTENANCE IN ORDER TO
PREVENT FOREIGN MATERIALS FROM ENTERING THE SYSTEMS; DO NOT USE TAPE.
CAUTION
DO NOT BEND THE CABLES; THEY MAY BREAK IF THEY ARE CONTINUOUSLY BENT.
CAUTION
KEEP EXPLOSION-PROOF COVERS, DOORS, PANELS AND BOXES CLOSED; ALL FASTENING DEVICES
MUST BE PROPERLY TIGHTENED, UNLESS INSPECTIONS ARE TO BE CARRIED OUT.
CAUTION
WHILE DISCONNECTING ANY ELECTRIC CABLES, DO NOT PULL THEM; DISCONNECT THEM ONLY
BY GRASPING THE CONNECTORS.
CAUTION
MAKE SURE THAT THE RELIEF AND THE CONTROL VALVES ARE INSTALLED IN COMPLIANCE WITH
THE PROPER FLOW DIRECTION.
CAUTION
MAKE SURE THAT ANY BROKEN PARTS ARE EXCLUDED AND THAT A SIGN SPECIFYING «DO NOT
USE» IS PLACED ON THE CONTROLS AND SWITCHES. DO NOT USE THE COMPRESSOR IF ANY OF
ITS COMPONENTS AND ACCESSORIES ARE NOT PROPERLY WORKING.
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CAUTION
IF THE COMPRESSOR IS NOT USED FOR LONGER PERIODS, PRESSURIZE ITS INNER PART WITH
INERT GAS (NITROGEN): PLEASE REFER TO THE PRESCRIPTIONS SHOWN IN THE RELEVANT SECTION
OF THIS MANUAL.
THE PURCHASER WILL BE HELD RESPONSIBLE FOR ANY DAMAGES DUE TO A STANDSTILL PERIOD
DURING WHICH THE PRODUCT HAS NOT BEEN PROPERLY MAINTAINED SO AS TO ENSURE ITS
PERFECT PRESERVATION.
CAUTION
ALWAYS MAKE SURE THAT THE FASTENING DEVICES (SCREWS, NUTS, ETC.) ARE PROPERLY
TIGHTENED WITH THE TORQUE VALUES SHOWN IN THIS MANUAL.
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2 - MOVING, HANDLING, STORAGE
1 Moving and handling ...................................................................................................................................32 1-32

2 Storage ...............................................................................................................................................................34 1-34
3 SKID-MOUNTED UNITS ................................................................................................................................40 1-40
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SAFETY PRECAUTIONS - GENERAL INFORMATION
2.1 Moving and handling
WARNING
PRIOR TO UNDERTAKING ANY PROCEDURE FOR MOVING THE UNIT (SLINGING, HOISTING,
ETC.), CAREFULLY READ THE INFORMATION SHOWN IN THE GENERAL INFORMATION
SECTION, RELEVANT TO GENERAL SAFETY PRECAUTIONS.
ALL PERSONNEL OPERATING ON THE COMPRESSOR AND AROUND IT MUST BE EQUIPPED
WITH ADEQUATE PROTECTION FOR THE BODY. IN PARTICULAR, THEY MUST WEAR WORK
GLOVES, HELMET, WORK BOOTS, GOGGLES, OVERALLS. IF IT IS IMPOSSIBLE TO EXCLUDE
WITH CERTAINTY THE PRESENCE OF HARMFUL OR POISONOUS OR HAZARDOUS GASES OF
ANY KIND COMING FROM PLANTS, MACHINERY AND SURROUNDING EQUIPMENT,
PERSONNEL MUST ALSO BE EQUIPPED WITH BREATHING MASK. THE ADVISABILITY OF
EQUIPPING PERSONNEL WITH ANTI-NOISE EAR PROTECTION SHOULD ALSO BE
CONSIDERED. PERSONNEL MUST NOT APPROACH MOVING PARTS WHILE WEARING LOOSE
CLOTHING, PERSONAL ORNAMENTS, OR LONG HAIR.
THE LOCAL SAFETY RULES AND THOSE OF THE PLANT MUST ALSO BE COMPLIED
WITH.
WHEN USING HOISTING SYSTEMS, ENSURE THAT THEY HAVE ADEQUATE CAPACITY AND
SAFETY FACTOR, THAT THEY ARE IN A PERFECT STATE OF PRESERVATION AND THAT THEY
COMPLY WITH THE VARIOUS SAFETY REGULATIONS (SHOP, LOCAL, ETC.). MOREOVER,
PERSONNEL ASSIGNED TO HANDLING MUST POSSESS THE NECESSARY QUALIFICATION
AND EXPERIENCE.
AS CONCERNS WEIGHTS OF THE HEAVIEST COMPONENTS TO BE HANDLED, REFER
TO THE STATIC LOADING DIAGRAM OR TO THE WEIGHTS, C.O.G. POSITION AND
DATA FOR FOUNDATION/SUPPORTING STRUCTURE STATIC DESIGN AND LIFTING/
HANDLING OF COMPONENTS DIAGRAM (SEE DATA SHEETS AND SCHEMATICS
VOLUME), TO THE DRAWINGS OF THE EQUIPMENT (PULSATION SUPPRESSION
DEVICES, GAS COOLERS, SEPARATORS), CONTAINED IN THE PART LISTS VOLUME,
TO THE SHIPPING DOCUMENTS AND TO THE INDICATIONS SHOWN ON THE
PACKAGES.
MISSING SPECIFIC PRESCRIPTIONS ON DATA SHEETS AND SCHEMATICS, FOLLOW THE
INDICATIONS SHOWN ON THE PACKAGES. USE THE LIFTING POINTS SHOWN ON THE CASES
OR ON THE SINGLE COMPONENT, SUCH AS FOR EXAMPLE:
COMPRESSOR SKID OR ITS AUXILIARIES; IN THIS CASE REFERALSO TO THE
PRESCRIPTIONS SHOWN IN THE FOLLOWING PARAGRAPH DEDICATED TO THEM;
SEPARATORS;
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OTHER VERTICAL EQUIPMENT.
REGARDING COMPRESSOR FRAMES AND CYLINDERS INSTALLED DIRECTLY ON THE

FOUNDATION, SEE FIGURE 1 , FIGURE 2 , FIGURE 3 AND FIGURE 4 , IF THERE ARE
NO SPECIFIC PRESCRIPTIONS FOR THE MACHINE SUBJECT OF THIS MANUAL IN
DATA SHEETS AND SCHEMATICS VOLUME. KEEP IN MIND THAT, UNLESS
OTHERWISE SPECIFIED, NO LIFTING GRIPS THAT MAY BE PROVIDED ON THE FRAME
CAN BE USED FOR LIFTING THE COMPRESSOR. THESE LIFTING GRIPS ARE
GENERALLY PROVIDED FOR USE EXCLUSIVELY IN THE SHOP AND ARE NOT SIZED
FOR LIFTING THE FRAME COMPLETE WITH SHAFT, CRANK GEAR OTHER
COMPONENTS WHICH MAY BE ATTACHED. IN SIMILAR MANNER, THE EYEBOLTS
PROVIDED ON THE CYLINDERS CAN BE USED FOR LIFTING ONLY IF THE CYLINDERS
ARE BARE, I.E., WITHOUT HEAD, PACKING, VALVES, COVERS, OR DISTANCE PIECE
CONNECTED TO THEM. SOME COOLER COMPONENTS MAY ALSO BE PROVIDED
WITH LIFTING GRIPS TO BE USED EXCLUSIVELY FOR LIFTING THEM DURING
MAINTENANCE PROCEDURES. THESE LIFTING GRIPS SHOULD NOT BE USED TO LIFT
THE COMPLETE EQUIPMENT, UNLESS OTHERWISE SPECIFIED ON THE RELEVANT
DRAWING, FOUND IN THE PART LISTS VOLUME OF THE MANUAL.
REGARDING LIFTING OF SOME TYPICAL PARTS NOT PACKED IN CRATES AND NOT
PROVIDED WITH ADEQUATE LIFTING GRIPS, SEE FIGURE 1 , FIGURE 2 , FIGURE 3
AND FIGURE 4 .
ENSURE THAT THE EYEBOLTS ARE CORRECTLY TIGHTENED. WHEN USING THEM, ENSURE
TO FOLLOW THE SPECIFIC RECOMMENDATIONS, IF ANY, SHOWN ON THE COMPONENTS
DRAWINGS (SEE PART LISTS VOLUME).
ENSURE THAT THE LIFTING MEANS DO NOT CAUSE DAMAGE. FOR EXAMPLE, ADEQUATELY
PROTECT MACHINED SURFACES AGAINST LIFTING CABLES AND ENSURE THAT THE CABLES
DO NOT EXERT UNACCEPTABLE STRESS ON PARTS OF THE PIECES. IN THIS REGARD, IT IS
ADVISABLE TO USE, WHEN POSSIBLE, SYNTHETIC STRAPS INSTEAD OF METAL CABLES FOR
LIFTING; THIS MAY FACILITATE THE LIFTING OF ASYMMETRICAL COMPONENTS. IT SHOULD
ALSO BE KEPT IN MIND THAT ANY SHARP EDGES OF COMPONENTS (E.G., ON THE
CONNECTING ROD BIG END) CAN DAMAGE THE LIFTING EQUIPMENT.
LASTLY, AS REGARDS LIFTING OF AUXILIARY COMPONENTS, REFER TO THE RELEVANT
INSTRUCTION MANUALS (SEE AUXILIARIES-MISCELLANEUS EQUIPMENT VOLUME).
PIECES MUST BE HANDLED WITH THE NECESSARY PRECAUTIONS. ABRUPT AND
EXCESSIVELY FAST MOVEMENTS MUST BE AVOIDED, THE PIECES MUST BE KEPT IN THE
REQUIRED POSITION WITHOUT OVERTURNING, AND ANY IMPACT MUST BE AVOIDED.
12-2010 1003084 Page 1-33

2.2 Storage
Unless special agreements have been made with the Customer in the Contract, the material included
in this supply has been shipped after having been protected and packed according to NUOVO
PIGNONE standards.
Selection of the type of protection and packing is made on the basis of various factors: means of
transport used, duration of the shipping, duration and environment of storage, if any. These factors
have been appropriately defined in the Contract; that document, therefore, specifies the time for
which the protection applied is able to guarantee adequate preservation.
At the time of receipt, it will be the Customer's responsibility to check immediately that the various
parts of the packing have undergone no damage during transport and that the protection of the
material has not been impaired.
If the packing or protection has been damaged, it will be necessary to proceed immediately to
restoring it to its original conditions.
WARNING
IF THE MATERIAL IS TO BE PUT IN STORAGE OR IN CASE OF DELAY IN SETTING AT WORK NOT

FORESEEN BY THE CONTRACT, CONSIDER THAT LONG PERIODS OF INACTIVITY CAN DETERMINE
HARMFUL DETERIORATION UNLESS SPECIFIC INSPECTIONS ARE CARRIED OUT AND SUITABLE
PRESERVATION IS IMPLEMENTED. CONSEQUENTLY, THE CUSTOMER MUST:
A. CHECK, UPON THEIR ARRIVAL ON SITE, THE CONDITION OF THE CASES AND/OR MATERIALS
IF THE CASES ARE OPENED;
B. STORE THE CASES IN A PLACE PROTECTED AGAINST ATMOSPHERIC AGENTS AND/OR
CONDITIONED AIR IN RELATION TO THE TYPE OF PACKING USED. IN ANY CASE, IF THE
CASES ARE OPENED, THE MATERIAL MUST BE STORED IN AN ENCLOSED, AIR-CONDITIONED
AREA;
C. CHECK PERIODICALLY THE MATERIALS WITH THE FOLLOWING SCHEDULE:
- EVERY 12 MONTHS MAX. IF THE MATERIAL IS PACKED IN INTEGRAL CASES WITH
«BARRIER BAG» NOT EXPOSED TO WATER OR TO ANY RISK FACTOR
- EVERY 6 MONTHS (OR EVERY 3 MONTHS IN MARINE, OR TROPICAL AREAS OR DAMP
ENVIRONMENT) IF STORAGE IS IN AN ENCLOSED AIR-CONDITIONED AREA, EVERY 4
MONTHS (OR 2 MONTHS IN THE ABOVE-MENTIONED AREAS) IF STORAGE IS
OUTDOOR UNDER ROOF.
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NOTE
NUOVO PIGNONE if requested, can send a specialist to the jobsite to inspect the material and its
state of preservation. In any case, Nuovo Pignone's responsibility cannot be extended to cover
any item not included in the Contract.
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Figure 1
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Figure 2
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Figure 3
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Figure 4
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2.3 SKID-MOUNTED UNITS

In addition to the general instructions given in the previous paragraph, consider that during
procedures for hoisting and transport skid-mounted units, it will be necessary to avoid any deformation
of the skid such as to cause dangerous stresses on the compressor and on the other equipment.
Deformation in the skid, occurring during transport, can derive from the following factors:
a. Uneven surface of the transport means and/or deformation caused by the load or by the road
or railway.
b. Uneven storing surface at the port or at the railway station, or at the job site.
c. During transport by ship, uneven surface of the deck.
As regards lifting, the units must be supported exclusively by the points shown on the packing.
As regards support of the units during transport, the following cases may be defined:
a. Skid with compressor or driver only (including any auxiliaries)
The skid will be placed on two beams positioned at the lifting points (see Figure 5 ).
b. Skids with auxiliaries only.
These skids will be simply placed on the flatbed of the transport means.
c. Skids of three-point support type.
These will be placed on beams positioned at the supports (see Figure 5 ).
d. Skids with compressor and driver (and auxiliaries, if any).
These skids will be placed on three beams of identical thickness: two of these will be placed at
the points of support, the third will be placed at equal distance from the others (see Figure 5 ).
For greater safety Nuovo Pignone may deliver the units with the coupling bolts of the driving
components loosened. The same precaution may be taken also for other components of the unit.
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Figure 5
LEGEND
A BEAM
B SUPPORT
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3 - INSTALLATION
1 SAFETY PRECAUTIONS - PROCEDURES PRECEDING GROUTING OF EQUIPMENT ..............43 1-43

1.1 Safety precautions .......................................................................................................................................43 1-43
1.2 Installation site ...............................................................................................................................................44 1-44
1.3 Foundation check .........................................................................................................................................45 1-45
1.4 Foundation cleaning ...................................................................................................................................45 1-45
2 POSITIONING SKID ALIGNMENT CHECK ...............................................................................................47 1-47
2.1 Positioning ........................................................................................................................................................47 1-47
2.2 Alignment check ............................................................................................................................................47 1-47
2.2.1 Procedure .........................................................................................................................................................48 1-48
2.2.2 Definitions ........................................................................................................................................................49 1-49
2.2.3 Taking alignment data ...............................................................................................................................50 1-50
2.3 Checks on assembled unit ........................................................................................................................52 1-52
2.3.1 Taking alignment data ...............................................................................................................................52 1-52
2.3.2 Recording data ..............................................................................................................................................52 1-52
3 SKID ANCHORING ...........................................................................................................................................67 1-67
4 CONNECTING CYLINDERS TO FRAME, RUN-OUT ..............................................................................72 1-72
4.1 Installation .......................................................................................................................................................72 1-72
4.1.1 Vertical cylinders to be connected onsite .........................................................................................72 1-72
4.1.2 Horizontal cylinders to be connected onsite ...................................................................................73 1-73
4.1.3 Horizontal cylinders already connected in the shop ...................................................................74 1-74
4.2 Run-out ..............................................................................................................................................................74 1-74
5 AUXILIARIES SKIDS POSITIONING AND ANCHORING .....................................................................77 1-77
5.1 Positioning ........................................................................................................................................................77 1-77
5.2 Anchoring .........................................................................................................................................................77 1-77
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3.1 SAFETY PRECAUTIONS - PROCEDURES PRECEDING GROUTING OF

EQUIPMENT
3.1.1 Safety precautions
CAUTION
- Prior to undertaking any installation procedure, carefully refer to the information shown
in the GENERAL INFORMATION Section, relevant to the GENERAL SAFETY PRECAUTIONS.
- Personnel assigned to unit installation must possess the necessary capability and skill. If
the subject has not already been dealt with in the offer or contract, the customer must
contact NUOVO PIGNONE MEST department (Florence Headquarters Italy) for information
on the number and skill of the operators needed.
- All personnel operating on the compressor and around it must be equipped with adequate
protection for the body. In particular, they must wear work gloves, helmet, work boots,
goggles, overalls. If it is impossible to exclude with certainty the presence of harmful or
poisonous or hazardous gases of any kind coming from the plants, machinery and
surrounding equipment, personnel must also be equipped with breathing mask. The
advisability of equipping personnel with anti-noise ear protection should also be
considered. Personnel must not approach moving parts while wearing loose clothing,
personal ornaments, or long hair. The local safety rules and those of the plant must also
be complied with.
- The Customer shall provide adequate roofing, during the erection stage, if this takes place
outdoors. During erection special attention shall be given to verify sealing of nozzles,
cylinders, frame ports, pressure vessel flanges, etc., to prevent the entrance of water,
sand, dirt in general.
- If presence of flammable gases is possible (or the formation of explosive mixtures) coming
from installations in the vicinity of the working area or if it is impossible to prevent this
possibility with absolute certainty, it will be compulsory to avoid the use of any flame,
welding, electrical machines and tools, miscellaneous tools (even manual) which could
generate sparks during use.
- The directions given in the Section of this Manual relevant to PROTECTION DURING
IDLENESS, dedicated to the preservation of already installed units during periods of
idleness, are valid, where feasible, also for units which are erected over an extensive period
of time or which are not started immediately after erection.
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NOTE
state of preservation. In any case, NUOVO PIGNONE cannot be held responsible for anything not
established by contract.
CAUTION
- During positioning procedures, ordinary lifting devices can accidentally damage parts of
the unit (e.g. piping, instruments). To avoid this, it is advisable either to locate the unit to
its position prior to removing the packing case, or to use suitable fixtures for lifing the
equipment. In any case, refer to paragraph SAFETY PRECAUTIONS - GENERAL
INFORMATION in the Section MOVING, HANDLING, STORAGE.
- Installation must be performed in suitable environmental conditions. For example,
installation must never take place in conditions of dusty atmosphere or sandstorms. In
case of ambient temperatures lower than 0°C, it could be necessary to employ special
techniques for pouring the grouting for the machine. We recommend contacting the
suppliers of the grouting products, both as regards selection of same and as regards
methods for pouring the grout.
- Special precautions are mandatory in case of installation of oxygen compressors. Refer
to the instructions shown in the paragraph SAFETY PRECAUTIONS - MAINTENANCE
PROGRAM in the MAINTENANCE Section.
- Regarding removal of waste materials, packing to be recycled or pollutants (e.g. plastic
wraps, dehydrating compounds, etc.), comply with local and plant regulations.
3.1.2 Installation site

Check that the environment in which the unit is to be installed is well ventilated. This is even more
important when the compressor handles flammable or toxic gases.
Lighting must be adequate to ensure that in any ambient conditions and at any stage of installation,
operation and maintenance, procedures can be carried out with ease. Accordingly, appropriate fixed
lights and movable lights shall be provided.
The site of installation shall be equipped with an appropriate lifting system, sized for the heaviest
part to be lifted during maintenance, as shown in the compressor's DATA SHEETS (see the part of
REFERENCE DRAWINGS volume).
Prior to initiating the installation work, ensure that the space available for maintenance of the unit
complies with the requirements of the GENERAL ARRANGEMENT drawing (see abovecited part).
Have ready all items required to carry out the work (materials, tools, connections of utilities, etc.).
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WARNING
THE STRUCTURES ON WHICH THE COMPRESSORS, THEIR DRIVER AND THE VARIOUS AUXILIARIES
ARE TO BE INSTALLED MAY UNDERGO DEFORMATION CAUSED BY THE WEIGHT OF THE
EQUIPMENT.
ACCORDINGLY, IT IS RECOMMENDED TO CARRY OUT FINAL ALIGNMENT, ANCHORING AND
COUPLING OF THE COMPRESSION UNITS ONLY AFTER ALL THE RELEVANT EQUIPMENT HAS BEEN
LOCATED ON THE STRUCTURES. IF THIS IS IMPOSSIBLE, PERFORM PRELIMINARY ALIGNMENT ONLY;
A FINAL CHECK WILL, IN ANY CASE, BE MADE AFTER ALL THE COMPONENTS HAVE BEEN
INSTALLED.
3.1.3 Foundation check

Check that the foundations comply with relevant drawing, allowing a correct positioning of the unit.
The following procedure is recommended:
a. With the engineer in charge of the civil works, establish a reference level related to the zero
level of the foundations.
b. Check the exact height of the various planes of the foundations in respect to this reference
level.
c. Taking as reference the level of the machine centerline, verify that the distance between the
foundation and the base of the machine is equal to the dimension marked on the above-
mentioned drawing or that in any case such distance ensures a correct anchoring. If this
distance is too low, the machine must be lifted.
d. Trace the two fiducial axes of the horizontal planes; to facilitate the procedure, refer to the
scheme of the above-mentioned foundation drawing.
Then check the distance between the centers of the foundation bolt pits and the fiducial axes.
e. With the same reference as that of item d , check also the distances of the foundation bolt
pits of the auxiliaries. If specific instruments are not available, empirical means may be
employed. For example, to measure heights of plinths located at a distance from the main
body of the foundation, use optical instruments or, more simply, a transparent pipe filled with
water, as shown in Figure 6 .
f. Check the depth of the foundation bolt pits (between end of bolt and pit bottom there must
be a distance of at least 100 mm) and their width (between wall of pit and bolt there must be
at least 40 mm).
3.1.4 Foundation cleaning

Carefully follow the instructions of the supplier of the mortar or resin. As a general rule, for anchoring
with mortar, the following is advisable:
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- Prior to making the grouting, remove any deteriorated or non-solid cement from the
foundations and roughen the surfaces by means of chipping or other suitable system.
- Remove all traces of dirt (oil, grease, dust, etc.) from the surfaces that will be in contact with
the grouting.
- Saturate the foundation surfaces with water for at least 12 hours before pouring the grouting.
- Remove, with compressed air if possible, any non-absorbed water or water stagnating inside
the foundation bolt pits.
For anchorage with resin, it is recommended that:
- Prior to making the grouting, remove deteriorated or non-solid cement from the foundations
and roughen the surfaces.
- Thoroughly clean and dry the foundation surfaces.
Figure 6
LEGEND
A TRANSPARENT PIPE
B WATER LEVEL
C MEASUREMENTS
D FOUNDATION
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3.2 POSITIONING SKID ALIGNMENT CHECK
WARNING
REGARDING UNIT LIFTING AND HANDLING, FOLLOW THE INSTRUCTIONS SHOWN IN THE
SAFETY INSTRUCTIONS - GENERAL INFORMATION - "MOVING, HANDLING AND STORAGE"
SECTION
3.2.1 Positioning
- After the skid has been lifted, clean the surfaces that will be in contact with the grout,
degreasing them and removing any deposit, rust, etc.
Insert the foundation bolts B (see Figure 7 ) in their housing on the skid A screwing the nuts
until the bolts protrude by about two threads. The upper part of the bolts will be wrapped with
a sheet of polyethylene or with adhesive tape F for a length of approximately 10 times the
diameter. This procedure will ensure adequate elasticity of the foundation bolts after
anchoring.
- Place the skid on the foundations. Verify its position in reference to the axises shown on the
FOOTPRINT diagram (see part of Reference Drawings Volume of this Manual). If leveling screws
E are used, position a plate D on the foundation below each of them. If instead jack screws G
are used, position them on the foundation at the points of greatest stiffness of the skid, as
shown on the General Arrangement drawing (see part of Reference Drawings Volume of this
Manual). Then place the skid on the foundation.
- The gap between skid and foundation must be suitable to ensure correct filling with the
anchoring grout. There should be a distance of at least 100 mm between end of foundation
bolts and pit bottom, and at least 40 mm between pit walls and foundation bolts.
- Carry out general leveling of the skid, placing a precision level on the appropriate plates and
operating on the leveling screws or the jack screws.
- Pour the grout for the foundation bolts alone. Wait for setting time to elapse, then tighten the
nuts slightly.
Then proceed checking the alignment.
3.2.2 Alignment check

The alignment of the compressor bearings and alignment between compressor and driver has
already been carried out in the workshop prior to shipment. However, it is always advisable to carry
out a check at the jobsite, since it may happen that the anchoring procedure causes deflections in
the skid that make alignment defective. Note that the compressor bearings alignment check is not
required in case of crankshaft with two journals only.
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WARNING
ALIGNMENT SHOULD BE CHECKED WITH MAXIMUM CARE BY HIGHLY SKILLED PERSONNEL. A

DEFECTIVE ALIGNMENT CAN CAUSE SEVERE DAMAGE TO BEARINGS, SHAFTS AND COUPLING
WITHIN A VERY SHORT TIME.
3.2.2.1 Procedure
If the flywheel is assembled on the compressor crankshaft its weight must be totally supported by
the same crankshaft; it shall never rest on the shaft of the coupled driver.
The sequence of procedures to be followed for checking the compressor bearings alignment is the
following (see Figure 8 ):
a. Measure the shaft deflection with the flywheel assembled. To do this, place an internal
micrometer gauge E onto the first crank, (coupling side) in the position shown in Figure 8
Then slowly rotate the shaft, checking the deformation shown by the internal micrometer
gauge during a complete revolution.
Repeat the procedure on all other cranks.
The mutual displacements of the faces of the webs must be taken back to the original values
recorded in the workshop. To do this, act in parallel on the leveling screws or the jack screws
and on the nuts of the foundation bolts, which will always be lightly tightened to the skid.
In this way, any displacement or deformation in the skid occurring during grouting and
shrinking of the foundation will be overcome or at least corrected to some extent.
Next, check the alignment between compressor and driver.
a. Place the compressor shaft in the position of mid-deflection of the webs of the first crank
(coupling side), during one complete revolution.
b. Measure the total length of the coupling (with the two half couplings correctly spaced from
each other, as specified by the coupling manufacturer).
c. Position the compressor shaft at the middle of its own axial clearance without rotating it out
of the position previously given. To do this, using a dial gauge, measure the axial end positions
of the shaft, which will be positioned at the midpoint of instrument range.
d. If the driver is provided with sleeve bearings, position the driver shaft according to the
reference that ensures rotor magnetic field centering. If this reference is missing, start the
motor without load (by the personnel responsible for running it), and mark the position taken
by the shaft during rotation.
e. Displace the driver, if necessary, to obtain the distance between the two half couplings
mentioned in item b
f. In this position, check the alignment between the two shafts as explained in the "Taking
Alignment Data" Paragraph 2.2.3
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NOTE
As wear or settling may alter, over the course of time, the mutual position of the
coupled shafts, the misalignment values at installation should be minimized as far
as possible.
g. Any required corrections on the horizontal plane will be carried out through the horizontal
adjusting screws for the driver provided on the skid. Any required corrections in the vertical
plane will be obtained by using the leveling screws and the shims placed under the driver in
coincidence with the anchoring bolts at the four corners (any other bolts shall be loosened
and, if necessary, the relevant shims shall be removed).
For tightening correctly the driver anchor bolts, proceed as follows:
a. Tighten three of the four bolts and then measure with a feeler gauge the thickness of the shim
required under the fourth bolt.
b. Insert shims as measured above and then tighten the fourth bolt.
c. Place a dial gauge between skid and motor frame, as close as possible to the fourth bolt, and
then loosen it. Any settling will be revealed by a rising of the frame. In this case, add more
shims, according to the indications given by the dial gauge; then the bolt shall be tightened
again.
d. With the dial gauge, carry out the same measurement as above on the three other bolts
(loosening them, one at a time). The positioning of the machines will be acceptable when the
indication given by the dial gauge for any bolt is less than 0.1 mm.
e. Shim the intermediate bolts, verifying with the dial gauge the correctness of the shims
inserted.
After having completed the above mentioned procedure, proceed to mating the two half-couplings.
In carrying out this procedure, respect any markings for holes and connecting tie rods. After having
poured the grouting of the skid (see Paragraph 2.2.2 ) and tightened the foundation bolts, repeat
the deflection check on the first crank webs (this check is not required in case of crankshaft with
only two journals).
3.2.2.2 Definitions
The alignment of two shafts is carried out by correcting the radial and angular deviation, so as to
bring the axises of these shafts to the required position, within the specified tolerance limits.
- Radial alignment:
this consists of limiting the relative displacement d of the axises of the two shafts presumed to be
parallel (see Figure 9 ). Noting that the alignment is carried out operating on the driver side, consider
the vertical line VV as passing through the centre P of the drives shaft end and the horizontal line 00
as also passing through P (see Figure 11 ). The radial displacement d is generally taken by measuring
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its vertical component dv along the vertical axis and its horizontal component do along the horizontal
axis.
Angular alignment:
- this consists of limiting the angular divergence between the axises of the two shafts
presumed to be convergent (see Figure 10 ). If we consider two planes, one vertical (containing
the axis of the compressor shaft and the VV line) and the other horizontal (containing the axis
of the compressor shaft and the 00 line), the angular misalignment is generally taken by
measuring the vertical component v on the vertical plane and the horizontal component
o on the horizontal plane (see Figure 12 ).
3.2.2.3 Taking alignment data
Alignment data may be taken in two ways:

a. By rotating one of the shafts, and letting the dial gauges (see further) slide on the end face of
the other, which is not rotated.
b. By rotating both shafts at the same time.
It is preferable, when possible, to rotate the two shafts at the same time, since in this case the
alignment will be made on two axises created by the rotation of the components to be aligned, and
the resulting alignment will be less dependent on the degree of machining and on the shape of the
shaft ends.
If the flywheel has been assembled on the compressor shaft, it will tend to oscillate due to the
different flexural stiffness of the shaft in different positions in the turn. In this case, the alignment
reading will be made by rotating the driver shaft, with the compressor shaft steady.
Using either one or the other system, take the data during a complete 360° turn, recording the
readings every 90° and indicating the direction of rotation given.
The dial gauges should work with the index of the millimetres loaded at approx. 50%, while the index
of the hundredths should be set to zero (see Figure 13 , a).
When recording the data, the positive sign (+) will be given when the feeler pin of the dial gauge
enters its seat, i.e. when the pointers tend to go toward 100% full scale (the dial gauge is said to be
"loading"; see Figure 13 , b). The negative sign (-) will be given when the feeler pin protrudes, that is
when the pointers tend to go to 0% full scale (the dial gauge is said to be "unloading"; see Figure 13 , c).
3.2.2.3.1 Taking radial alignment data
- Place the dial gauge R on the vertical plane, as shown in Figure 14 .

- Take the data during a complete 360° turn, indicating the distance L between the two shaft
ends (see Figure 15 ).
- The value of the radial misalignment V in the vertical plane will be given by a half of the reading
(x) taken on the dial gauge after a rotation of 180°.
V =x/2
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- The value of radial misalignment O in the horizontal plane will be given by the half-difference
in the readings taken on the dial gauge after a rotation 90° (y) and a rotation of 270° (z).
O = (y - z) / 2
NOTE
The algebraic sum of the values taken on the horizontal plane (90°C and 270°C) will be equal,
except for minor errors, to the value taken on the vertical plane (180°C), i.e.:
x=y+z
3.2.2.3.2 Taking angular alignment data
- Place the dial gauges A1 and A2 displaced by 180° on the vertical axis; record the distance
between them (D) and between the two shaft ends (L), as shown in Figure 16 ).
The need to use two dial gauges is due to the fact that, during the rotation, axial displacement
of the two shafts may occur. The use of two dial gauges compensates for the effects of any
mutual axial displacement.
- Take the values during one complete 360° turn (see Figure 17 ).
- The value of angular misalignment V in the vertical plane will be given by the algebraic half-
difference in the readings (considered with their signs) made on dial gauges A1 and A2 after
a 180° rotation, i.e.:
V = (b - f) / 2
If the result has a negative sign, the shaft ends open at the bottom; if it has a positive sign,
they open at the top.
- The value of angular misalignment O in the horizontal plane will be given by the algebraic half-
difference in the readings (considered with their signs) made on dial gauges A1 and A2 after
a rotation of 90° and of 270°, i.e.:
O = (c - d) - (e - g) / 2
If the result has a negative sign, the shaft ends open at the left; if the result has a positive sign,
they open at the right.
3.2.2.3.3 Permissible misalignment
3.2.2.3.3.1 Radial misalignment

V = ± 0.05 mm
O = ± 0.05 mm
3.2.2.3.3.2 Angular misalignment

Axial measurements:
V = ± 0.00175 mm for each 10 mm of distance between the dial gauges
O = ± 0.00175 mm for each 10 mm of distance between the dial gauges.
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3.2.3 Checks on assembled unit
3.2.3.1 Taking alignment data
After having aligned and coupled the machines, connect an appropriate fixture to the driver shaft
end (see Figure 18 ) bearing a dial gauge with radial direction and a dial gauge with axial direction.
While rotating the shafts simultaneously, take and record (see following item) the excursions of the
two instruments during one complete turn.
When it is required to check the alignment during operation of the unit, this procedure will be
repeated and the new readings will be compared with those recorded. Thus it will not be necessary
to disconnect the machines.
NOTE
In addition to the excursions of the instruments, it is necessary to record: the position in which
the fixture is assembled on the shaft, the angular position of the shafts relevant to the first
reading, the direction of rotation of the shafts. If, when checks are carried out, these parameters
are not repeated, the instrument readings will be meaningless.
It should also be kept in mind that any modification or substitution of the fixture could determine
a variation in the measurements, regardless of the machines alignment.
3.2.3.2 Recording data
For recording alignment data, the tables included in this manual will be useful.
Table 1 regards the following alignment measurements made with the coupling not yet assembled.
- Deflection in the webs.
- Axial and radial misalignment between the shafts after they have been aligned, with the
compressor shaft in the position of mid-deflection of the webs of the 1st crank.
- Axial clearance between the two half couplings.
- Axial clearances of the shafts.
- Table 2 refers to the following alignment measurements taken after the coupling has been
assembled:
- Deflection in the 1st crank webs coupling side.
- Axial and radial misalignment between the shafts.
- Axial clearances of the shafts.
1. Deflection in webs
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2. Radial and axial misalignment between the shafts after completion of alignment, with compressor shaft in position of mid-
deflection of 1st crank webs coupling side.
3. Axial clearance between the two half couplings.
4. Axial clearances of the shafts
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Table 1 - MEASUREMENTS WITH COUPLING NOT ASSEMBLED
1. Deflection of 1st crank webs coupling side
2. Axial and radial misalignment between shafts
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3. Axial clearances of shafts
Table 2 - MEASUREMENTS WITH COUPLING ASSEMBLED
Figure 7
LEGEND
A SKID
B FOUNDATION BOLT
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C FOUNDATION
D PLATE
E LEVELING SCREW
F POLYETHYLENE LINING
G JACK SCREW
Figure 8
LEGEND
A COMPRESSOR SHAFT
B FLYWHEEL
C DRIVER
D COUPLING
E INTERNAL MICROMETER GAUGE
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Figure 9
LEGEND
A GEAR REDUCER SHAFT

B COMPRESSOR SHAFT
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Figure 10
LEGEND

B COMPRESSOR SHAFT
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Figure 11
LEGEND

B COMPRESSOR SHAFT
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Figure 12
LEGEND

B COMPRESSOR SHAFT
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Figure 13
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Figure 14
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Figure 15
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Figure 16
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Figure 17
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Figure 18
LEGEND
A COMPRESSOR SHAFT
B GEAR REDUCER SHAFT
C COUPLING
D FLYWHEEL
E, F DIAL GAUGE
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3.3 SKID ANCHORING

The term "grouting" indicates the skid anchoring to the same block (see part of Reference Drawings
Volume of this Manual).
This will be done after having anchored the foundation bolts and aligned the skid as explained in
the paragraph entitled "Skid positioning, alignment check".
To carry out grouting, proceed as follows:
- Assemble a wooden formwork around the skid as shown in typical Figure 19 . The dimensions
of the formwork should be such that, between its sides and the sides of the skid, there be a
distance of at least 100 mm. At least 180 mm shall be left on the side from which the grout is
to be poured. The formwork should be high enough to ensure correct execution of the grouting.
The formwork should be stiff, well anchored and sufficiently tight. It should not allow mortar
leakage; for this reason, it will be necessary to seal any gaps between the components of the
same formwork with silicone or other suitable material.
- Prepare the mortar. We recommend a mixture of the type described in the "Mixture for mortar"
paragraph.
- Fill the formwork with the mortar. The grout should be poured all at once.
- With the aid of iron bars, push the mortar into every area of the formwork, and check that
there are no air pockets. If enough room is left by the skid, the mortar can be stirred during
pouring, using appropriate systems. The casting surface shall be approx. 10 mm lower than
the upper face of the skid base.
- The mortar should be poured rapidly and continuously.
If possible, stop any other machines located in the vicinity; vibrations could impair the adhesion
of the grout.
- When the civil work engineer considers that the mortar has reached enough setting, loosen
symmetrically the leveling screws, if any, and remove them.
- When the setting time has elapsed, tighten the foundation bolts, checking with a dial gauge
to detect any settling of the skid. Tightening will be performed with a torque wrench, to half
of the torque value specified either in the FOOTPRINT diagram (see part of Reference Drawings
Volume of this Manual) or in the Table of tightening torque values (see Maintenance Section)
according to the diameter of the foundation bolts.
The nuts will be tightened following the numerical order (1-2-3, etc.) shown in the typical
Figure 20 . At a later time, the procedure will be repeated applying the entire torque value
required.
- After having completed tightening as above, check again with a mechanical level the levelling
of the compressor and of the crosshead extensions.
- Check the alignment between the two machines and correct, as required, acting on the shims
inserted below the driver frame.
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- After having completed the alignment, proceed to final connection of the coupling.
- Lastly, cover the exposed outer edges of the grouting with a layer of ordinary plastic mortar
composed of one part of cement and two parts of sand, which will prevent them from
crumbling. After this covering has dried and hardened, the edges will be painted with oil-
resistant paint.
WARNING
THE ALIGNMENT OF THE MACHINES MUST BE CHECKED AFTER EACH INSTALLATION OF THE
GROUP ON FOUNDATION OR AFTER ANY REPOSITIONING OF THE MACHINES ON THE SKID.
Figure 19 - Wooden Formwork Assembly
LEGEND
A SKID
B FORMWORK
C GROUTING
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Figure 20 - Nuts Tightening Sequence
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MIXTURES FOR MORTAR

General information
Safe and stiff adhesion of the machine to the foundation block derives essentially from a suitable
mortar mixture.
It is also essential that, prior to positioning the unit, the foundation block is chipped, cleaned, and
dampened to create a good adhesion surface for the mortar (see paragraph entitled Preliminary
Procedures Preceding Grouting of Equipment).
It will be necessary to use a mortar that is fluid, flowing, non-shrinking, possessing a high initial and
final mechanical strength, of the oil-resistant type.
It should be possible to subject the mortar, without any problems arising, to waiting times that may
be quite long (of the order of 60 minutes) between preparation and pouring.
When pouring the grouting, make sure that the mortar layer under the unit is even.
If the unit is skid-mounted, utilise any openings on the skid to pour the mortar into spaces not
accessible from the outside.
The mortar for the grouting may be composed of:
- Cement-based mixtures.
- Resin-based mixtures.
Cement-based mixtures
If available on the jobsite, we recommend the use of expansive cement.
These are mixed in powders, ready for use, to be mixed with water and composed of cement,
aggregate, fluidizing additives, antioxidants, anti shrinkage additives.
WARNING
WE DO NOT RECOMMEND THE USE OF MIXTURES CONTAINING PARTICLES OF METALLIC IRON AS

SHRINKAGE BALANCING COMPONENTS. THESE PARTICLES COULD CAUSE FAST DETERIORATION
OF THE ANCHORAGE.
To obtain a mortar of average consistency, the following proportions are generally observed:
- 50 Kg of non-shrinking cement;
- 7 to 8 litres of water.
The amount of water specified above is merely indicative, since the correct proportion depends on
various factors, such as ambient conditions, dimensions of the foundation block, etc. It is however
advisable to contact the supplier of the cement, especially when working in very cold or very hot
environmental conditions. The supplier can recommend special techniques such as, for example,
heating or cooling the mixture and/or the water, etc.
With the above quantities, a volume of approximately 20 litres of mortar is obtained. In preparing
the mortar, organise the work so that pouring occurs without interruptions.
After having diluted the mortar to obtain the required fluidity, mix thoroughly.
Mixing should be done as close as possible to the place where the mortar is to be used.
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After having started the cement mixer, pour into it all the water that will be used and slowly add the
mixture.
Avoid, if possible, diluting the mortar already prepared with additional water.
Resin-based mixtures
These are generally used where especially high mechanical properties are essential. These types of
mortar may be appropriately used, for example, for skid-mounted equipment, to anchor the
compressor to the skid.
These mortars are obtained mixing several elements on site. The most important of these are:
- resin (liquid);
- hardener (liquid);
- siliceous aggregates of controlled granulometry.
The components proportion varies according to the product and to the application made with these
mixtures.
In any case, however, it is recommended to require assistance from the resin supplier.
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3.4 CONNECTING CYLINDERS TO FRAME, RUN-OUT
3.4.1 Installation
For vertical cylinders arrived at the jobsite already connected to the frame, no procedure in this
respect will be carried out. If instead the cylinders arrive at the jobsite still not connected, their final
positioning will be carried out upon completion of anchorage of the skid, i.e. after the skid has been
perfectly levelled and the foundation bolts fully tightened.
The following procedure is recommended.
WARNING
FOR THE CORRECT ARRANGEMENT OF THE CYLINDER ON THE FRAME, REFER TO THE GENERAL
ARRANGEMENT DRAWING OF THE COMPRESSOR INCLUDED IN THE REFERENCE DRAWINGS
VOLUME OF THIS MANUAL. IN CASE THAT MORE CYLINDERS ARE DUE TO THE SAME STAGE, REFER
TO THE WORKSHOP ASSEMBLING CARD FOUND IN THE QUALITY DATA BOOK OF THIS
COMPRESSOR.
If the cylinders reach the jobsite already connected, no special procedure need to be carried out for
vertical cylinders. For horizontal cylinders, start from step d of Paragraph 4.1.2 and after having
completed step e , loosen the nuts of the stud bolts fastening the cylinder to the frame. Then proceed
to steps f and following.
When the cylinders are to be connected to frame at the jobsite, after the procedure has been
completed, the piston must be connected to the crosshead. Refer to the CROSSHEAD paragraph in
the Section FRAME AND CRANK GEAR and the PISTONS PISTON RODS paragraph in the Section
CYLINDERS ASSEMBLIES.
3.4.1.1 Vertical cylinders to be connected onsite
a. Thoroughly inspect the mating faces between frame and cylinder, removing any traces of dirt
or machining residue (rust, burrs, etc.).
b. Grease the surfaces specified in item a . Prepare and apply a gasket, obtained from a sheet
of thin paper, on one of the surfaces.
c. Sling the cylinder. This procedure must be carried out very accurately in order to obtain correct
positioning of the cylinder in relation to the frame.
d. If the cylinder is complete with the piston assembly, bring the crosshead to the inner dead
centre.
e. After having correctly positioned the cylinder in relation to the reference points (punching,
dowels, etc.), insert the base of the cylinder into the spigot on the crosshead extension (or
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distance piece) making sure to carry out, with the lifting means, small steps to allow the stud
bolts and the dowel pins (if any) to smoothly enter their respective holes.
f. Place the cylinder gently on its seat and proceed to crossover tightening of the bolts. Tighten
to the torque value specified in the CYLINDER ASSEMBLING DATA Table. (See PART LISTS
Volume of this Manual).
3.4.1.2 Horizontal cylinders to be connected onsite
If a completely assembled cylinder is to be installed, it is advisable to carry out the procedure after
having disassembled the partition cover. This will avoid impacts between piston rod and partition
cover, which are possible if cylinder lifting and positioning is performed without the necessary
experience or using improper equipment.
a. Proceed as in steps Paragraph 4.1.1 , a , b , c , d , e .
b. Approach the cylinder until the mating faces between frame and cylinder are distant from
each other by a few tenths of a millimetre.
c. Screw but not tighten the nuts on the stud bolts joining the cylinder to the frame.
d. Place a screw jack under the cylinder, as close as possible to the point in which the support
is to be connected, keeping in mind that the jack must not interfere in subsequent support
assembly and anchoring procedures.
e. Put the jack under stress, paying attention not to displace move the cylinder from its position
(check that the distance between the mating faces does not change); release the cylinder
from the sling.
f. Using a feeler gauge, measure the distance between the faces to be mated. By operating
appropriately on the jack, bring the faces perfectly parallel with each other.
g. Install the cylinder support. With the through screws C, connect the foundation plate to the
support (see typical Figure 21 ), after having cleaned and degreased the surfaces that will be
in contact with the grouting.
h. Insert a shim D approx. 5 mm. thick between plate and support. Insert the foundation bolts;
screw the nuts till a couple of bolt threads protrude.
i. Assemble a formwork G around the support, prepare the mortar and make the casting,
following the procedures described previously in this Section.
j. When the setting time has elapsed, remove the jack and check the parallelism between the
mating faces (cylinder/frame). If corrections are required, add or reduce shimming D.
k. Gradually tighten the foundation bolts to the specified torque value (see MAINTENANCE
Section), checking the parallelism of the mating faces.
l. Gradually tighten the nuts (fastening the cylinder to the frame), crosswise two-by-two, to the
torque value specified in the CYLINDER ASSEMBLING DATA Table.
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After the cylinder has been connected to the frame, the piston assembly must be connected to the
crosshead. Refer to the CROSSHEAD paragraph in the Section FRAME AND CRANK GEAR and the
PISTONS - PISTON RODS paragraph in the Section CYLINDERS ASSEMBLIES.
3.4.1.3 Horizontal cylinders already connected in the shop
In this case, irrespective of the configuration of the cylinders already installed, deformation and
misalignment are not to be excluded. For this reason, the coplanarity check between the mating
surfaces of cylinder and frame must be repeated. Proceed as follows:
- Loosen or even remove any accessory (e.g. piping) that could hinder the free movement of the
cylinder.
- Loosen the bolts that lock the cylinder to the frame.
- With a feeler gauge, make sure that the two mating surfaces are parallel.
- In case of defect, loosen the bolts that fasten the support A to the skid (see Figure 22 ), support
the cylinder with suitable equipment (e.g. screw jack) in the right position, then correct the
shim B between support and skid.
- After the jack has been removed, tighten again the bolts that fasten the support onto the skid,
and measure again the gap between cylinder and frame faces.
- When the parallelism between cylinder and frame faces is correct, the connecting bolts will
be definitively tightened, operating gradually and crosswise, to the torque value specified in
the CYLINDER ASSEMBLING DATA Table (see PART LISTS Volume of this Manual).
3.4.2 Run-out
The term "run-out" indicates the oscillation of the geometric axis of the piston rod on horizontal
cylinders, during one complete revolution of the crank.
It is advisable to proceed to measuring run-out and recording the measured values, immediately
after having completed the first assembly; a run-out value higher than the limit value (shown in the
ROD DROP AND RUN-OUT DATA Table of the PART LISTS Volume or in the CYLINDER ASSEMBLING
DATA Table) is an indication of defective alignment. Consequently, in this case, it will be necessary
to repeat the alignment procedure described above.
Furthermore:
- the comparison between the original readings and those measured after a certain period of
operation will provide an indirect indication of wear on piston rider rings and cylinder bore;
- the comparison between the original readings and those measured with no wear, or known
wear, on piston rider rings and cylinder bore, will provide an indirect indication of a permanent
cylinder alignment.
As regards methods for measuring the run-out, see the CYLINDERS ASSEMBLIES Section in the
paragraph PISTONS - PISTON-RODS.
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Figure 21
LEGEND
A FOUNDATION PLATE
B SUPPORT
C SCREW
D SHIM
E CYLINDER
F GROUTING
G FORMWORK
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Figure 22
LEGEND
A SUPPORT
B SHIM
C CYLINDER
D SKID
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3.5 AUXILIARIES SKIDS POSITIONING AND ANCHORING

Positioning and anchoring of any skid of auxiliaries will be carried out after the compressor has been
definitively anchored.
3.5.1 Positioning
- After having lifted the skid, clean the surfaces that will be in contact with the grouting.
- Insert the anchor bolts in their housings on the skid and screw the nuts, leaving approx. two
threads of the bolts protruding outside.
- Transfer the skid onto the foundations. Check its position in reference to the FOOTPRINT
diagram, (see REFERENCE DRAWINGS Volume of this Manual). Position a plate below each
leveling screw, if any.
- Position the skid and level it with a mechanical level, operating on the leveling screws or jack
screws. At the same time, assemble the prefabricated piping, if any, interconnecting the
auxiliaries of the skid to the other equipment installed elsewhere.
At this point, the anchorage grout can be poured.
3.5.2 Anchoring
Proceed as follows:
- Build a wooden formwork, prepare the mortar, pour the grout, following the procedures
described in the paragraph relevant to compressor anchoring.
- When the civil work engineer considers that the mortar has reached enough setting, loosen
the leveling screws symmetrically and remove them.
- After the setting time has elapsed, tighten the foundation bolts. Using a torque wrench, tighten
all bolts to half of the torque value specified either on the FOOTPRINT diagram or in the Table
of torque tightening values (see MAINTENANCE Section) on the basis of the diameter of the
bolts shown on the FOOTPRINT diagram. Repeat the above procedure, tightening to the entire
torque value required. After tightening, check that the interconnecting piping does not force
on the various equipment.
- After the mortar has set, cover the exposed outside edges of the grouting, with a layer of
ordinary plastic mortar (one part of cement, two parts of sand), which will prevent crumbling.
After this covering has dried and hardened, the edges should be painted with oil-resistant
paint.
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4 - OPERATION
1 GENERAL INFORMATION .............................................................................................................................79 1-79

1.1 Operating schematics ................................................................................................................................79 1-79
1.1.1 PROCESS GAS P&I Diagram ......................................................................................................................79 1-79
1.1.2 LUBE OIL P&I Diagrams ..............................................................................................................................79 1-79
1.1.3 COOLING SYSTEM P&I Diagram ..............................................................................................................80 1-80
1.1.4 CAPACITY CONTROL P&I Diagram .........................................................................................................80 1-80
1.1.5 Engine air, fuel and exhaust P&I Diagram ........................................................................................81 1-81
1.2 Procedures preliminary to setting at work .......................................................................................81 1-81
1.3 Safety precautions preliminary to putting into operation .........................................................81 1-81
1.4 Procedures .......................................................................................................................................................82 1-82
1.5 Auxiliaries .........................................................................................................................................................83 1-83
1.6 Operation defects ........................................................................................................................................83 1-83
2 ANNEX A - COOLING WATER ACCEPTABILITY LIMITS .....................................................................83 1-83
2.1 Introduction .....................................................................................................................................................83 1-83
2.2 Antifreeze ..........................................................................................................................................................83 1-83
2.3 Water Treatment ..........................................................................................................................................84 1-84
3 SAFETY PRECAUTIONS ..................................................................................................................................86 1-86
4 PREPARING COMPRESSOR FOR STARTUP ...........................................................................................90 1-90
4.1 General information ....................................................................................................................................90 1-90
4.2 Coolant preheating procedure ..............................................................................................................94 1-94
4.2.1 Closed loop with coolant to water heat exchanger .....................................................................94 1-94
4.2.2 Closed loop with partial main water circulation ............................................................................94 1-94
5 NO-LOAD RUNNING-IN ................................................................................................................................97 1-97
5.2 Complete running-in ...................................................................................................................................98 1-98
5.3 Running-in for piston rings plus rider rings and/or packing seals .......................................99 1-99
6 PIPING CLEANING, PICKLING, FLUSHING, BLOWING OUT, PURGING ......................................100 1-100
6.1 Process gas system .....................................................................................................................................100 1-100
6.2 Lube oil system ..............................................................................................................................................102 1-102
7 START UP AND LOAD-TAKING RUNNING-IN UNDER LOAD .........................................................105 1-105
7.2 Start-up and load-taking ..........................................................................................................................105 1-105
7.3 Running-in under load ................................................................................................................................107 1-107
8 CAPACITY CONTROL ......................................................................................................................................110 1-110
9 COMPRESSOR SUPERVISION .....................................................................................................................111 1-111
10 COMPRESSOR SHUT DOWN ......................................................................................................................114 1-114
10.1 Temporary shut down ................................................................................................................................114 1-114
10.2 Shut down for maintenance ....................................................................................................................114 1-114
10.3 Shut down for plant inactivity .................................................................................................................115 1-115
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4.1 GENERAL INFORMATION
4.1.1 Operating schematics

For the user’s convenience, a list of information is included here. This information, when applicable
to the unit subject of this Manual, may be found in the REFERENCE DRAWINGS volume. The
information is arranged by order of the diagram to which it belongs.
NOTE
In the above-mentioned part and in the part of the Manual relevant to CONTROL PANEL,
schematics are inserted giving description and position of the local and panel mounted controls,
of safety, protection and interlock functions and of the electric system.
4.1.1.1 PROCESS GAS P&I Diagram
- Design and operating pressure and temperature for coolers, pulse dampers, separators.
- Air cooler fan drivers characteristics.
- Approximate flow rate of condensate to be discharged from separators.
- Flow rate of oil discharged from cylinders and drained from stuffing boxes.
- Flow rate and pressure of pressurising gas for distance pieces and/or frame.
- Flow rate of buffer gas for distance pieces.
- Minimum gas pressure for plant flushing.
- Setting of various instruments.
4.1.1.2 LUBE OIL P&I Diagrams
4.1.1.2.1 Compressor frame, speed reducer, driver lubrication
- Main filters characteristics.

- Coolers design and operating pressure and temperature.
- Main pumps characteristics.
- Oil recommended viscosity and grade.
- Oil operational pressure and temperature ranges.
- Oil volume required for oil sump filling.
- Main heaters characteristics.
4.1.1.2.2 Cylinders and packing lubrication
- Oil recommended viscosity and grade.
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- Oil volume required for lubricator filling.

- Oil refilling rate.
- Main oil heater characteristics.
4.1.1.3 COOLING SYSTEM P&I Diagram
NOTE
Unless expressly specified in the COOLING SYSTEM P&I DIAGRAM or in another part of the Manual,
the minimum specifications of the water recommended for satisfactory operation of the unit are
those given in Annex A of this paragraph.
4.1.1.3.1 Open circuit cooling system
- Coolant total flow rate.

- Coolant inlet pressure.
- Coolant inlet temperature and maximum discharge temperature.
- Coolant maximum pressure drop through stuffing boxes.
4.1.1.3.2 Closed loop cooling system
- Design and operating pressure and temperature of coolers not included in Paragraph 1.1.1
and Paragraph 1.1.2 .
- Coolant used in closed loop.
- Coolant total flow rate.
- Coolant temperature and pressure at equipment inlet.
- Coolant volume.
- Coolant pump driver main characteristics.
- Information on fluid that cools down the coolant.
4.1.1.4 CAPACITY CONTROL P&I Diagram
- Type and pressure range of control gas driving actuators.

- Control sequence.
- Compressor load status in absence of control gas and/or power supply.
- Possible limits or precautions during capacity control.
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NOTE
The solenoid valve power supply characteristics are given in the FIELD INSTRUMENTS LIST AND
SETTING VALUES sheets (see REFERENCE DRAWINGS volume of this Manual).
4.1.1.5 Engine air, fuel and exhaust P&I Diagram
- Gas driving starting motor pressure.

- Speed controller feeding air pressure.
- Gas fuel feed pressure.
4.1.2 Procedures preliminary to setting at work

Before the compressor is put in service, it must be subjected to the following procedures:
- No-load running-in
- Piping blowing (if required)
- Purging (if required)
- Running-in under load.
NOTE
Other special procedures, if any, are given in the GENERAL INFORMATION Section. NUOVO
PIGNONE personnel, however, can undertake procedures not included in this Manual when
required by particular circumstances.
Unless other specific contractual requirements have been stipulated, the compressor has already
undergone no-load running-in: blowing, purging, running-in under load will be carried out at the
jobsite, after complete and final machine anchoring.
The way to follow these procedures is explained in the relevant paragraphs of this Section. No-load
running-in must be performed when this procedure has not been carried out before and also when
main worn parts have been replaced.
4.1.3 Safety precautions preliminary to putting into operation
WARNING
- IF THE MACHINE HAS BEEN SHIPPED AFTER HAVING UNDERGONE THE NUOVO PIGNONE
STANDARD PROTECTIVE TREATMENT, IT IS NOT NECESSARY TO REMOVE THE APPLIED
PROTECTIVE OILS PRIOR TO START-UP. THESE OILS ARE COMPATIBLE WITH THE
LUBRICANTS USED IN OPERATION.
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- IF SPECIAL PROTECTIVE AGENTS INCOMPATIBLE WITH OPERATION HAVE BEEN REQUIRED,

THE INSTRUCTIONS FOR REMOVING THEM WILL BE FOUND IN THE GENERAL INFORMATION
SECTION.
- FOR THE PURPOSE OF PROTECTION, SPECIAL CORROSION-INHIBITING PRODUCTS (E.G. VCI,
VPI, ETC.) MAY HAVE BEEN USED. THESE PRODUCTS MUST BE REMOVED PRIOR TO STARTING
OPERATION. SUCH SUBSTANCES GENERATE TOXIC AND FLAMMABLE VAPOURS; DURING
REMOVAL, SPECIAL CAUTION IS REQUIRED. SINCE THESE PRODUCTS ARE POLLUTING, THEY
MUST BE REMOVED ACCORDING TO LOCAL AND PLANT REGULATIONS.
- FOR OXYGEN COMPRESSORS, THE INTERIOR OF EVERY COMPONENT MUST BE INSPECTED
FOR REMOVAL OF ANY DEHYDRATING PRODUCTS PRESENT.
- DO NOT SET MACHINE INTO OPERATION UNTIL ENSURING THAT ASSEMBLY, TIGHTENING,
AND ALIGNMENTS HAVE BEEN PERFECTLY PERFORMED ON COMPRESSOR, DRIVER AND
AUXILIARIES.
- ANY UNCORRECTLY FASTENED CONNECTION (E.G. CYLINDER HEAD TO CYLINDER, PISTON
ROD TO PISTON, PISTON ROD TO CROSSHEAD, CONNECTING ROD CAPS) MAY INVOLVE
FAILURE OF MAIN MECHANICAL COMPONENTS DURING OPERATION. SERIOUS DAMAGE
MAY OCCUR TO THE MACHINE STRUCTURE, INCLUDING FLYING PARTS AND/OR ESCAPE
OF COMPRESSED GAS.
- IF FOR ANY REASON THE PRESENCE OF DIRT INSIDE THE MACHINE IS SUSPECTED, PROCEED
TO APPROPRIATE CLEANING.
- ALSO THE PRESENCE OF LIQUIDS MAY BE EXTREMELY HARMFUL. CONSEQUENTLY, IF THE
COMPRESSOR HANDLES WET GAS (CONDENSABLE COMPONENTS), DO NOT START BEFORE
DRAINING, USING THE VALVES INSTALLED ON THE MACHINE AND ON THE SYSTEM.
- THIS SHOULD BE DONE IN PARTICULAR AT THE START OF THE OPERATION OR AFTER A
LONG PERIOD OF INACTIVITY. FOR THE SAME REASON, ROTATE THE MACHINE FOR A FEW
TURNS WITH THE BARRING GEAR TO DISCHARGE ANY LIQUID THAT MIGHT HAVE ENTERED
THE CYLINDERS.
- PRIOR TO ANY START UP, THE INSTRUCTIONS GIVEN IN THE PARAGRAPH PREPARING
COMPRESSOR FOR STARTUP MUST BE FOLLOWED.
- THE NEXT PARAGRAPH, SAFETY PRECAUTIONS, LISTS A SERIES OF GENERAL
REQUIREMENTS. PERSONNEL INVOLVED WITH MACHINE OPERATION ARE REQUESTED TO
STRICTLY OBSERVE THESE REQUIREMENTS, AS WELL AS THE SPECIFIC ONES GIVEN IN
OTHER PARAGRAPHS OF THIS SECTION.
4.1.4 Procedures
The procedures described in the next paragraphs of this Section are general and do not consider
any particular features of the machine such as, for example, sequences implemented from a special
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Control Panel. If the Control Panel is supplied by NUOVO PIGNONE, refer to the FUNCTIONAL LOGIC
DIAGRAM included in the part of the Manual relevant to the CONTROL PANEL.
4.1.5 Auxiliaries
Regarding the compressor auxiliaries, see the relevant part of this Manual.
4.1.6 Operation defects

If any defect should appear during compressor operation, check with the TROUBLESHOOTING GUIDE
prior to undertaking any other action.
WARNING
- IF THE COMPRESSOR MUST CONTRACTUALLY RUN IN MORE THAN ONE SERVICE HAVING
DIFFERENT OPERATING CONDITIONS AND/OR DIFFERENT GAS COMPOSITION, IT MAY BE
NECESSARY TO EQUIP THE CYLINDERS WITH A DEDICATED SET OF SUCTION/DISCHARGE
VALVES.
- THE USE OF WRONG SET OF VALVES MAY CAUSE SERIOUS COMPRESSOR DAMAGE AND BE
THE CAUSE OF OPERATING PARAMETERS OUT OF ALLOWABLE LIMITS.
- FOR THE PROPER SET OF CYLINDER VALVES IN RESPECT TO THE SERVICE, REFER TO
"REFERENCE DRAWINGS" VOLUME. REFER ALSO TO THE “CAPACITY CONTROL P&ID” WHERE
NOTES RELEVANT TO VALVE SET UP MAY BE ALSO INDICATED.
4.2 ANNEX A - COOLING WATER ACCEPTABILITY LIMITS
4.2.1 Introduction
The minimum cooling water specifications recommended for satisfactory operation of the unit are
those given in Table 3 .
NOTE
For water with antifreeze, refer to the water properties BEFORE the addition of the anti-freeze
itself.
In case of refilling of a closed cooling system, the refilling water should comply with the defined
limits.
4.2.2 Antifreeze
The use of a commercial antifreeze product having appropriate corrosion inhibitors is STRONGLY
RECOMMENDED. The use of corrosion inhibited ethylene or propylene glycol is suggested.
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The antifreeze vendor will be consulted for specific recommendations about the replacement
intervals, the corrosion inhibitor additives, the dangers involved in adding antifreeze to another
existing coolant, the antifreeze concentration. As an indication, typical antifreeze concentrations are
shown in Table 4 .
For closed circuits, for the initial filling of the system, the water and concentrated antifreeze should
not be added separately, directly to the system. It is recommended to mix the water and antifreeze
in an external tank (such as a drum) at the correct ratio, before adding the resulting solution to the
system. A record of the total amount of solution introduced should be kept.
NOTE
- In case of medium refilling for closed cooling systems, this should have the required
antifreeze concentration. Refilling water and antifreeze should be mixed at the correct
ratio into an external tank, as suggested for the initial filling.
- The inhibitor in one type of coolant (antifreeze) may not be compatible with another type
of coolant and can generate gums, as well as destroy the effectiveness of the inhibitor
itself.
When changing coolants (such as changing from one type of antifreeze to another) the cooling
system should be drained and flushed thoroughly to protect against coolant contamination from
incompatible solutions.
4.2.3 Water Treatment

Periodical tests are required in order to verify the compatibility of the water with the specified limits,
and to evaluate the antifreeze ratio and the inhibitors/biocide ratios in the cooling system. Tests
must be carried out almost on a weekly basis for open cooling circuits and on a monthly basis for
closed cooling circuits. If parameters of the cooling water don’t respect the specified limits, an
adequate treatment is required (with corrosion inhibitors and/or biocides) in order to restore the
water characteristics to the acceptable range for the parameters.
ANY COOLING MEDIUM TREATMENT SHOULD BE PERFORMED BY SPECIALIZED PERSONNEL.
LANGELIER INDEX -0.4/+0.4

SULPHATES 50 ppm (mg/I) max
CHLORIDES 50 ppm (mg/I) max
TOTAL BACTERIA 10,000/ml max
Table 3 - MINIMUM SPECIFICATION FOR COOLING WATER FOR OPEN AND CLOSED
COOLING SYSTEMS WITH OR WITHOUT ANTIFREEZE (INHIBITED ETHYLENE OR
PROPYLENE GLYCOL)
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EXPECTED LOWEST AMBIENT TEMPERATURE Vol. % Glycol
°C °F Ethylene Propylene
0÷-5 32 ÷ 23 15 20
- 5 ÷ - 10 23 ÷ 14 25 25
- 10 ÷ - 15 14 ÷ 5 30 35
- 15 ÷ - 20 5÷-4 35 40
- 20 ÷ - 25 - 4 ÷ - 13 40 45
- 25 ÷ - 30 - 13 ÷ - 22 45 45
- 30 ÷ - 35 - 22 ÷ - 31 50 52
- 35 ÷ - 40 - 31 ÷ - 40 55 Not recommended
- 40 ÷ - 45 - 40 ÷ - 48 60 Not recommended
- 45 ÷ - 50 - 48 ÷ - 58 60 Not recommended
Table 4 - INDICATIVE ANTIFREEZE SOLUTIONS STRENGTH
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4.3 SAFETY PRECAUTIONS
WARNING
THE PERSONNEL IN CHARGE OF COMPRESSOR OPERATION MUST ALWAYS REMEMBER THAT

OPERATING AROUND A RECIPROCATING COMPRESSOR AND ITS AUXILIARIES INVOLVES CERTAIN
RISKS NOT TO BE IGNORED OR UNDERESTIMATED.
SOME SAFETY RULES HAVE BEEN GIVEN IN THE GENERAL INFORMATION SECTION RELEVANT TO
GENERAL SAFETY PRECAUTIONS. THE USER WILL OFTEN FIND SPECIFIC WARNINGS IN THE
VARIOUS SECTIONS OF THE MANUAL. IN THIS PARAGRAPH, GENERAL SAFETY RULES ARE GIVEN
RELEVANT TO OPERATION.
ALL THESE RULES SHOULD BE STRICTLY FOLLOWED; IGNORING OR NEGLECTING THEM CAN
CAUSE ACCIDENTS WITH INJURIES AND PROPERTY DAMAGE.
- Personnel assigned to operation of the unit must possess suitable capability and preparation.
Essential requirements are:
- Basic technical instruction orientation
- Specific training in:
- reciprocating compressor theory
- structure of reciprocating compressor
- operation of reciprocating compressor control, protection and safety devices
- hazards of operation
- accident prevention
- Thorough knowledge of the contents of this Manual.

- Suitable physical and psychological ability and aptitude for operating this type of machine.
- Ability to deal with emergencies.
The absence, even partial, of these essential capabilities should be sufficient reason for
excluding any person from this activity. Consequently, personnel should be subjected to
periodic examinations to verify their aptitude.
Nuovo Pignone offers its customers the opportunity to follow suitable instruction courses, held
by specialized technicians, either at the N.P. shop or at customer‘s premises.
- Before starting the compressor, check that any exposed moving parts are equipped with
adequate guards. Ensure that all personnel not involved in operation are not in the vicinity of
the machine that is about to start.
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protection for the body, the eyes, ears and breathing. In particular, they must wear work gloves,
helmet, work boots, goggles, overalls. When the compressor is running, anti-noise ear
protection is recommended; this is mandatory when and where the noise level exceeds the
limits allowed. In this regard, see the «NOISE DATA SHEET» included in the COMPRESSOR DATA
SHEETS (See part of REFERENCE DRAWINGS volume of this Manual). If the compressor handles
harmful or poisonous gases or hazardous gases of any kind, personnel must also be equipped
with breathing mask, the use of which is compulsory even while the machine is stopped. Similar
requirements are to be observed if these hazards come from installations in the vicinity of the
compressor.
Personnel must not approach moving parts while wearing loose clothing, personal ornaments,
or long hair. The local safety rules and those of the plant must also be complied with.
- While the machine is running, the following operations are permitted: control of oil rate to
cylinder and packing, control of pressure and temperature of lube oil to the frame (see the
relevant paragraph in the LUBRICATION Section, coolants pressure and temperature control
(see paragraph PREPARING COMPRESSOR FOR STARTUP in this Section), and other control
operations described in the operating schematics (see part of REFERENCE DRAWINGS of this
Manual).
- No maintenance procedure can be carried out on the compressor while running. If the
compressor is equipped with dual auxiliaries (e.g. pumps, coolers, filters), maintenance of these
during machine running is permitted, after having isolated the component on which
maintenance is to be performed and switched over to the standby component.
- The walls of cylinders and accessories strictly linked to them usually have high temperature
and are dangerous to touch. With the compressor running, avoid contact with these surfaces
unless equipped with adequate protection. Even while the compressor is stopped, avoid
contact with these surfaces, unless equipped with adequate protection, until 1.5 to 0.5 hours
after shutdown.
- The machine should not operate outside of the limit environmental conditions specified in the
compressor DATA SHEETS (see above-mentioned part).
- Since the machine has been designed to satisfy precise and clearly specified requirements of
the User; it must never be used in operating conditions other than the design conditions
specified in the above-mentioned DATA SHEETS. Otherwise the machine would be subjected
to stresses for which it is not designed and consequently to the risk of accidents with injuries
and damage to property. If any change must be made in operating conditions in respect to
the design conditions, contact NUOVO PIGNONE - Florence Headquarters (SEMA Department).
Unacceptable operating conditions include those arising from:
- failures (e.g. valve malfunction, frame oil pressure drop, abnormal pressure, temperature
and flow rate variations of various fluids, abnormal level variations of lube oil, condensate,
etc., abnormal variations of power requirement, consumption, rotation speed, etc.).
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- negligence (e.g. failure to refill oil,

- failure to change frame oil, failure to clean coolers).
- external troubles (e.g. voltage drop).
- instinctive reactions of personnel
- personnel acting along the «line of least fatigue».
- Like the compressor, all materials and equipment must be operated complying with the
prescriptions of their respective suppliers.
- In the presence of flammable gas (or gas which forms explosive mixtures), it is absolutely
forbidden to use flames, welding machines, electrical machines and tools, miscellaneous tools
(even manual) which could cause sparks during use.
- Maximum care must be taken to ensure that the gas does not entrain into the machine
corrosive, fouling or polluting compounds, oxidants, dusts or fluids in general, which have not
been clearly evidenced to Nuovo Pignone during final design of the system. The presence of
these entrained elements can be not only critical to the correct operation of the compressor
but also extremely hazardous.
- Special attention should be dedicated to identifying any hazardous malfunction in process,
such as the leakage of non-inert gas (especially gases that are explosive, poisonous, etc.),
overpressure and excessively high temperatures consequent to failure of the safety devices,
insufficient flow of cooling medium, etc.
- In case of general hazardous situations, fire, emission of hazardous substances (such as
leakage of gas of type H2, HS, CI2, C2H4, etc.), perform emergency shutdown and follow the
regulations in force (local, those of the plant, etc.).
- High temperature and particular components of the handled gas may result in the formation
of carbon deposits in particular points of the machine or of the plant. In this case, perform
periodic inspections and cleaning.
- Gas leakage may occur at various points in the compressor (valve covers, cylinder heads,
packing, plant valves, piping, etc.). Do not stand in areas where such leakage could occur
except for the time strictly necessary. In any case, if the compressor is treating poisonous gas
or gas which is dangerous to breathe, use adequate breathing mask. This hazard is even more
likely to be present at vents outlets and in drain points (separators, dampers, condensate
collection barrels and those for oil recovery from stuffing box, etc.).
- If smoke is observed during operation, stop the machine immediately and search for the cause.
This is almost always caused by excessively high temperature due to friction between moving
parts or seizure.
- When excessively high temperature is found on one or more parts of the machine, stop
immediately and wait at least 15 minutes before opening the inspection doors. Opening them
immediately could cause explosion.
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- When continuous bubbles of gas can be seen through the flow indicators in the cooling
system's outlet lines, stop the machine immediately, locate the origin of
- the leakage and repair. Gas in the cooling system's fluid, besides impairing the efficiency of
the system itself, can be highly dangerous in case of non-inert gases. If such gas bubbles are
observed in the cooling system, investigate whether the gas has been propagated into the
environment (e.g. through the sewage system).
- Pay attention to the destination of vents and drains. Gases which are poisonous, explosive or
in any case hazardous can accumulate in areas even far from the compressor, involving risks
to persons and objects.
- It should always be kept in mind that, at least in most cases, polluting residue is present, and
thus it must be dealt in compliance with local regulations. The same may be said for water/
glycol mixtures and other cooling media.
- It should also be kept in mind that the fluids discharged from drains may be caustic in case
of contact with the skin.
- If the condensate is drained and removed by pumps, ensure that it does not entrain gas that
could cause cavitation.
- All safety devices should be periodically checked, tested and calibrated.
- When a safety valve opens, the machine must be stopped immediately and the cause of the
opening must be investigated.
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4.4 PREPARING COMPRESSOR FOR STARTUP
4.4.1 General information

Prior to starting the unit, all compressor components including electrical parts and control panels
must be assembled and set for operation. For the foregoing, refer to the documents included in
REFERENCE DRAWINGS Volume of the Manual and in the parts regarding the control panels.
Prior to each compressor startup, prepare the machine as follows:
- Check that all supplies (e.g. electric power) are correct, making reference to the SCHEMATICS
and to the data plates on various equipment. Ensure also that all protective devices (before
carrying out the various connections) are working.
- Ensure that the control and safety devices for the various circuits are perfectly set and
operating. The technical personnel in charge of these operations must make reference to the
setting values given on the SCHEMATICS and on the FIELD INSTRUMENT LIST AND SETTING
VALUES (see above-mentioned Volume), as well as to the technical documentation included
in the AUXILIARIES Volume of the Manual.
- Prior to calibrating any level instruments of the differential pressure type with «WET LEG»
assembly, fill their balancing pipe with fluid of the same type as that accumulated in operation
(water, oil, fuel oil or other). This will prevent the fluid (condensing in the balancing pipe, empty
at the time of calibration) from altering, with time, the calibration itself.
- Proceed to simulated check of the control panels and of the connections between these and
the local instrumentation. Make reference to the pages inserted in the Volume of the Manual
relevant to these auxiliaries.
- In the presence of «tracing» for heating gas piping and vessels, always turn on the system.
While the machine is running, the system must be kept in operation.
If the lube oil piping is traced, turn on the system if the ambient conditions make this necessary:
after starting, evaluate the possibility of turning off the system.
In any case, prior to starting, wait long enough for temperatures to equalize.
- Set the cooling system for operation. The system should be filled with the coolant specified on
the COOLING SYSTEM P&I DIAGRAM (see REFERENCE DRAWINGS volume).
WARNING
WHEN FILLING OR TOPPING UP, AVOID DIRECT CONTACT WITH FLUIDS SUCH AS
GLYCOL, ISOBUTYL ALCOHOL OR SIMILAR. IF THESE FLUIDS ARE TO BE REPLACED,
THEIR REMOVAL MUST BE CARRIED OUT IN COMPLIANCE WITH LOCAL
REGULATIONS.
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When water is used for cooling, its properties should comply with the requirements stated in
the GENERAL paragraph of this Section.
For correct filling, let the fluid enter from the lowest drain connection keeping all of vents open.
Fill very slowly, ensuring that air is fully vented. Close the vents definitively only when liquid
alone flows out of them. During filling, all the check valves must be open.
If there is a surge tank closed with a pressure cap, the cap shall be removed to allow free
venting, and put on again only when the tank has been filled up to the normal level.
If the cooling system is a closed loop and an electric heater is provided, follow the instructions
given in the PROCEDURE FOR PREHEATING COOLANT section of this paragraph.
WARNING
REGARDLESS OF THE TYPE OF COOLING SYSTEM, IN ORDER TO AVOID THE

POSSIBILITY OF CONDENSATE FORMATION IN THE CYLINDERS WITH SEVERE
DAMAGING OVERSTRESSES TO THE VARIOUS PARTS OF THE MACHINE (VALVES,
CRANK GEAR, BEARINGS, ETC.), THE COOLANT TEMPERATURE AT CYLINDERS INLET
SHOULD BE AT LEAST 5°C HIGHER THAN THE PROCESS GAS INLET TEMPERATURE.
THIS CONDITIONS MUST BE MAINTENED DURING PREPARATION FOR START-UP AS
WELL AS DURING OPERATION.
In addition, if the fluid is circulated by a pump, proceed to setting up the system according to
the instructions given in the P&I diagram.
- Check that the level in the tank is correct, and top up if required.
- Actuate the cooling system for the coolant in closed circuit and ensure that all components
are correctly operating.
- Check that the throttling valves upstream and/or downstream of the stuffing boxes are
completely open.
- Ensure that the separators of the "VERTICAL WITH VANE PACK" type, if provided, are correctly
prepared for operation. That is, check that the lower end of the vane pack drain pipe is at least
100 mm below fluid level. The position of the end of this pipe in respect to the bottom of the
vessel is shown on the relevant drawing in the PART LISTS Volume of this Manual. The liquid
level can be checked through the indicator installed on the separator. If the level is low, water
must be added through the inspection door.
WARNING
WATER SHOULD BE ADDED ONLY WHEN THE VESSEL IS AT ATMOSPHERIC PRESSURE

AND DOES NOT CONTAIN PROCESS GAS.
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- If the compressor cylinders are lubricated, check the oil level in the lubricator. At first start-up,
thoroughly empty the tank and fill it with the oil specified in the CYLINDERS AND PACKINGS
LUBE OIL P&I DIAGRAM.
- If cylinders and packings are lubricated, at first startup and when emptying the cylinder, loosen
the pipe fittings on all lube oil inlets. Then start up the system and check that all pipes are filled
with oil, verifying that the oil comes out of the loosened fittings. Tighten the fittings again.
Prelubricate, letting ten to twenty drops of oil enter the cylinder and the packing. Do not exceed,
to avoid accumulation of oil in the cylinders.
- Check the frame oil level in the oil sump. A too low level can allow air to enter the system; a
too high level can determine defective lubrication, if the moving parts are immersed in the oil
causing foam.
WARNING
SINCE OIL IS A POLLUTING FLUID, DISPOSE OF THE USED OIL IN COMPLIANCE WITH
LOCAL REGULATIONS.
NOTE
As regards oil grade and quantity, consult the LUBE OIL P&I DIAGRAMS in
REFERENCE DRAWINGS Volume of the Manual and the LUBRICATION Section.
- If the lube oil system is to be filled or topped up, proceed as described in the LUBRICATION
Section, CRANK GEAR LUBRICATION paragraph. In any case, ensure that all relevant pumps
are primed.
- The compressor can be equipped with «RUN-DOWN TANK", to guarantee a sufficient
lubrication during shut-down deceleration in case of oil pump failure. Prior to each start, check
that the accumulator's nitrogen reservoir is pressurized. For inflating procedure, refer to the
manufacturer’s instructions (see AUXILIARIES Volume of this Manual). Note that the inflating
pressure should be approx. 0.1 bar. A higher inflating pressure could result in an insufficient
quantity of oil in the device.
- Verify that the frame lube oil's temperature is higher than the minimum value given in Table
5 . If the temperature is lower, proceed with heating.
WARNING
PRIOR TO ACTUATING THE HEATER, CHECK THAT THE OIL LEVEL IS CORRECT. A TOO
LOW LEVEL CAN SERIOUSLY DAMAGE THE HEATER. CARRY OUT THE SAME CHECK
ON ALL TANKS EQUIPPED WITH HEATER.
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- If the compressor is equipped with a pump with own driver, start it up. Check that the pressure
reaches the range of values specified in the COMPRESSOR FRAME LUBE OIL P&I DIAGRAM (if
necessary, proceed as shown in the above-mentioned Section and paragraph) and that it is
not subject to fluctuation. Check that the pump operates correctly. If the compressor is
equipped with a prelubrication hand pump, actuate this until reaching a pressure value within
the required range.
- If after the above procedure the oil level in the sump is found to be too low, top up.
WARNING
PRIOR TO STARTING THE COMPRESSOR, ENSURE THAT THE OIL IS NOT EMULSIFIED
AND DOES NOT CONTAIN AIR, AS THIS MAY IMPAIR LUBRICATION. IF NECESSARY,
REMOVE THE CAUSES OF THE CONTAMINATION. ANY AIR IN THE CIRCUIT WILL BE
BLED THROUGH THE VENTS PROVIDED IN THE SYSTEM.
- Rotate the compressor shaft by a few revolutions with the barring gear, or even by hand, (on
condition that the machine is completely depressurized), to check that there is nothing
abnormal in the movement. Disconnect the barring device, if used.
- Set all compressor instrumentation system for operation.
NOTE
It is preferable never to run with oil temperature below the minimum set on the
temperature switch. However, if impossible to meet this condition at start-up, for
operational reasons, the temperature switch can be appropriately set to prevent
tripping. As soon as normal temperature conditions have been reached,
immediately set the temperature switch again to the operation value.
- After a final oil pressure check, the compressor is ready for starting.
WARNING
AFTER STARTUP, CHECK THAT THE OIL PRESSURE AND THE TEMPERATURE AT THE
VARIOUS SYSTEM POINTS ARE WITHIN THE LIMITS SPECIFIED IN THE PERTINENT
SCHEMATICS. IF NECESSARY, OPERATE THE ALREADY MENTIONED DEVICES AS
REGARDS OIL PRESSURE, AND ON THE THROTTLING VALVES AROUND THE COOLER,
TO CORRECT THE TEMPERATURE. LEAVE THE VALVES UPSTREAM AND/OR
DOWNSTREAM OF THE PACKING COMPLETELY OPEN.
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4.4.2 Coolant preheating procedure

When the cylinders have been idle without coolant circulation (pumps stopped), if ambient
temperature is low, proceed as follows.
NOTE
If two or more compressors are served by the same console, the folowing procedure shall be
carried out on one only of the compressors. The coolant check valves for the other compressors
must be closed. When the sequence has been completed on the preheated compressor, start it
up and then open the check valves for another compressor. In this way, the heat from the running
compressor will contribute to preheat the second one, and so on.
4.4.2.1 Closed loop with coolant to water heat exchanger
For more compressors served by a single console, follow the instructions given in the note of the
preceding item.
Refer to Figure 23 .
a. Manually set the thermostatic valve A on the "WARM" position, thus interrupting its automatic
operation.
b. Start main water circulation in the heat exchanger.
c. Start the circulation pump B .
d. Let the water circulate until the temperature of the fluid in the loop is approximately the same
as that of the main water.
e. Restore the automatic operating conditions of valve A ("COLD" position).
f. Keep the heater C activated, until the temperature of the coolant is close to the process gas
inlet temperature.
g. Manually switch off the heater if an automatic device for this is not provided.
4.4.2.2 Closed loop with partial main water circulation
- Proceed as in step a of Paragraph 4.2.1
- Start main water circulation, opening
any cut-off valves on the cylinder.
- Let the water circulate, until the water temperature on the cylinder outlet is approximately
the same as that on the inlet.
- Proceed as in step e of Paragraph 4.2.1
- Start the circulation pump B.
- Proceed as in steps f , g of Paragraph 4.2.1
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Oil viscosity at 40 °C (cSt) Minimum temperature at startup (°C)
100 10
150 15
220 20
Table 5 - MINIMUM OIL TEMPERATURE AT STARTUP
Figure 23 -
LEGEND
A THERMOSTATIC VALVE
B PUMP
C HEATER
D CYLINDERS AND STUFFING BOXES
E OUTER WATER SYSTEM
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Figure 24 -
LEGEND
A THERMOSTATIC VALVE
B PUMP
C HEATER
D CYLINDERS AND STUFFING BOXES
E OUTER WATER SYSTEM
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4.5 NO-LOAD RUNNING-IN

This procedure is carried out to ensure initial bedding of the various components of the machine (in
particular the seals) and to check that they are operating correctly.
No-load running-in shall be carried out on a new or completely overhauled machine or on one where
the main bearings have been replaced, or, where the connecting rod bearings or bushes or
crosshead shoes have been partially replaced; or on a machine that has undergone replacement,
even partial, of seals (piston rings and packing rings) or piston rider rings.
No-load running-in is performed on completely assembled machine, with the exclusion of all
cylinder valves, and isolated from the plant. In case of particular conditions for carrying out this
procedure, specific instructions are included in the GENERAL INFORMATION Section.
After having prepared the machine (see PREPARING COMPRESSOR FOR STARTUP paragraph),
proceed as follows:
- Start up the compressor.
In case of defects, stop immediately to prevent any damages and search for the cause,
referring to the TROUBLESHOOTING Section.
WARNING
DURING THIS FIRST START-UP, CHECK THE DIRECTION OF ROTATION OF THE

COMPRESSOR; THIS IS SHOWN BY A PLATE LOCATED ON THE SHIELD (NDE) OF THE
FRAME.
WARNING
FOR VARIABLE SPEED DRIVE, REFER TO THE GENERAL INFORMATION SECTION FOR
ANY LIMITATIONS TO BE OBSERVED DURING NO-LOAD OPERATION.
- Check that the pressure in the oil system remains constant and is within the required range
of values. If necessary, operate as specified in the LUBRICATION Section.
- Check the oil temperature at frame inlet. If necessary, operate the cooler to bring the
temperature within the limits specified in the COMPRESSOR FRAME LUBE OIL P&I DIAGRAM
(see REFERENCE DRAWINGS Volume of this Manual).
- Ensure that the frame oil is not emulsified and does not contain air, as this may impair
lubrication. If necessary, remove the causes of contamination. Any air in the circuit will be bled
through the vents provided in the system.
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- If cylinders and stuffing boxes are lubricated, ensure that the relevant lubrication system is
operating. Check also that oil feed is regular and in compliance with the prescriptions shown
in LUBRICATION Section.
If necessary, adjust the lubrication system. The technical documentation regarding the
LUBRICATOR or the LUBE OIL CONSOLE is included in the AUXILIARIES Volume of the Manual.
- If the prelubrication pump is motor-driven and it is interlocked to a signal supplied by a
pressure switch, the latter will automatically cut it off as the oil pressure rises above the set
value. In the absence of a pressure switch, stop the pump manually when the compressor
rotation speed has reached its rated value. In any case, check the oil pressure value, after
stopping this pump.
- During the no-load running-in the main packing, the intermediate packing and the partition
covers shall not be buffered.
No-load running-in may be either complete or restricted to the seals and/or to the piston rider rings,
(see Paragraph 5.2 and Paragraph 5.3 ).
NOTE
We recommend that the various running-in steps described below in Paragraph 5.2 and
Paragraph 5.3 be preceded by the following preliminary procedure: start the machine and, after
having carried out the checks described above, cut off the driving power completely; then note
the time needed for passing from the rated speed to full stop. Subsequently, this time interval
will be compared with the time measured during the various stops required by running-in
procedure; a decrease in stopping times would be a first indication of trouble.
4.5.2 Complete running-in

This procedure will be carried out on a new or completely overhauled machine, or one that has been
subjected to replacement of the main bearings or replacement, even partial, of the connecting rod
bearings or bushes or of the piston rider rings or of crosshead shoes.
Operate according to the procedure described below.
a. After 2 to 5 minutes of running, stop the compressor.
b. Remove the covers from the frame and from the crosshead extensions.
c. Ensure that the main bearings and the connecting rod big end bearing and the cross heads
are not excessively heated.
d. If the cylinders are lubricated, check that the oil film on the piston rods is light and even. In
case of trouble, inspect the packing.
e. Check that the rods temperature does not exceed 180°C. If this limit is exceeded, check that
the inner parts of the stuffing box are correctly assembled. Otherwise, install them correctly.
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If everything is in order, since the high temperature is due to the absence of leakage through
the packing, typical for no-load operation, continue running-in with the packing disassembled.
f. Make sure that the cylinder liners are free from scratches. Inspection may be carried out either
from the valve ports or by removing the cylinder head.
g. If everything is normal, reassemble the parts and start up the compressor again.
h. Stop running after approximately 10 minutes, then after 30 minutes, and finally after 4 hours,
repeating after each stop the steps a through f of the procedure.
i. During each operation step, accurately check the pressure drop through the frame lube oil
filter. In caase of fast pressure drop, stop immediately and investigate to find the cause.
4.5.3 Running-in for piston rings plus rider rings and/or packing seals
Operate according to the procedure described below.
a. See step a , Paragraph 5.2
b. Remove the covers from the crosshead extensions.
c. See step d , Paragraph 5.2
d. Check that the rods temperature does not exceed 180°C. If this limit is exceeded, check that
the inner parts of the packing are correctly assembled; otherwise, install them correctly. If
everything is in order, since the high temperature is due to the absence of gas leakage through
the packing, typical for no-load operation, remove the packing and complete the running-in
without it.
e. See step f , Paragraph 5.2
f. See step g , Paragraph 5.2
g. Stop running after approximately 10 minutes, then after 30 minutes, and finally after 2 to 4
hours, repeating after each stop the steps b through e of the procedure.
If the cylinders are non lubricated, run for 10 minutes, 30 minutes and finally for 1 hour.
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4.6 PIPING CLEANING, PICKLING, FLUSHING, BLOWING OUT, PURGING
WARNING
FOR ALL CHEMICAL TREATMENTS, WHEN APPLIED, CAREFULLY FOLLOW THE INSTRUCTIONS
PROVIDED BY THE PRODUCT'S MANUFACTURER, AS WELL AS LOCAL AND PLANT REGULATIONS,
FOR BOTH USE AND DISPOSAL. SIMILAR PRECAUTIONS SHOULD BE TAKEN ALSO FOR
DETERGENTS, SOLVENTS AND SIMILAR PRODUCTS.
4.6.1 Process gas system

Prior to start up, it will be necessary to perform appropriate CLEANING treatment to the plant piping
that conveys the gas to the compressor. When required, perform also PICKLING and passivation.
Make sure that no entrained dirt (as residue of welding, oxidation, scale) ever remains inside the
piping. The dirt, carried by the gas, may enter the compressor and damage various components.
For this reason, temporary filters must be installed on all process gas connections at the inlet battery
limits of the compressor. The standard for these filters is shown in the PROCESS GAS P&I DIAGRAM
(see REFERENCE DRAWINGS Volume of this Manual).
For the same reason, all the equipment and the interstage piping must also be subjected to proper
CLEANING and PICKLING prior to installation.
In practice, when the compressor gas piping has been machined and/or installed on the jobsite
(where conditions and working methods may not be optimal), it is always possible that some dirt
remains inside. Consequently, temporary filters must be inserted on each stage inlet. These filters
are not required when the interstage piping arrives completely assembled and installed on the
machine, as for example in the case of "PACKAGE" groups. Note however that even for packages,
there may arise the need (to be checked in each case) to follow special precautions if, for accidental
reasons, some pipe sections have remained exposed prior to being put in service.
The temporary filters position in the system is shown in the PROCESS GAS P&I DIAGRAM.
Once the piping has been cleaned, close all its openings, if it is not to be immediately installed on
the machine. Remove the protections just prior to installation.
CAUTION
Special precautions are required during installation of machines in dusty or sandy zones. The
presence of dust or sand in the gas system could cause damage to valves, seals, rider rings and
cylinder liners, during operation.
Consequently, if in spite of all precautions, dirt should enter it will be necessary to thoroughy
clean all parts of the system (cylinders, vessels, piping).
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WARNING
IF THE GAS IS DANGEROUS (E.G. OXYGEN), REMOVE DIRT OF ANY KIND PRIOR TO LETTING IN THE
GAS. IN THIS REGARD, A PERIOD OF BLOWING CARRIED OUT FEEDING THE COMPRESSOR WITH
AIR OR INERT GAS IS REQUIRED. CONSIDER THAT BLOWING IS MORE EFFICIENT THE HIGHER THE
PRESSURE OF THE GAS USED.
IN ANY CASE ENSURE THAT THE OPERATING CONDITIONS DURING BLOWING COMPLY WITH THE
SPECIFIED CONDITIONS.
Prior to letting in the process gas, inspect and clean the temporary filters, and continue blowing until
all the dirt is removed from the filters.
In order to prevent the compressed gas from coming into contact with air, it is necessary, prior to
starting the compressor, to PURGE the system with inert gas. This procedure is carried out by opening
the inert gas inlet valve and all drains in the system and in the discharge to atmosphere, for a duration
of at least 15 minutes. Purging may require a substantially longer duration in relation to various
factors, for example, the capacity (in volume) of the plant and the degree of purging desired. If the
inert gas does not flow sufficiently to the discharge of the compressor or if a faster and effective
purge is needed, the purging process can be performed while the compressor is running.
CAUTION
Also the operating conditions during purging, must comply with the specified conditions.
Ensure that all the lines are purged by opening and closing bypasses, and recycle lines, vents, etc.
Approximately every 5 minutes, open and close any additional clearance volumes on cylinders and,
if purging has been performed with machine idle, rotate the compressor, either manually or with the
barring device, for a couple of revolutions. To verify that purging has been completed, it is advisable
to carry out chemical analysis on gas samples taken from the discharge. Analysis may be required
if the air concentration must be reduced below set values. If the analysis results show correct gas
quality, gradually close the discharges again, proceeding from upstream to downstream. The
discharge to atmosphere on compressor delivery will be closed last, simultaneously with the inert
gas inlet. When this has been done, the process gas can be let into the system.
During the initial period of operation, the temporary filter conditions should be checked frequently.
This check is made easier if instruments for measuring the pressure drop, and thus clogging, are
installed. Detaching the dirt can be facilitated and accelerated by knocking lightly against the pipes.
CAUTION
If no particular limitations exist, do not allow pressure difference through the temporary filters
to exceed 5% of the operating pressure, up to a maximum of 2.5 bar.
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Note that entrance of dirt into the compressor may lead to very serious problems and even severe
damage. Consequently, the temporary filter must not be removed until, after repeated inspections,
it is absolutely certain that the piping is free from dirt. It is a good practice to install the temporary
filter again whenever work has been completed on the upstream piping or on the equipment. It
should however be considered that the service life of a temporary filter is rather limited, in the order
of about 1 month, due to the damage that may occur to the mesh. If filters are to be used for an
extensive period, they are to be replaced regularly.
CAUTION
As previously stated, perfect cleanliness of the gas is an essential condition for satisfactory
service life of the various components of the compressor. For this reason, whenever it is supposed
that the gas may entrain particles of dirt of small granularity, it is advisable to equip the
compressor with a filter of adeguate type and efficiency on the suction, since temporary strainers
only (generally of cone or “T” type, with 200 gauge mesh) are not sufficient protection in these
operating conditions.
In particular we do not recommend prolonged running (exceeding 4 hours) with the compressor
set to total recycle, if high filtering degree gas filters (>99.9% for particles with 5 µm) have not
been installed on the compressor suction (or however downstream of the recycle line return).
The presence of entrained liquid in the gas also has a negative effect on the compressor,
especially on the valves and on non-lubricated cylinders. Consequently, in the event of
entrainment of condensates, appropriate separators must be provided as well as drains, in the
piping at points where liquid can accumulate. This to avoid the sudden entrance of liquid or,
more generally, quantities of liquid greater than those for which the separators have been
designed. During the initial period of operation, frequently check for possible entrainment of
liquid toward the cylinders, draining the pulsation dampers periodically if they are equipped with
drains. If the machine is installed in a dusty or sandy area, special precautions will also be required
during operation. Opening of the compressor will be limited to cases where this is strictly
necessary, and will never be carried out in the presence of air currents or when digging is
underway in the vicinity. Otherwise, do not hesitate to thoroughly clean all internal parts of the
system.
4.6.2 Lube oil system

The frame oil circuit must be subjected to FLUSHING to ensure absolute absence of any traces of
dirt, particularly in the section downstream of main filter.
The following procedure is recommended:
a. Inspect the various parts of the system to verify whether pickling is needed.
b. Remove the oil cooler tube bundles and clean them thoroughly. They will be reassembled
following the first step of circuit cleaning.
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c. Remove the oil filter cartridges and close the filter casing after having carefully cleaned it.
Also these cartridges will be reassembled in a second step.
d. Disconnect the oil piping from the crankcase inlet. Connect this piping to the end of a very
clean section of pipe (of whichever kind) bearing at the other end a basket filter made with a
200 mesh wire net. Place the basket filter in a position such as to let the filtered fluid fall into
the frame sump.
e. If there is a frame oil manifold, remove the plug on the end opposite to the oil inlet and connect
a very clean hose. On the other end of the hose, install a filter like that on point d and position
it in the same way as above.
f. Cut off the circuit's pressure gauges.
g. Fill the sump with flushing fluid up to the normal oil level. The flushing fluid may be a very thin
oil (if an oil heater is installed) however not heated above 80 °C. Otherwise diesel oil can be
used.
h. Start flushing by alternatively running the main and the spare oil pumps, if they have their
own driver, otherwise apply a motor driven pump just for this purpose. Verify that flushing
occurs in all branches of the circuit.
CAUTION
During flushing, appropriate metallic devices may be used for hammering the oil
system outside the frame if made, even partially, with non stainless material.
i. Stop flushing, inspect the trap of point d and remove any dirt. Flushing will be satisfactory
completed when, at least after 2 hours circulation, no more than three particles per sq.cm.
can be found.
j. Drain the flushing fluid from the sump through the existing drain connections.
k. Remove the trap of point d .
l. Connect a hose to the pipe of point d , while introducing the other end of the hose into an
empty container.
m. Start the circulating pump (in alternation in case of two pumps) to remove the residual fluid
from the circuit.
n. Blow air into the circuit to remove any traces of fluid.
o. Reassemble the tube bundles and the cartridges in their housing.
p. Clean inside the frame and the sump using appropriate fully lint free rags.
q. Close the drain connection of the sump.
r. Fill the sump with the lubrication oil to be used during operation. Heat up the oil with the
available means and keep it warm.
s. Connect the pressure gauges again.
t. Start oil circulation; discharge the first amount of oil coming out from the hose of point l .
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u. Stop again, remove the pipe of point d and connect again the piping section between filter
and frame.
v. Start oil circulation again and check whether the oil coming out from the hose of point e is
clean.
w. Remove such hose and plug the oil manifold again.
NOTE
During the final steps of flushing, the crankshaft shall be rotated at various times
using the barring device or other available means.
x. If the system is equipped with two pumps, start the second one also topping up the oil, if
necessary.
y. Check the pressure drop through the filter; clean or replace the cartridges until, after at least
4 hours circulation, such pressure drop is les than the maximum acceptable with clean filter
(see FRAME LUBE OIL P & I DIAGRAM in REFERENCE DRAWINGS Volume).
z. After these operations, flushing is completed. The oil shall be replaced if chemical-physical
analysis reveals the presence of polluting compounds.
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4.7 START UP AND LOAD-TAKING RUNNING-IN UNDER LOAD

For the first start up of the machine after installation and, in any case, after any parts of the gas
system have been opened, it is advisable to make a preliminary check, with the machine idle, of the
system connections sealing. For hazardous gases (harmful, flammable), proceed by pressurising the
system with inert gas (e.g. nitrogen). If not harmful or hazardous, the process gas can be used for
pressurisation. Leakage can be detected using specific instrumentation (or, in the absence of this,
by the application of soapy water). Obviously, the search for possible leaks is to be continued when
the machine has been commissioned, when the pressure in the system rises.
The procedure for compressor start up and taking-up load is shown in Paragraph 7.2 . If the machine
is new or has been completely overhauled, or if it has undergone replacement of worn parts, prior
to commissioning, a period of running-in under load is generally required, through the procedure
shown in Paragraph 7.3 .
CAUTION
During compressor operation, the conditions specified in the GENERAL INFORMATION Section
must be strictly observed.
4.7.2 Start-up and load-taking

After having carried out the steps described in the paragraph PREPARING COMPRESSOR FOR START
UP, and after having ensured that the recommendations shown in the blowing and purging
paragraph have been followed, proceed as described below:
a. Close any valves that, if open, would subject the compressor to pressures higher than the
suction pressure.
b. Set the compressor unloading devices (bypass, vents, etc.) to the no-load position. If the
compressor is equipped with valve unloaders, also set these to the no-load position. If the
compressor is equipped with a suction throttling valve, set it as shown in the CAPACITY
CONTROL P&I DIAGRAM (see REFERENCE DRAWINGS Volume).
CAUTION
The gas used for actuating the control devices must always and without exception
be dried, to avoid moisture blocking the devices. For oxygen compressors, the
control gas must be absolutely oil free.
c. Make sure that the check valve on the intake is completely open.
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d. Make sure that the check valve on the discharge is completely open.
e. For lubricated cylinders, check that the lubrication system is operating correctly. Check that
the oil amount delivered is as specified in the LUBRICATION Section, CYLINDERS AND PISTON
ROD PACKINGS paragraph.
f. Check that the frame lube oil pressure is within the specified limits.
g. Start up the compressor.
CAUTION
If the compressor is started for the first time, check the direction of rotation; a plate
installed on the compressor non-drive end shows the correct direction.
CAUTION
In case of trouble, stop the machine immediately to avoid damaging it, whatever
the stage of running-in or of operation.
h. When the compressor has reached the rated speed, stop the frame prelubrication pump, if it
is driven by its own motor and is not interlocked to a pressure switch. In any case, check the
oil pressure and if necessary adjust the appropriate devices in the system (see LUBRICATION
Section) to bring it within the range specified in the COMPRESSOR FRAME LUBE OIL P&I
DIAGRAM (see above).
i. Check the oil temperature at frame inlet. If required, act properly on the cooling system to
bring the temperature within the values range specified in the above mentioned diagram.
j. Check the oil level in the sump. Top up if necessary.
k. Ensure that the frame oil is not emulsified and does not contain an amount of air that may
impair lubrication. If necessary, remove the causes of contamination. Any air in the circuit will
be bled through the vents provided in the system.
l. If the compressor is to be subjected to running-in under load, follow the instructions shown
in Paragraph 7.3 . If instead the compressor does not require running-in under load, when
the rated speed has been reached, set the unloading devices to the "loaded machine" position.
In any case, before the load is applied to the compressor, it is advisable for the oil temperature
to be brought up to 30 to 35°C.
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CAUTION
If the unloading device is total bypass or suction throttling, unloading must be

carried out gradually.
If the unloading device consists of a set of vent valves, their closing will be carried
out gradually, beginning from the last compression stage.
If the unloading device consists of suction valve unloaders, the cylinder ends must
be loaded gradually, beginning from the last stage.
m. Once the compressor is under load, the valves mentioned in item a can also be opened
gradually. When this has been carried out, the compressor is in normal operating condition.
CAUTION
If the machine is equipped with vessels or headers directly connected to the

flanges of several cylinders, (at suction or discharge, or both), carry out the
following procedure, immediately after the first start-up:
- Operate at rated conditions.
- Wait for the time strictly necessary for temperatures to stabilise in the
various parts of the machine and of the plant.
- Stop and depressurize the machine immediately.
- Immediately afterward, with the machine still hot, slightly loosen the stud
bolts of the flanges connecting the cylinders with headers or vessels. This
allows the correct positioning between cylinders and header or vessel,
eliminating mutual stress.
- Tighten the flange stud bolts again.
Note that the above is required only when the seal on the cylinder flanges is in the
form of flat gaskets; it does not apply in the case of ring gaskets.
4.7.3 Running-in under load

This procedure is carried out to complete the bedding of various parts of the machine, started during
no-load running-in.
Running-in under load shall be performed on a new or completely overhauled machine, or one which
has been subjected to replacement of worn parts.
During running-in under load the machine will be run up to normal operating conditions, under the
strictest supervision of the operator, and by the gradual process required by those components for
which bedding is completed during operation.
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For this reason, it must be clearly understood that the procedures described above are to be
considered as indicative and that, in performing running-in, the operator's sensitivity and experience
play a leading role.
CAUTION
Never operate with temperatures and pressures higher than those specified in the GENERAL
INFORMATION Section.
It is important that, throughout the running-in period, the various operating parameters are kept
under control with all the instrumentation available.
Any special running-in procedure required for the compressor is described in the above
mentioned Section.
- Running-in of crank mechanism. If the crank gear is new or has been overhauled with
replacement of the main bearings, or with replacement, even partial, of the connecting rod
bearings or bushes or of the crosshead shoes, this procedure will be carried out by gradually
increasing the load up to the maximum value in approximately 2 hours, as far as this is allowed
by the available capacity control devices (steps with valve unloaders, bypass, etc.).
- Running-in of seals and/or piston rider rings. This procedure shall be carried out when
operating pressure exceeds 80 bar. To perform the running-in, the discharge pressure will be
gradually increased up to the normal operating value in the time intervals specified below, as
a function pressure:
> 80 to 150 bar: 3 hours
> 150 to 350 bar: 6 hours
over 350 bar: 12 hours
After reaching the rated pressure, the compressor will be stopped and the temperatures of main
bearings, connecting rod bearings, cross heads, stuffing boxes, piston rods and shoulder rings, shall
be checked.
If upon completion of the steps described above no problems have arisen, the compressor is ready
for operation. If problems have in fact appeared, refer to the TROUBLESHOOTING Section to find their
causes.
CAUTION
When carrying out running-in of crank gear, check the state of main and temporary filters during
the first hours (see also, for filters, the LUBRICATION Section, CRANK GEAR paragraph). In any
case it is advisable to replace the oil after about a hundred hours of operation.
During the first hours of operation, adjust the amount of oil delivered to the cylinders and stuffing
boxes, as specified in the respective paragraph in the LUBRICATION Section.
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During running-in and during operation, keep the unit under control as explained in the COMPRESSOR
SUPERVISION paragraph in this Section.
CAUTION
If the machine is running with the auxiliary oil pump on, with the main pump out of order, keep
in mind that this is an emergency condition, and take action immediately to find the cause and
restore the normal conditions.
Regarding the checks to be carried out during the first period of operation or after any general
overhauls, and the periodic maintenance procedures to be applied, refer to the appropriate
paragraph in the MAINTENANCE Section.
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4.8 CAPACITY CONTROL

The CAPACITY CONTROL P&I DIAGRAM (see part of REFERENCE DRAWINGS volume) shows the control
systems and procedures for the compressor subject of this Manual.
If the compressor has automatic control, the relevant sequence is included in the part of the Manual
pertinent to the CONTROL PANEL.
Any data concerning control that does not appear on the above diagram may be contained in the
GENERAL INFORMATION Section.
WARNING
IF THE COMPRESSOR CONTROL DEVICES HAVE PNEUMATIC ACTUATION, THE RELEVANT CONTROL
GAS MUST WITHOUT EXCEPTION BE DRIED, TO AVOID MOISTURE IMPAIRING THE ACTION OF THE
DEVICES. FURTHERMORE, THE CONTROL GAS PRESSURE MUST BE WITHIN THE LIMITS SPECIFIED
ON THE CAPACITY CONTROL P&I DIAGRAM.
INADEQUATE PRESSURE VALUES ALTER THE ACTION OF THE DEVICES, AND THIS MAY RESULT IN
FUNCTIONAL AND MECHANICAL PROBLEMS. FOR OXYGEN COMPRESSORS, THE CONTROL GAS
MUST BE ABSOLUTELY OIL FREE.
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4.9 COMPRESSOR SUPERVISION

The correct operation of the machines depends on the capability and skill of the supervision
personnel.
It is obvious that supervising the installation will be the less demanding the more it is equipped with
instrumentation and alarm and trip automatisms. The following remarks, therefore, rather than
describing procedures to be carried out by the personnel responsible for operating the system,
highlight those factors, parameters, system components, phenomena, etc., that must be kept under
control to avoid having severe problems arising from small troubles that have not been given
adequate attention. As a general rule, it is advisable to check at intervals of about two hours that
the temperature and pressure values of gas, oil and coolants remain within the given limits and show
no sudden variation. Longer intervals between one check and another are specified in the technical
documentation, when unattended compression units are equipped with appropriate additional
instrumentation.
In any case, we recommend performing the checks listed below DAILY and recording the main
compressor operation data in a special logbook, if an automatic data acquisition system is not
available.
NOTE
If any problems should appear during the checks, refer to the Section TROUBLESHOOTING.
Frame lube oil

- Ensure the absence of foam.
- Make sure that there is no decrease nor increase in oil level.
- Make sure that there is no presence of other liquids or air.
Auxiliary oil pump
- Make sure that the pump is operating correctly.
- Cylinder and piston rod packing lubrication (where applicable)
- Check the oil level in the lubricator.
- Check the oil flow rate and correct operation of each oil line.
- Make sure, through the flow indicators, that the check valves are efficient.
- Check that there is no leakage at the oil injection quills on the cylinders.
Actuators
- Check that the control gas pressure for the actuators is within the limits specified on the
CAPACITY CONTROL P&I DIAGRAM (see part of REFERENCE DRAWINGS volume).
- If the actuators remain idle for a long period, actuate them for a few seconds at least once
during each shift, to avoid the possibility that they remain blocked due to inactivity.
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- Ensure that there is no gas leakage from the actuators of valve unloaders and of valves of the
cylinder heads (if any).
Liquid accumulation
- Check all machine or system parts in which liquid can accumulate: for example, distance
pieces, separators, tanks collecting condensate from dampers and coolers, from piston rod
packings, from balanced cylinder ends, etc. In the absence of level gauges, always drain these
elements. After each draining, close the valves again.
Frame
- Check that there is no oil or gas leakage from the frame.
- If the compressor is equipped with thermocouples for taking the main bearings temperatures,
and if a sudden temperature increase is observed, increase attention and find the cause. It is
advisable, in any case, that the bearing temperature is not more than 25C above the oil
temperature at frame inlet, shown in the COMPRESSOR FRAME LUBE OIL P&I DIAGRAM (see
part of REFERENCE DRAWINGS volume).
Cooling medium
- Through the inspection glasses, ensure that the coolant is circulating correctly and that it does
not carry gas bubbles.
- Discharge any air pockets through the vents.
- In a closed loop check the level of the fluid in the tank.
- Check the temperature.
- Check that there are no leaks.
Drains on distance pieces
- Drain and check that the amount of accumulated oil shows no variation over time.
Vents from piston rod packings
- Ensure that the gas flow through these vents remains constant over time.
- If flow meters for checking leakages are not provided, one of these procedures can be followed:
- use a gas detector or visual check at the end of recovery pipe,
- detect any significant variation in the recovery pipe temperature close to the packing
flange (as far as possible).
Vents from distance pieces between cylinders and frame

- See preceding item.
Cylinder valves
- Check for any malfunction indicated by valve covers temperature rise or abnormal noise
emissions. Variations in temperature clearly indicate the start of abnormal valve operation. It
should be emphasized that continuing to operate with valves already damaged may lead to
excessive increase in temperature in the cylinders or to valve parts breakage. These broken
parts, entering the cylinder, can damage other components and impair safety. Keep in mind
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the information given in the MAINTENANCE Section, SAFETY PRECAUTIONS - MAINTENANCE

PROGRAM paragraph, GENERAL item.
Clearance pockets
- If closed, they must be drained
- For variable volume pockets, check that there is no gas leakage from the seals.
Abnormal knocking
- Listen for any abnormal knocking, coming from the crank gear or from the cylinders.
Operating parameters
- Check that the temperature and pressure of gas, oil and coolant remain within the specified
limits and do not show sudden variations.
WARNING
EVERY 3 MONTHS, OR AT OTHER INTERVAL ESTABLISHED ON THE BASIS OF THE DIRECT

EXPERIENCE ACQUIRED BY THE MACHINE USER, A CHECK MUST BE MADE REGARDING THE STATE
OF CLEANLINESS OF THE OIL FILTER, THE EFFICIENCY OF ANY FILTERS OR SEPARATORS LOCATED
IN THE GAS LINES, THE EFFICIENCY OF ALL THE INSTRUMENTS (PRESSURE GAUGES,
THERMOMETERS, PRESSURE SWITCHES, TEMPERATURE SWITCHES, CONDENSATE DRAINERS,
ETC.) IN THE SYSTEM.
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4.10 COMPRESSOR SHUT DOWN
NOTE
For the emergency shut down sequence, refer to the indications shown in the Control Panel
technical documentation.
WARNING
REGARDING SHUT DOWN OF COMPRESSOR AND OF ANY COMPONENT EQUIPMENT, CONSIDER

THE REQUIREMENTS FOR THE MAXIMUM NUMBER OF START UPS PER HOUR ALLOWED FOR EACH
ELECTRIC MOTOR. THIS NUMBER, IF SPECIFIED, IS SHOWN ON THE DATA SHEETS FOR THE MOTORS
INSERTED IN THE TECHNICAL DOCUMENTATION FOUND IN THE AUXILIARIES PART OF THE
MANUAL.
4.10.1 Temporary shut down

If the compressor is kept idle for a very short time, proceed as follows:
a. Set the compressor in the no-load condition.
b. After having isolated the compressor from the rest of the system, depressurize the gas circuit.
c. Stop the compressor.
d. If a cylinder lubrication system is provided, driven by own driver, stop it.
e. If the main frame oil pump is driven by its own driver, stop it after a few minutes to allow the
temperature of the crank gear to equalize. For the same reason, if the main pump is driven
by the crank shaft, switch on the auxiliary pump for a few minutes.
f. Let the coolant flow. If the stop is to be protracted for more than a few minutes, also cut off
the coolant flow.
4.10.2 Shut down for maintenance

If the compressor is to remain idle for maintenance, proceed as shown below:
- Follow the instructions shown in steps a through e of Paragraph 10.1 .
- Before cutting off the flow, let the coolant flow for at least 15 minutes in the various loads (oil
coolers, gas, cylinder jackets liners and stuffing box, etc.) to dissipate the accumulated heat.
WARNING
THIS PRESCRIPTION IS MANDATORY WHEN THE CHECK VALVES ARE OF THE L.O.
TYPE (LOCKED OPEN, I.E., LOCKED OPEN WITH A KEY).
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- If the compressor handles harmful or flammable gases, the system must be PURGED. The
procedures for carrying out this operation are shown in the pertinent paragraph in this Section
and refer to any applicable local safety rules.
- In relation to the environmental conditions, the nature of the fluid and the duration of the shut
down, consider the possibility of completely emptying the cooling system.
4.10.3 Shut down for plant inactivity

The possibility of performing purging (see point 2) must be considered also in case of simple shut
down for reasons of plant production, in relation, for example, to the duration of the shut down, the
environmental conditions around the machine, the properties of the handled gas, etc.
WARNING
IF THE COMPRESSOR IS TO BE STOPPED FOR A LONG TIME, REFER TO THE PROTECTION DURING
IDLENESS SECTION.
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5 - TROUBLESHOOTING
1 TROUBLES, CAUSES, CORRECTIVE ACTIONS .......................................................................................117 1-117
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5.1 TROUBLES, CAUSES, CORRECTIVE ACTIONS

A list of problems that may occur while operating reciprocating compressors is shown in Figure 25
and Figure 26 . Using the code numbers assigned to each problem, the possible causes and the
pertinent corrections may be found referring to the guide in Table 6
In undertaking work on the machine, the procedures contained in the Sections INSTALLATION,
OPERATION, MAINTENANCE, FRAME AND CRANK GEAR, CYLINDERS ASSEMBLIES, LUBRICATION, must
be followed as closely as possible.
NOTE
This part of the Manual contains general information. The user should therefore consider the
particular characteristics of his own machine, and thus the suitability of the information
contained in this Section. In compiling this handbook, our guidelines have been our wide
experience in the field of reciprocating compressors, and the need for sufficient clarity and
simplicity for the user. Therefore we consider it advisable to point out the great use of the Manual,
strongly urging that it shall be carefully read prior to undertaking works of any kind on the machine.
At the same time, we highly recommend consulting the Nuovo Pignone Technical Assistance
Service whenever interpretation of problems is doubtful.
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Figure 25 - Troubles
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Figure 26 - Troubles
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CAUSE-CORRECTION CODE CAUSE OF PROBLEM POSSIBLE CORRECTION
1 Foundations too small - Reinforce foundations or increase
their size
2 Foundations poorly made or deteriora - Pour mortar again correctly
ted
3 Foundation bolts loosening - Perform correct bolt tightening after
having checked their status
- Restore correct compressor align
ment
4 Pipings not properly anchored - Strengthen bracketing
- Add new supports
5 Driver not powerful enough - Reduce compressor capacity (e.g. by
acting on interstage recycle or other
capacity control devices)
- Replace driver
6 Inadequate power supply - Restore correct setting of electric sa
fety devices
- Tighten motor terminals correctly
- Restore correct motor excitation
- Rise the power factor
- Increase motor supply voltage
7 Suction line too small, too long or ha - Reduce pressure losses to normal va
ving equipment with excessive pressu lues by operating either on the line or
re drop on the equipment
8 Gas intake filter clogged - Clean the filter
- Reduce the amount of product to be
separated, by operating on the line or
on the upstream plant
9 Excessive pressure pulsation - Restore compressor design operating
conditions
- Insert orifices in the piping
- Modify the size or the shape of the pi
ping or add pulsation suppressors de
vices
10 Excessive carry-over of condensates in - Restore the minimum condensate le
process gas vel in the separators
- Increase frequency of draining liquids
from separators
- Restore design operating conditions
(pressures and temperatures of pro
cess gas)
- Clean the separators
- Add drain valves at low points of gas
piping where liquid can accumulate
- Modify the shape of piping that col
lects drained liquids
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11 Solid particles carry over in process gas - Insert an intake filter, if not provided,
or replace it with a more adequate one
- Operate on the upstream system, to
prevent abnormal quantities and qua
lities of solid matter from reaching the
separator
- Perform correct blowing of gas piping
and of compressor auxiliaries
- Improve separator efficiency on com
pressor intake
12 Excessive vibrations in crankshaft - Restore correct tightening of the fly
wheel to the crankshaft
- Replace journal bearings
- Restore correct alignment of coupled
machinery
- Rework the damaged shaft and install
undersized bearings, or replace the
shaft
13 Components incorrectly assembled - Repeat assembly, following the cor
rect sequence shown on the assembly
drawings
14 Drive components incorrect positioning - Restore correct positioning of driving
system, comply with the magnetic
center of the electric motors, the va
rious axial clearances, the alignment
in the axises of the shafts as specified
by the manufacturer
15 Defective instrumentation or devices - Restore correct operation of the in
struments or devices, or replace them
if necessary
16 Defective operation of valve unloaders - Increase the pressure of the control
gas
- Eliminate leakages in the control gas
system
- Use a control fluid with a lower dew
point
- Clean the actuator stem, or replace it
if corroded or worn out
- Replace worn out seals
- Restore correct clearance in the ac
tuator-unloader system
- Install the valves correctly on the cy
linders
- Modify the valve unloader control sy
stem
17 Final pressure of compressor higher - Restore correct operation of overall
than normal operating value bypass
- Restore correct operation of capacity
control devices
- Operate on system equipment
- Remove any partial occlusion in the
discharge line
18 Too long unloaded running of cylinders - Avoid this condition, or comply with
the unloaded operation times speci
fied in this manual
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19 Loosening of flywheel or of driving pul - Perform correct tightening, after ha
ley or of the driver rotor ving restored the mating surfaces
- Restore correct alignment in the drive
system
20 Belts slippage - Restore correct tension of belts
- Use belts all of the same length
- Bring compressor load back to the ra
ted value
- Restore correct alignment of com
pressor flywheel with the driving pul
ley
- Use suitable belts
21 Cylinder valves loosening - Tighten the valve cover bolting with
the torque specified in this manual
- Correctly assemble the valves and the
relevant cages on the cylinders
- Avoid overheating the cylinders
- Restore the valve seats in the cylinder
- Avoid liquid and solid substances en
trance in the cylinder
22 Loosening of piston rod crosshead con - Tighten correctly the rod after having
nection restored or replaced any damaged
parts
- Restore the locking device of the rod's
nut
- Prevent rod overheating
- Avoid liquid and solid substances en
trance in the cylinder
23 Loosening of crosshead pin or cros - Tighten correctly after having resto
shead shoes red or replaced any damaged parts
24 Cylinder misalignment - Restore alignment
25 Improper cylinder lubrication - Use oil having the properties specified
in this manual
- Restore the correct oil level in the lu
bricator
- Stop any lube oil leaks from the oil sy
stem
- Increase or reduce as necessary the
oil rate to the cylinders
- Heat the oil and insulate the oil lines
- Use a different oil grade, if the com
pressor handles a gas carrying sol
vents not known at the time of
machine design
- Replace lubricator plungers
- Replace the check valve of oil injection
quills on the cylinder
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26 Crank gear oil pressure too low - Use oil having the properties specified
in this manual
- Repair or replace the pressure gauge
- Set correctly the bypass valve
- Restore the correct level of oil in the
sump
- Remove contamination of water or air
from the oil
- Stop leaks of lube oil from the oil sy
stem
- Increase the oil cooler efficiency
- Set correctly the oil system safety val
ve
- Clean the filter
- Replace the crank gear bearings
27 Insufficient cooling - Increase the coolant flow rate
- Upgrade the cooling system and
clean the heat exchanger surface
- Use a less fouling coolant
- Stop any compressed gas leaks into
the coolant system
28 Poor operation of the oil scraper rings - Assemble the oil scraper rings accor
ding to instructions
- Replace worn out or scored oil scraper
rings
- Replace worn out or scored piston rod
29 Excessive gas leakage from packings - Correctly install the packing rings, as
specified in this manual
- Remove clogging from the vent sy
stem
- Restore the normal pressure of gas
recovery from stuffing boxes
- Remove any dirt blocking the packing
rings inside the cups
- Restore correct clearance between
packing rings and cups
- Replace the worn out packing rings
- Replace the piston rod
- Restore correct cylinder alignment
- Rebore the cylinder and use piston ri
der rings of proper size to obtain cor
rect alignment
30 Gas leakage through the gasket - Apply adequate tightening torque to
the fastening bolts
- Avoid overheating the parts holding
the gaskets
- Avoid gaskets overload induced by sy
stem components
- Replace damaged gaskets
- Use gaskets of different type
- Apply gaskets of a different material,
if corroded
- Restore the condition of the surfaces
holding the gaskets
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31 Gas leakage from surfaces mating wi - Restore or increase correct tightening
thout gaskets of bolts fastening the parts
- Recondition the state of the mating
surfaces
- Use adequate seal paste
32 Poor piston ring seal - Perform a precise check on piston
rings
- Remove grime blocking the rings in
their groove
- Restore clearance between piston
rings and their grooves
- Replace the worn out piston rings
- Recondition sliding surfaces
- Replace the cylinder liner
- Restore correct cylinder alignment
33 Clearance outside specified limits - Restore correct assembly of compo
nents
- Replace any worn out or damaged
parts
- Rework parts out of tolerance
34 Corrosion of parts on which mechanical - Eliminate the corrosive agent
components slide or roll - Keep temperatures and pressures wi
thin values specified in this Manual
- Prevent contact of corrosive agent wi
th these parts
- Change the material of these parts
- Improve separation of condensates
- Investigate the presence of eddy cur
rents
35 Corrosion of cylinder valve springs - Eliminate the corrosive agent
- Change the material of the springs
- Improve separation of condensates
36 Excessive wear or scoring of sliding or - Clean the filters
rolling parts - Improve the separators efficiency
- Change the lubricant grade
- Increase the lubricant flow rate
- Remove the causes of components
overheating, which may be due to: gas
backflow, insufficient cooling, abnor
mal operating conditions
- Restore correct clearances as speci
fied in this Manual
- Change the material of sliding or rol
ling parts
- Restore correct alignment of compo
nents supporting the damaged parts
37 Scaling of antifriction metal lining - Avoid any entrainment in the oil (wa
ter, air, etc.)
- Clean the lube oil system
- Restore correct lubrication
- Replace any parts having antifriction
metal lining
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38 Oil leakage - Replace the seal ring on the crank
shaft
- Restore correct seals on the frame wi
th covers, shields and crosshead ex
tensions
Table 6 - Possible causes and corrective actions
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6 - MAINTENANCE
1 MAINTENANCE INFORMATION .................................................................................................................127 1-127

1.1 GE Oil & Gas Technical Communication ............................................................................................127 1-127
1.2 RM&D for New Equipment ........................................................................................................................128 1-128
1.3 RM&D Service .................................................................................................................................................129 1-129
2 SAFETY PRECAUTIONS MAINTENANCE PROGRAM ..........................................................................132 1-132
2.2 Safety precautions .......................................................................................................................................134 1-134
2.3 Checks and procedures to be carried out after first start-up or after complete overhaul139
................................................................................................................................................................................ 1-139
2.3.1 After 30 to 60 hours of operation ..........................................................................................................139 1-139
2.3.2 After 500 hours of operation ...................................................................................................................139 1-139
2.3.3 After 1,000 hours of operation ..............................................................................................................142 1-142
2.4 Checks and procedures to be carried out for periodic maintenance .................................142 1-142
2.4.1 Every 4,000 hours of operation .............................................................................................................142 1-142
2.4.2 Every 8,000 hours of operation for non-lubr. cylinder compressors, 12,000 for142
lubricated cylinder compressors .......................................................................................................... 1-142
2.4.3 Every 24,000 hours of operation ...........................................................................................................143 1-143
3 TORQUE WRENCH SETTING AND HYDRAULIC TIGHTENING PRESSURE ................................145 1-145
4 CLEARANCES, WEAR, OVALIZATION .......................................................................................................148 1-148
4.1 Shaft and crank gear ..................................................................................................................................148 1-148
4.2 Cylinders ...........................................................................................................................................................148 1-148
4.3 Piston rods .......................................................................................................................................................148 1-148
4.4 Miscellaneous .................................................................................................................................................148 1-148
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6.1 MAINTENANCE INFORMATION
6.1.1 GE Oil & Gas Technical Communication

Service Bulletins represent the official means used by GE Oil & Gas to communicate our latest
technologies and to provide customer’s service personnel with technical recommendations and
solutions to known fleet issues as well as better maintenance practices and upgrades for optimizing
existing equipment.
GE Oil & Gas publishes two kinds of documents:
- Service Bulletin “NIC”(Customer Information Note) informs Customers about modifications
and upgrades that may impact the operation of the unit or maintenance performance.
- Service Letterinforms Customers of changes to standard inspection procedures or
maintenance policies
The Compliance Category, stated on the top of the document, identifies the benefit or severity of the
Service Bulletin as indicated below:
O – Optional
Identifies product improvements that may be beneficial to some but not necessarily all Customers. GE
Oil & Gas recommends implementation at the Customer’s discretion or convenience.
R – Routine
Identifies product improvements or inspections that primarily enhance product life and reduce life-
cycle maintenance costs. GE Oil & Gas recommends implementation in accordance with the Timing
Code for the Service Bulletin, which is generally during routine, scheduled maintenance.
C – Campaign
Identifies product improvements or inspections that primarily enhance product reliability. GE Oil & Gas
recommends implementation in accordance with the Timing Code for the Service Bulletin, which is
generally at the next scheduled or unscheduled maintenance. Implementation may also be required
prior to a specific operating time or cycle limit. Failure to implement in accordance with the Service
Bulletin Timing Code could result in forced engine outage and/or engine component damage.
A – Alert
Identifies product improvements or inspections to ensure product safety and/or enhance product
reliability. GE Oil & Gas recommends immediate action by the customer to plan and schedule
implementation in accordance with the Timing Code for the Service Bulletin, which is generally at the
first opportunity during scheduled or unscheduled maintenance. Implementation may also be required
prior to a specific operating time or cycle limit. Failure to implement in accordance with the Service
Bulletin Timing Code could result in a forced engine outage, engine damage, facility damage, and/or
injury to personnel.
Complete definitions of Compliance Categories, Compliance Levels and Timing Codes are indicated
at the end of each Service Bulletin (paragraph # 11 – Glossary of Terms)
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An application called theTechnical Updates Portalis available on the official GE Oil & Gas web site
to enable faster and simpler delivery of all Technical Bulletins. After registering, customers can log
in anytime to easily access and download all bulletins relating to their specific GE equipment. Queries
can be made by technology type, equipment serial number, bulletin number, title/keyword, issue
date and category.
Additional key features are:
- implementation status by units
- customer feedback form
There is even an option for receiving automatic email notifications of bulletins relating to the
customer’s equipment without having to log in to the Portal.
To register and get started, simply go to http://www.geoilandgas.com/ and select Technical Bulletins
from the Online Tools menu at the left side of the page. Click GO and you're on your way.
All the instructions for obtaining access to this Technical Updates Portal, for subscribing to
automatic mail notification, and for any additional information relevant to the application have been
provided in following document: TECHNICAL UPDATES PORTAL LAUNCH (NIC 07.37.SL)
6.1.2 RM&D for New Equipment

RM&D System description
The Remote Monitoring and Diagnostics (RM&D) System‘ s goal is to collect and archive equipment-
operating data making them available to RM&D engineers and the project manager community.
Data collection, preprocessing, and fault detection are carried out using the On Site Monitor (OSM).
The OSM is a server grade PC equipped with operating system and data acquisition software
designed to collect data from control systems and external devices as needed (PLCs, Vibration
monitoring systems, etc.).
The OSM is a READ-ONLY device, which cannot modify any control logic.
In addition to the OSM, the RM&D system requires also the networking devices to connect the system
on site with GE network and enable continuous flow of information from the remote site to the GE
headquarter.
Data acquisition is done on a continuous basis at the maximum sampling rate allowed by the data
to insure that a precise assessment of the machine condition can be made even during transient
operation. Typical data frequencies are 1 sample/ second and 1 sample/ minute. Data are stored in
a local database: analog data are stored both at high frequency (typically once per second) and low
frequency (typically once per minute), alarms and events are stored on a ‘change detection’ basis.
Acquired data are normally transferred to the RM&D Center several times per day and stored in the
central database; data are checked by RM&D engineers and used to assess machines status and
potential problems or anomalies.
Cumulated equipment data will be stored in the OSM nominally for three consecutive months; older
data will be automatically deleted. Under normal circumstances low frequency and alarm/event
data will be periodically retrieved by the RM&D Center and archived in the central database for a
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minimum of one year. High frequency data are transferred only on an ‘on demand’ basis for limited
time intervals, thus enabling the analysis of specific events with the highest data resolution available.
Also direct connection is available on “on demand” basis.
In general the system is designed not only to support RM&D on historical data but also to allow GE
technicians to connect to the OSM and to the control system HMI; this is a key feature to ensure
prompt commissioning support and remote troubleshooting during critical operating phases.
Figure 27
6.1.3 RM&D Service

Commissioning & Startup support
RMD connectivity deployment enables a comprehensive remote support during the commissioning
& startup phases.
As needed, onsite TAs can effectively leverage HQ expertise and HQ experts are allowed to reach
real time and historical data for trending and further detailed analysis.
The main advantages are here below reported:
By means of RMD data transfer:
- Creation of an historical data repository
- Reliable, automated and continuous diagnostic data collection and transfer
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- Machine monitoring from starting phases

- Data driven troubleshooting and root cause analysis
- Triplog information
By accessing the HMI:
- Commissioning support and real time engineering troubleshooting for both driver and driven
equipment and relevant systems (e.g. DGS, Lube Oil)
- Trace trends with high resolution (40 ms for MkV and MkVI)
- Graphic changes to the HMI
- If in the same LAN of the HMI, it is possible to access Bently Nevada racks (3500) thru the Rack
Configurator and examine configuration and diagnostic alarms sent to the HMI
- Apply a software TIL
- Doublecheck potential issues arisen from RMD remarks
Operations support
Machine experts working 24 hours a day at the RM&D Center are dedicated to determine conditions
of site equipment, to help in operating the asset below the alarm levels, to identify anomalous trends
and to determine incipient failures by analyzing data acquired by the RM&D System. GE proprietary
performance evaluation programs are then used to evaluate current performance level and
degradation effects during equipment operating life.
The aim of remote monitoring service is to detect potential problems before an equipment shutdown
occurs or before certain operating phases can lead to components or system failure. If necessary,
maintenance or repair action are suggested to customer and GE site technicians quickly, thus
minimizing the extent of repair and avoiding potential collateral damages.
In general the RM&D System gathers hundreds of gas turbines and driven equipment parameters
from site devices that become available for historical and statistical analyses and trending. The long-
term analysis executed on data is mainly aimed to define degradation effects on main machine
systems; the main machine parameters are selected and plotted against time as raw or normalized
value. Also design behavior is used to determine anomalous conditions. Focus of this analysis is on
data steps, threshold crossing or increase of the values also when the measure is below alarm or
trip level. The short-term analysis is mainly performed on one-second data resolution and is used
to find correlation between signals and anomalies starting point.
Equipment data used on trend analysis mainly include:
- Equipment and system trips, alarms and other significant events;
- Lube oil system pressure and temperatures;
- Compressor seal systems (i.e. pressures and leakage flows);
- Thermodynamic parameters such as pressures, temperatures and flows;
- Counters status (fired hours, starts, trips, etc.);
- Control parameters (i.e. compressor anti-surge parameters);
- Shaft radial vibrations and axial position, and casing vibration.
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Performance assessment programs have been developed to provide estimation and trending of
equipment main components efficiencies and output. These tools are based on GE proprietary
algorithms and provide information about the main machine sections; the availability and details of
results depend on the machine available instrumentation.
The calculated machine performances are compared with expected values specific for each
machine; the comparison between values takes into account the analysis of historical data
belonging to the specific unit and the set of data collected from the whole installed fleet as well.
The preliminary elaboration carried out with the data validation, operating running status definition
and actual performance evaluation produces data used to fully describe the actual engine
thermodynamic behavior.
In the attached table is reported a list of possible analyses linked with relevant raw data availability.
As general approach, after a first period of data storage and analyses, diagnostic engineers produce
and configure (on the RMD central system) a set of diagnostic thresholds that will be used as trigger
for anomalies. A prognostic engine scanning continuously raw and normalized data will then
promptly alert diagnostic engineers about incipient failures and type of threshold that have been
violated. The main recipients of any following notification are GE project manager and site
technicians.
RM&D Service benefits
Main benefits of the RM&D system deployment are:
- Reduction of time to reach stable and reliable operations
- Start production earlier
- Historical Data availability in case of investigations and troubleshooting from HQ
- Possibility to provide real time support to site control engineers during critical start up phase
- Opportunity to avoid damages increasing MTBF
- Demonstrated Availability increase.
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6.2 SAFETY PRECAUTIONS MAINTENANCE PROGRAM

A basic condition for keeping the unit at highest efficiency, is that the personnel in charge of operation
and maintenance takes maximum care of the machine and carefully performs the recommended
checks.
The maintenance program shown in this paragraph has been drawn up to be used for NUOVO
PIGNONE reciprocating compressors in general. It will be the operator's care to select the procedures
applicable to his machine. Note that the recommended time limits also are merely indicative for all
machines; furthermore, any specific instrumentation may make certain scheduled inspections
unnecessary. It must be considered that:
a. Solid particles entrained in the gas have a negative effect on valves, piston rings and piston
shoes, cylinder liners, packing rings, piston rods.
The effects may differ, depending on the size, hardness, shape (rounded or with sharp edges)
of the particles. Cracks may originate in valve rings and springs as a result of the presence of
particles in the gas.
For this reason, when the continuous entrance of dirt is possible, a high degree of filtering on
the 1st stage suction (e.g. at least 3 µm) is absolutely necessary. Filters on inlet of the next
stages will be also required, if there is a possibility that rust form in the interstage piping and
equipment.
b. The entrance of liquids can overload the piston rods and other parts (cylinders, etc.) and may
start cracks on valve seats, rings and springs. Drops of liquid even small in size between seats
and plugs have the same effect as solid particles due to the high speed of impact of the plugs
on the seats, and can severely deform the rings.
Moreover, if fractions of hydrocarbon liquids (or other solvents) are carried by the gas, the
cylinder lube oil may be diluted, with consequent poor lubrication.
For all of these reasons, the presence of fluids in the gas stream must be absolutely avoided.
c. The gas physical parameters must remain constantly in accordance with the design
parameters.
d. Generally the oil flow rate to cylinders must be as specified, but variations may occur in relation
to the operating behavior of the lubricated components. Always remember that both
insufficient or excessive lubrication can cause problems to valves, piston rings and packing
seals.
The grade of lube oil can only be changed, upon previous authorization by N.P.
e. It is possible to use a device for checking the rods drop due to wear on the rider rings, thus
improving machine safety and avoiding the need to disassemble the cylinders for checks. If
proximity probes are used (Bently Nevada), alarm and trip signals can be generated. In these
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conditions, shutdowns for maintenance can be scheduled at the best to avoid negative effects
on production.
N.P. can supply these devices upon request.
f. It is recommended to pay particular attention to the operation of the cylinder valves, which
can be verified for example by checking the valve covers temperatures or by verifying the
absence of abnormal noise emissions. As a general rule, consider that:
- a difference in temperature up to 5° C between valve covers of the same duty on the
same cylinder is acceptable.
- a difference of 5° to 10° C may mean that the hottest valves have problems.
- differences of more than 10° C generally mean that the hottest valves need to be
checked.
In case of damage to a valve it can happen that broken parts of it (rings and/or springs) enter
the cylinder and cause damage to other components. It can also happen that broken valve
rings on discharge side cause gas backflow, with consequent lack of thrust reversal on the
crosshead pins. In this situation, severe damage to the bearings and to other vital parts of the
crank gear or frame is possible.
To avoid these risks, temperature sensors can be installed on the crosshead pins and/or
thermocouples on the suction and discharge valve covers. The relevant signals are to be
transmitted to an alarm-shut down system.
g. Measurement of gas leakage from the recovery of the piston rod packing is useful for
preventive maintenance purposes. Appropriate systems may be devised, on condition that
appropriate parameters are measured (in general, the pressure of the gas downstream of the
recovery).
h. As regards lubrication of the crank gear, the following should be considered:
- the oil pressure must be kept at the values specified in the COMPRESSOR FRAME LUBE
OIL P&I DIAGRAM.
- a sudden change in the main journals temperature is an indication of problems such
as detachment or overheating of the white metal.
- the oil cooler should be periodically cleaned on the water side, especially in case of open
circuit.
- lubricating oil shall be periodically analyzed (at least once a month), especially
regarding:
1. viscosity
2. corrosive compounds (only traces allowed)
3. particles with / of white metal (sudden increase)
4. water (only traces allowed)
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- avoid letting air to mix with the oil in the form of foam. The effect is similar to a reduction
in viscosity. Therefore it is strongly recommended that the oil level in the sump is kept
always above the minimum. Periodically, check also the tightness of the
i. It is not advisable to start the machines when the oil temperature after the cooler is too low
(refer to section OPERATION paragraph PREPARING COMPRESSOR FOR STARTUP). This could
result in localized metal-to-metal contact, with possible shortening of the life of the bearings.
j. The presence of liquid in the gas should be avoided also because it could cause high overloads
which would shorten the life of the bearings. The oil film between bearing and pin could
become so thin to disappear at all, resulting in local metal-to-metal contact.
It may happen that an examination of various parts and of the data relevant to running parameters
(see also section OPERATION, paragraph COMPRESSOR SUPERVISION) indicates the need to follow
a more adequate program. In this regard, we recommend as a minimum, to record in detail (for each
machine), the various interventions, the events which have made them necessary, the number of
hours of operation of the machine involved, any other checks that have been made on these
occasions. This will make it easy to optimize the preventive maintenance program on the basis of
operating experience. Furthermore it will be possible, at each moment, to evaluate the exact, detailed
behavior of each component of the machine.
During disassembly and assembly procedures and when performing checks, follow the instructions
contained in the paragraphs relevant to the various parts of the machine, found in the Sections
FRAME AND CRANK MECHANISM and CYLINDERS ASSEMBLIES.
NOTE
Regarding the unit's auxiliary components, refer to the relevant part of the Manual, following the
Manufacturer's instructions.
6.2.2 Safety precautions
WARNING
FOR PROCEDURES REQUIRING THE DISASSEMBLY OF ANY PART OF THE MACHINE, WE

RECOMMEND STRICT OBSERVANCE OF THE INSTRUCTIONS GIVEN IN THE GENERAL INFORMATION
SECTION, RELEVANT TO THE GENERAL SAFETY PRECAUTIONS AND IN THE SECTION MOVING,
HANDLING, STORAGE, THE PARAGRAPH SAFETY PRECAUTIONS, GENERAL INFORMATION. IN
ADDITION, WE RECOMMEND STRICT OBSERVANCE OF THE FOLLOWING SPECIFIC PRECAUTIONS,
FOR ANY TYPE OF RECIPROCATING COMPRESSOR AND SERVICE.
- Personnel assigned to operation of the unit must possess suitable capability and preparation.
Essential requirements are:
- Basic technical instruction orientation
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- Specific training in:

- reciprocating compressor theory
- structure of reciprocating compressor
- hazards in maintenance
- accident prevention
- Thorough knowledge of the contents of this Manual.

- Training and specific practice in disassembling and assembling reciprocating
compressors.
- Theoretical and practical knowledge of the various control instruments and procedures.
The absence, even partial, of these essential capabilities should be sufficient reason for
excluding any person from this activity. Consequently, personnel should be subjected to
periodic examinations to verify their aptitude.
Nuovo Pignone offers its customers the opportunity to follow suitable instruction courses, held
by specialized technicians, either at the N.P. shop or at customer‘s premises.
protection for the body. In particular, they must wear work gloves, helmet, work boots, goggles,
overalls. If it is impossible to exclude with certainty the presence of harmful or poisonous or
hazardous gases of any kind coming from the compressor or from surrounding plants,
machinery or equipment, personnel must also be equipped with breathing mask. In addition,
the advisability of equipping personnel with anti-noise ear protection should be considered.
Personnel must not approach moving parts while wearing loose clothing, personal ornaments,
or long hair. The local safety rules and those of the plant must also be complied with.
- No maintenance procedure should be carried out on the compressor while it is running. In
case of maintenance, shutdown must be performed as described in the OPERATION Section,
COMPRESSOR SHUTDOWN paragraph, relevant to SHUTDOWN FOR MAINTENANCE. If the
compressor is equipped with dual auxiliaries (e.g. pumps, coolers, filters), maintenance of these
during machine running is permitted, after having isolated the component on which
maintenance is to be performed and switched over to the standby component. In any case,
when maintenance procedures are to be carried out on crank gear oil coolers, coolers of the
cooling units, gas coolers with gas in shell, the coolant check valves shall be closed only after
having allowed the fluid to circulate for enough time to remove the heat accumulated in the
cooler. This precaution is mandatory when the check valves are of the L.O. type (locked open,
i.e., locked open with a key).
- Prior to starting any maintenance or repair work, put order and clean thoroughly all around
the machine (floor, gratings), and dry any liquid to avoid risk of slipping.
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- Prior to starting any maintenance or repair work, give maximum attention to ensuring that
the machine is completely isolated from all systems and all sources of energy (gas, coolant,
lubrication, electric and pneumatic power, steam, fuel gas, etc.). In case of more compressors
installed in the same plant, isolate all of them, or isolate the one on which work is to be carried
out.
- Whenever a machine is stopped to carry out maintenance or repair, a system must be provided
to lock the same machine in the desired position, to prevent accidental movement of any parts
during the work. Locking can be accomplished, for example, with the barring gear or, when
this is not present, by interposing wooden blocks between crosshead and crosshead
extensions, or by locking the flywheel with suitable blocks. In any case, the locking system
must ensure total safety.
- Whenever the machine is stopped for repair or maintenance, it will be necessary to ensure
that it is not accidentally started again. To prevent this possibility, it is advisable to put the
starting system in safety conditions, as well as to affix a card to the system, indicating that
starting is prohibited, due to work in progress. In case of electric motor drive, disconnect the
power supply panel and ensure that it cannot be switched on again.
- Before working on electric components, switch off the power supply and take the necessary
precautions to avoid any possibility that it will be switched on again accidentally. Before
operating the control panels, switch off also any auxiliary supplies, if any.
- No maintenance or repair work should be started in a system which is pressurized or
overheated (cylinders, piping, etc.). Proceed first of all to depressurize the system. Hollow
pistons must also be depressurized and, if the handled gas is hazardous or poisonous or
harmful, they must also be purged with inert gas (e.g. nitrogen). See also the paragraph
PISTONS-PISTON RODS in the Section CYLINDERS ASSEMBLIES.
- The walls of cylinders and accessories strictly linked to them usually have high temperature
and are dangerous to touch. With the compressor running, avoid contact with these surfaces
unless equipped with adequate protection. When the compressor has been stopped for less
than 1.5 to 0.5 hours, avoid contact with these surfaces, unless equipped with adequate
protection.
- If inert gas is used, it must be eliminated with air from all areas in which personnel will be
operating.
- When any type of maintenance or repair is to be performed on a compressor that handles
gases hazardous for their toxicity and flammability, it will be necessary to ensure that all lines
(gas, fluids, drains, vents) are cut off and that the compressor is perfectly isolated. To obtain
this it will be necessary, in addition to using the normal check valves, to detach the piping and
apply blind flanges on the inlets and outlets of gas, fluids, drains, vents. The machine will then
be purged with nitrogen, discharged in a safe zone at atmospheric pressure. Purge the
distance pieces between crankcase and cylinders, also, before opening for maintenance or
repair. Therefore, if the distance pieces are equipped with a nitrogen purging or pressurization
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system, maintain such system in operation for a reasonable time after compressor stopping
and depressurization. In any case, even after purging, breathing mask must be used. It is even
more important to use the masks if covers are to be removed or during internal inspection of
equipment.
- In the presence (or possible presence) of flammable gas (or gas forming explosive mixtures)
in the ambient, it is absolutely forbidden to use flames, welding machines, electrical tools,
miscellaneous tools (even manual) which could cause sparks during use.
- Only original spare parts shall be used. Spare parts that have not been inspected, checked
and tested by Nuovo Pignone can have physical/chemical, mechanical, dimensional features
which do not exactly comply with those required by the design. The use of such parts can
result in operating problems and damage to the mating parts, with consequences that may
be very serious.
- After having reassembled any part that has been opened it is advisable, if air which has entered
inside is incompatible with the gas or with the service, to purge with nitrogen prior to start
production.
- When work must be carried out with safety devices cut out, neutralize only one function at a
time.
- Avoid using inflammable solvent to clean machine components. If their use is deemed
indispensable, operate with maximum care, blowing with a strong stream of air the various
parts cleaned with the solvent. These procedures must be carried out in very well ventilated
rooms. In any case, when using detergents, solvents and similar substances, carefully follow
the instructions given by the manufacturer of the products, as well as the local and plant
regulations, regarding both use and disposal of said products.
- When using solvents the breathing mask shall be worn.
- The use of pressurized gas to clean parts calls for due precautions for personal protection, in
particular of the eyes.
- Avoid letting dirt or other foreign matter enter the machinery. External ports must therefore
be protected with appropriate means (paper, cloths, cardboard covers, etc.). Upon completion
of the work proceed to appropriate cleaning.
- For disassembly and assembly of the various parts, refer to the relevant drawings and look at
numbers, letters or other reference marks applied, as well as to the positions of the parts. In
the absence of reference marks on the parts, if the possibility of mixing them at reassembly
exists, mark the parts before disassembling. This procedure is recommended, in particular, for
shims.
- During disassembly and assembly of the various parts, take any possible precaution to ensure
that machined surfaces, especially moving parts and those being seal seats, undergo no
damage of any kind or extent.
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- Prior to proceeding with reassembly, check that the parts have no defects that could impair
their operation or their life.
- Remove, with fine emery paper or stone, any minor damage on surfaces to be mated.
- Check gaskets and replace those damaged.
- As far as possible, tighten bolts with the torque wrench, to the specified torque values, even
when this is not specifically stated, for the sake of brevity, in the procedures. For tightening
torque values, see the relevant paragraph in this Section.
- After any maintenance or repair and prior to start up, the machine should be turned either by
hand or with the barring gear, when present, for at least one complete revolution, to ensure
that there is no mechanical interference. Before doing this, ensure that the compressor is fully
depressurized.
- If the gas is flammable or in any case if air is in some way incompatible with the gas or with
the service, purge again after the work has been completed and before opening the gas inlet
valves, in order to prevent the formation of explosive air-gas mixtures inside the machine.
- All materials and equipment must be handled and used in full compliance with prescriptions
of their manufacturers.
WARNING
IN ADDITION TO THE PRECAUTIONS DESCRIBED ABOVE, IN CASE OF OXYGEN

COMPRESSORS, IN CONSIDERATION OF THE SPECIAL DANGER PRESENTED BY THIS
GAS, THE FOLLOWING INSTRUCTIONS ARE COMPULSORY.
- Make sure that the maintenance or repair work is performed in an absolutely clean area, free
from grease, oil and other flammable products.
- The personnel working on oxygen compressors should absolutely and in all cases avoid
touching any part with bare hands. They must use white cotton gloves, to be replaced
whenever they are contaminated by oil or grease or other combustible compound. For slight
contamination, when gloves are not replaced, they can be cleaned with non-flammable
detergents.
- All parts that have been disassembled and handled must be completely and carefully cleaned
with non-flammable solvent prior to being reassembled. If a brush is used, repeat the cleaning
procedure several times; at the end, blow abundantly with a jet of clean air, dry and absolutely
oil-free. If an adequate container and a heater are available, they can be used to generate
solvent vapour up to an adequate height above the surface of the liquid. The part to be cleaned
should be first immersed in the solvent for degreasing it and then suspended just above the
surface of the liquid, to allow the solvent vapour to condense on it so as to dissolve any residual
greasiness.
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- After the part has been cleaned, it should be handled only by personnel wearing cotton gloves,
as stated above and, if not immediately reinstalled, it should be placed in a dry, clean plastic
bag (or packed, if too big for a plastic bag) where it will remain hermetically sealed until it is
assembled.
- Prior to installing, ensure that all parts are absolutely free from oil or grease; these substances,
if present, will appear on white filter paper, rubbed on the parts.
- A film of appropriate silicone-based lubricant should be applied, on those parts which require
lubrication, using a clean stainless steel brush or similar clean tool.
- Do not touch with bare hands any part being assembled.
- The person in charge of maintenance and repair work must absolutely avoid the possibility
that any parts not perfectly clean are installed.
6.2.3 Checks and procedures to be carried out after first start-up or after complete
overhaul
The checks listed in this Table should be supplemented with the instructions shown in the OPERATION
Section, paragraphs relevant to RUNNING-IN.
6.2.3.1 After 30 to 60 hours of operation
Piston rod-crossheads locking nuts Check, and if necessary tighten again, the nuts locking the piston rods to the
crossheads. Any loosening is generally evidenced by knocking.
6.2.3.2 After 500 hours of operation
Crosshead pins Check, and if necessary tighten again, the screws fastening the
pins.
Piston-piston rod locking nuts Check that they are tightened as required in the paragraph
PISTONS - PISTON RODS, CYLINDERS ASSEMBLIES Section. This
procedure should be repeated 500 hours after replacement of
any of the parts of the assembly.
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Bolts and nuts Check, and if necessary tighten, the following:
- crosshead extensions to frame (•)
- distance pieces to crosshead extensions (•)
- cylinders to crosshead extensions or distance pieces

(•)
- connecting rod big end tie rods (••)
- stud bolts of main bearing caps (••)
- foundation bolts (•)
- cylinder supports (•).
NOTE
Checks on connections marked with an (•)

will be repeated after 4,000 hours (if con
nections are loosened thus producing
anomalous and excessive vibrations and
noises) and every 8,000/12,000 hours of
operation. Checks on connections marked
with an (••) will be repeated every
8,000/12,000 hours of operation. In case of
repeated loosening, search for the cause.
If foundation bolts loosening is observed
(relevant to frame, crosshead extensions,
cylinders, drive system), check the align
ment of main bearings, of cylinders and of
drive system.
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Non-metallic rider rings for pistons of horizontal cylin Check the wear (either directly or by the rod drop as described
ders in the PISTONS-PISTON RODS paragraph) after running-in un
der load of compressor and, subsequently, after 1,000, 2,000,
and 4,000 hours of operation
It will be observed that wear on rider rings during the first 100
to 200 hours is relatively fast, but subsequently stabilising at
lower values.
When an inspection reveals that the clearance between piston
bottom and cylinder has reduced to the minimum acceptable
value given in the PISTONS - PISTON RODS paragraph, proceed
as described therein.
We also recommend that the measurements taken should be
recorded and a diagram of wear on the rider rings should be
drawn up for the purpose of estimating the average life and
establishing a preventive program of operation to be carried
out on the basis of experience.
NOTE
It should be taken into account that the

first set of plastic rings has a shorter life
than that of the subsequent sets, insofar
as, in general, it must work with gas con
taminated by, for example, oxides coming
from the upstream apparatuses or from
products of the process coming from the
plant not yet finely set.
For cylinders without lubrication, it should
also be considered that the first set of pla
stic rings has an even shorter life than that
of subsequent sets. The first set, in fact,
works on a metallic surface that causes
relatively quick wear. The worn material is
not lost however, but adheres to the metal,
forming a plastic film on which the subse
quent sets work, with reduced wear. The
refore it is advisable, in any case, to have
available a set of spare rings, to be instal
led upon termination of the life of the first
set (see also the paragraph PISTONS - PI
STON RODS).
Non-metallic piston rings Check the radial wear and the axial clearance.
Piston rod packing with non metallic rings Check the radial wear and axial clearance of the rings.
12-2010 1003084 Page 1-141

6.2.3.3 After 1,000 hours of operation
Valves Inspect seats, springs and shutters, according to the procedure shown in the VALVES pa
ragraph of the CYLINDERS ASSEMBLIES Section. This inspection is also useful for determi
ning, in lubricated compressors, the correct oil quantity to be injected into the cylinders.
The valves should appear wet by a light film of oil.
Automatic control devices Check their correct operation and verify the absence of leakage through the seals on the
air feed side.
Crank gear lubrication Replace the lube oil completely. Clean the oil filters. Follow the instructions shown in the
LUBRICATION Section.
6.2.4 Checks and procedures to be carried out for periodic maintenance
6.2.4.1 Every 4,000 hours of operation
Bolts and nuts In case of components loosening, strong vibrations or anomalous noises, perform
the checks indicated in Table 8
Lubrication system If the analysis reveals poor quality of the lube oil, replace it. Clean the filters and
the oil sump. Follow the instructions shown in the LUBRICATION Section.
Crosshead pins Check, and tighten if necessary, the fastening screws on the pin retaining plates
(if provided).
Piston rod-crosshead locking nuts In case of components loosening, strong vibrations or anomalous noises, check
and tighten, if necessary, the nuts fastening the piston rod to crosshead.
Piston rings If compressor operation shows deterioration of the piston rings, replace the rings.
Piston rider rings Check the wear (either directly or by the rod-drop as described in the PISTONS -
PISTON RODS paragraph) whether wear on the rider rings is such to require their
replacement.
Stuffing box If compressor operation shows possible deterioration of the packing rings, replace
the rings.
Valves If equipped with metal shutter, inspect seats, springs and shutters, according to
the procedure shown in the VALVES paragraph of the CYLINDERS ASSEMBLIES
Section. This inspection is also useful for determining, in lubricated compressors,
the correct oil quantity to be injected into the cylinders. The valves should appear
wet by a light film of oil.
6.2.4.2 Every 8,000 hours of operation for non-lubr. cylinder compressors, 12,000 for
lubricated cylinder compressors
Bolts and nuts See note into Table 8 .
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Crosshead o-rings Replace them.
(hydraulic device)
Oil sump inspection Check for the presence of metal particles on the bottom. An excess
of these particles shows abnormal wear of some component (as
bearings) that must be singled out.
Bolts of valve covers, bolts of frame and distance Visual and ultrasonic inspection. In case of corrosion, replace them.
pieces, bolts of cylinder heads, bolts of packing
flange
Foundation bolts Visual and ultrasonic inspection.
Valves Replace shutters and springs. Inspect seats and counter-seats ac
cording to the procedure shown in the VALVES paragraph of the
CYLINDERS ASSEMBLIES Section
It is advisable to keep valves in stock as replacement for those that
are to be repaired, so that the compressor can be put back in service
immediately.
Automatic control devices Replace all seals and check their correct operation.
Cylinder liners Check for wear and ovalization. Refer to the instructions shown in
the CYLINDER BODIES paragraph of the CYLINDERS ASSEMBLIES
Section for checks and measurements to be made. On the basis of
these, consider the possibility of replacing the liner.
Piston rod Visual inspection and dye penetrant check on threads of both ends.
Check wear. Refer to the instructions given in the PISTONS - PISTON
RODS paragraph.
Partition covers Check the conditions of the oil scraper rings and gas seals.
NOTE
Every 8,000/12,000 hours of operation (non lu

br./lubr. compressors) it is advisable to replace
piston rings and rider rings, and piston rod pac
king seals.
6.2.4.3 Every 24,000 hours of operation
Main bearings and connecting rod bearings Visual inspection. Check wear of the bearings and the clearance. Refer
to the instructions given in the appropriate paragraph in this Section.
Cross head shoes Visual inspection. Check clearance between shoes and crosshead ex
tension. Refer to the instructions given in the appropriate paragraph in
this Section.
Crosshead pins Visual inspection.
Connecting rod small end bushes Visual inspection. Check clearance between bush and pin. Refer to the
instructions given in the appropriate paragraph in this Section.
Connecting rod small end Dye penetrant check, if the bush is removed.
Connecting rod big end bolts Visual inspection and dye penetrant check.
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Shaft Inspect for any scoring caused by dirt in the oil. Check wear on the pins
and consider the possibility of proceeding to reconditioning and the
consequent installation of smaller bearings.
Main bearings bolts Visual and ultrasonic inspection.
Counterweights Check tightening of the screws fastening the counterweights and the
retaining devices on the screws.
Piston bodies Visual and dye penetrant check. Inspect carefully the core plugs and the
surfaces mating with the rod.
Piston locking nuts Dye penetrant check. Check nut tightness, following the procedure ex
plained in the PISTONS-PISTON RODS paragraph.
Partition covers Replace oil scraper rings and gas seals.
Forged steel cylinder bodies Visual examination. Dye penetrant check.
Cooling system Clean the cylinders jackets, if cooling occurs by water in open circuit.
Bolts (studs and nuts) Verify the integrity of bolts in order to detect any corrosion, wear and
cracks, through visual check, dye penetrant check and, if required, ul
trasonic inspection.
Reuse esclusively the bolts found without any type of anomaly.
After 10 years replace completely all bolts.
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6.3 TORQUE WRENCH SETTING AND HYDRAULIC TIGHTENING PRESSURE

The torque wrench setting or the pressure for hydraulic tightening of connections of vital importance
to the machine are given in the FRAME ASSEMBLING DATA Table and in the CYLINDERS ASSEMBLING
DATA Table, or in other tables or drawings relevant to the various parts (see PART LISTS Volume of
this Manual).
The bolts for which tightening torques or hydraulic pressure are required are the following (as
applicable):
- Bolts fastening main bearing caps to crankcase
- Bolts fastening reinforcing beams to frame
- Bolts connecting crosshead extensions to crankcases
- Bolts fastening shoes to cross heads
- Bolts fastening connecting rod big end cap to body
- Bolts fastening counterweights to shaft
- Bolts fastening ballast to crosshead
- Bolts fastening crosshead extension to support
- Bolts fastening "RINGFEDER" ring for flywheels
- Connection bolts between coupling and flywheel or between coupling and adapter
- Connection bolts for oil pump side shield (if with main bearing)
- Connection of piston rod to crosshead
- Foundation bolts for crankcases
- Foundation bolts for crosshead extension support
- Bolts fastening crosshead pin
- Screws fastening torque limiter to coupling
- Screws fastening torque limiter to gear reducer
- Gauged bolts for flange-to-flange connection of compressor and motor shafts
- Bolts fastening cylinder to crosshead extension or distance piece
- Bolts fastening head to cylinder
- Bolts fastening valve covers to cylinder
- Bolts fastening packing to cylinder
- Bolts fastening distance pieces to crosshead extension
- Bolts fastening gas piping flanges
- Bolts fastening head with clearance pocket to cylinder
- Nut fastening piston rod piston
WARNING
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ENSURE THAT THE TIGHTENING EQUIPMENT (TORQUE WRENCHES, HYDRAULIC WRENCHES) HAS
TORQUE TOLERANCE WITHIN THE RANGE OF 0 TO PLUS 10%, UNLESS OTHERWISE SPECIFIED.
The screw threads and the contact surfaces of the nut or of the screw head must be clean and,
unless otherwise specified, greased with lubricants containing molybdenum disulphide MoS2 (for
ex., ROCOL, MOLIKOTE, etc.).
WARNING
FOR TIGHTENING THE BOLTS FASTENING THE FLANGE OF THE COUPLING TO THE FLYWHEEL OF
RECIPROCATING ENGINES USE THE TORQUE VALUES GIVEN IN TABLE 13 . THE FLYWHEEL WITH
COUPLING MATING SURFACES MUST BE THOROUGHLY CLEANED AND DEGREASED.
Listed in Table 14 are the tightening torque values for all of bolts and stud bolts used for connections
of secondary importance (e.g., doors, water jackets, brackets) for which no particular prescriptions
are given.
When tightening screws or stud bolts with torque wrench, consider the following:
- With the same value of torque applied, the bolt load varies, even substantially, in relation to
the degree of lubrication and the condition of the surfaces.
- When utilising a servo amplifier, take account of the reduction in torque, a part being
discharged onto the tightening devices due to the mechanics of the equipment; follow the
manufacturer's instructions.
- When tightening self-locking nuts, increase the tightening torque to the torque value
necessary to screw the nut.
Also take into account that:
- Repeated tightening of self-locking nuts produces progressive loss of self-locking capacity.
The advisability of replacing these nuts should therefore be considered.
- For fastening with split pins: if, after having tightened to the required torque value, the holes
are not aligned, turn the nut still further in the fastening direction.
TORQUE WRENCH SETTING

SCREWTHREAD
Nm
3/4" 10 - UNC 205
7/8" 9 - UNC 350
1" 8 - UNC 500
Screw threads as per ASA B1.1 Standards.
Table 13 - TORQUE WRENCH SETTING FOR BOLTS FASTENING COUPLING FLANGE TO

ENGINE FLYWHEEL
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TORQUE WRENCH SETTING TORQUE WRENCH SETTING
SCREW THREAD* SCREW THREAD*
Nm Nm
M8 12 M36 x 3 1305
M10 25 M39 1570
M12 45 M39 x 3 1670
M14 70 M42 1960
M16 110 M42 x 3 2110
M18 150 M45 2450
M20 210 M45 x 3 2650
M22 280 M48 2950
M22 x 1.5 310 M48 x 3 3240
M24 360 M52 3830
M24 x 2 400 M52 x 3 4120
M27 520 M56 4710
M27 x 2 570 M56 x 4 4910
M30 710 M60 5890
M30 x 2 790 M60 x 4 6180
M33 970 M64 7070
M33 x 3 1060 M64 x 4 7560
M36 1230
* Screw threads as per ISO Standards, origin UNI 4535-64.
Table 14 - TORQUE WRENCH SETTING
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6.4 CLEARANCES, WEAR, OVALIZATION
6.4.1 Shaft and crank gear

The FRAME ASSEMBLING DATA Table, included in the PART LISTS Volume of the Manual, supplies the
values of the clearances between the various components of the frame.
The assembly drawings of the various parts, showing the positions of the clearances listed in the
Table, are included in the above mentioned volume of the Manual.
6.4.2 Cylinders
The maximum values for wear and ovalization of the cylinder bore may be found in the paragraph
entitled CYLINDER BODIES, in the CYLINDERS ASSEMBLIES Section. For the various clearance values,
see the CYLINDERS ASSEMBLING DATA Table, included in the above mentioned PART LISTS Volume.
This volume includes also the assembly drawings of the various parts, showing the positions of the
clearances listed in the Table.
6.4.3 Piston rods

The maximum wear values are shown in the PISTONS-PISTON RODS paragraph in the CYLINDERS
ASSEMBLIES Section.
6.4.4 Miscellaneous
See, in the PART LISTS volume, the assembly drawings relevant to:
- Cylinder stuffing boxes
- Intermediate stuffing boxes
- Partition covers
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7 - FRAME AND CRANKGEAR
1 SAFETY PRECAUTIONS - GENERAL INFORMATION ..........................................................................151 1-151

2 FRAME ..................................................................................................................................................................153 1-153
2.2 Balancing reciprocating masses ...........................................................................................................153 1-153
2.3 Assembling the reinforcing beams .......................................................................................................154 1-154
3 SHAFT AND MAIN BEARINGS .....................................................................................................................155 1-155
3.1 Shaft ....................................................................................................................................................................155 1-155
3.1.1 General information ....................................................................................................................................155 1-155
3.1.2 Disassembly and reassembly .................................................................................................................155 1-155
3.2 Main bearings .................................................................................................................................................155 1-155
3.2.2 Clearance check ............................................................................................................................................155 1-155
3.2.3 Replacement ...................................................................................................................................................156 1-156
3.3 Shaft axial positioning ................................................................................................................................157 1-157
4 CONNECTING ROD AND BEARINGS ........................................................................................................160 1-160
4.2 Connecting rod ..............................................................................................................................................160 1-160
4.2.1 Disassembly ....................................................................................................................................................160 1-160
4.2.2 Assembly ...........................................................................................................................................................160 1-160
4.3 Big end bearing .............................................................................................................................................161 1-161
4.3.1 Clearance check ............................................................................................................................................161 1-161
4.3.2 Replacement ...................................................................................................................................................162 1-162
4.4 Small end bush ..............................................................................................................................................162 1-162
4.4.1 Clearance check ............................................................................................................................................162 1-162
4.4.2 Replacement ...................................................................................................................................................162 1-162
5 CROSSHEAD ......................................................................................................................................................166 1-166
5.2 Disassembly ....................................................................................................................................................166 1-166
5.3 Assembly ...........................................................................................................................................................166 1-166
5.4 Shoes ..................................................................................................................................................................166 1-166
5.5 Rod crosshead connection ......................................................................................................................167 1-167
5.5.1 Assembly ...........................................................................................................................................................167 1-167
5.5.2 Disassembly ....................................................................................................................................................168 1-168
6 PARTITION COVER ..........................................................................................................................................174 1-174
6.2 Maintenance ...................................................................................................................................................174 1-174
6.2.1 Disassembly ....................................................................................................................................................174 1-174
6.2.2 Assembly ...........................................................................................................................................................174 1-174
7 INTERMEDIATE PARTITION PACKING .....................................................................................................175 1-175
7.2 Maintenance ...................................................................................................................................................175 1-175
7.2.1 Disassembly ....................................................................................................................................................175 1-175
7.2.2 Assembly ...........................................................................................................................................................175 1-175
8 BARRING GEAR ................................................................................................................................................177 1-177
9 FLYWHEEL .........................................................................................................................................................179 1-179
9.2 Flanged shaft end, coupled connection .............................................................................................179 1-179
9.2.1 Disassembly ....................................................................................................................................................179 1-179
9.2.2 Assembly ...........................................................................................................................................................179 1-179
9.3 Flanged shaft end, coupling with single journal driver ...............................................................179 1-179
9.4 Parallel shaft end ..........................................................................................................................................180 1-180
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9.4.1 Disassembly ....................................................................................................................................................180 1-180
9.4.2 Assembly ...........................................................................................................................................................180 1-180
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7.1 SAFETY PRECAUTIONS - GENERAL INFORMATION

This Section of the Manual is intended for the personnel in charge of maintenance and repair work
on the machine.
For more convenient consultation, this material has been divided into two Sections. This Section
regards the FRAME AND CRANK GEAR parts and contains, besides a brief description, the
recommended procedures for disassembling, checking, restoring or replacing and installing the
various components of this part of the compressor; another Section of the Manual describes
CYLINDERS ASSEMBLIES.
NOTE
For disassembly and reassembly of the various components of the frame, special shop
equipment may be required, in addition to the usual tools. Refer to the appropriate Section in
the PART LISTS Volume of the Manual. Both the use of such equipment and its identification such
as lists, code numbers, possible assembly drawings, are shown in this Section.
Personnel are often limited in various ways, in working, by what is available on the jobsite. For this
reason too, the recommended procedures normally indicate the general lines of the work to be
carried out, without going into more detailed descriptions that might be useless and that would, in
any case, make the Manual less concise.
NOTE
A data plate containing information for identification as well as some pertinent technical data
is fastened to the frame.
WARNING
WHEN PERFORMING MAINTENANCE PROCEDURES ON THE MACHINE, KEEP WELL IN MIND THE
SPECIAL WARNINGS HIGHLIGHTED IN THE VARIOUS PARAGRAPHS OF THIS SECTION, THOSE
SHOWN IN THE PARAGRAPH ENTITLED SAFETY PRECAUTIONS- MAINTENANCE PROGRAM IN THE
MAINTENANCE SECTION, AND THE RULES SHOWN IN THE GENERAL INFORMATION SECTION,
RELEVANT TO THE GENERAL SAFETY PRECAUTIONS.
When disassembling parts, check them carefully. If defects are observed, either repair or replace
these parts. Any scratching, scoring, etc. on mating surfaces will be eliminated with fine emery cloth,
fine stone, etc. Protect unpainted disassembled parts with a light film of lube oil.
1003084
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WARNING
DURING MAINTENANCE PROCEDURES, UPON REASSEMBLY, CHECK THE CONDITIONS OF ANY

GASKETS AND REPLACE ANY OF THEM NOT IN PERFECT STATE. IF PARTS OF GASKETS SHOULD
REMAIN STUCK TO THE SURFACES, DO NOT USE A CHISEL TO REMOVE THEM, AS THIS COULD
DAMAGE THE METAL. OPERATE BY INSERTING A WIDE, FLAT WEDGE AND, STARTING FROM THIS
POINT, CAREFULLY SLIDE A BLADE BETWEEN GASKET AND SURFACE.
NOTE
Deformation caused by tightening or by thermal expansion can result in defective seal between
metal surfaces without interposed gaskets. To compensate these defects, special sealant pastes
are successfully used. For this reason, when carrying out disassembly procedures on the various
parts of the frame, check for the film made by these pastes, remove it and then restore it during
reassembly. Regarding this procedure, refer to the detailed description in the CYLINDERS
ASSEMBLIES Section, SAFETY PRECAUTIONS - GENERAL INFORMATION paragraph. Should it be
difficult to find these pastes on the market, paper gaskets prepared on site can be used instead.
WARNING
IF EVENTS CAUSING CONTAMINATION BY ABRASIVE SOLID PARTICLES SHOULD OCCUR (FOR

EXAMPLE WEAR OF BEARINGS), ONCE THE DAMAGE AND ITS CAUSES HAVE BEEN REMOVED AND
BEFORE STARTING THE MACHINE AGAIN, PERFORM THOROUGH CLEANING OF THE SYSTEM AND
OF THE ENTIRE FRAME, TO AVOID POSSIBLE FURTHER DAMAGE (SEE OPERATION SECTION,
PARAGRAPH RELEVANT TO CLEANING SYSTEMS).
WARNING
WHEN WORK REQUIRING OPENING OF THE FRAME IS CARRIED OUT, TAKE ALL PRECAUTIONS TO
ENSURE THAT NO DIRT ENTERS THE FRAME. ALL OPENINGS MUST BE APPROPRIATELY PROTECTED
(COVERS MADE WITH WOOD, CARDBOARD, CLOTH, ETC.). IN ANY CASE, CLEAN CAREFULLY UNLESS
ABSOLUTELY CERTAIN THAT NO DIRT HAS PENETRATED INSIDE THE MACHINES.
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7.2 FRAME

The frame is provided with transverse partition that contain the housings for the main bearings.
The two side walls of the frame are connected, at the top, by reinforcing beams fastened to them
by means of tie rods or stud bolts.
When no main oil pump with its own driver is provided for lubrication of the crank gear, the main oil
pump is housed on the shield mounted on the side opposite the compressor driver, and is driven by
the compressor shaft (see LUBRICATION Section).
The oil is distributed to the various points to lubricate both through a header and through a duct
inside the shaft. In some cases distribution is integrated by an appropriate header.
The oil collects at the bottom of the frame, which thus serves also as oil sump. A glass peephole
allows checking the level.
A cock, located at the lowest point of the frame, is used for oil draining when the oil is to be changed.
WARNING
SINCE IMPURITIES (WATER, SOLID PARTICLES, ETC.) MAY REMAIN TRAPPED INSIDE THE PIPING ON
WHICH THIS COCK IS LOCATED, IT IS ADVISABLE NOT TO USE THE DRAIN COCK FOR FILLING OIL,
IN ORDER TO PREVENT THEM FROM ENTERING INTO THE SYSTEM. FOR THIS PURPOSE A HOLE
WITH CAP IS PROVIDED ON THE FRAME COVER OR ON A SIDE COVER.
A vent-filter permitting ventilation of the oil sump is generally applied on the same frame cover (or
on a side cover). For special services or environmental conditions, alternative solutions may be
chosen. Oil leakage out of the frame and entrance from the outside through the passage of the
crankshaft are prevented by a seal ring inserted between shaft and frame and by an oil slinger
integral with the shaft.
7.2.2 Balancing reciprocating masses

For special installations, the compressor can be subjected to a careful balancing of reciprocating
masses, to reduce the dynamic loads transmitted to the supporting base to particularly low values.
The dynamic loads can be substantially modified by variations in weight of the following parts:
- pistons;
- piston rods;
- ballasts, if any;
- crossheads;
- connecting rods.
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The weight of the above-mentioned parts is determined by the summation of the weights of all their
components.
WARNING
IF THE COMPRESSOR HAS BEEN SUBJECTED TO BALANCING, THE ORIGINAL WEIGHTS OF THESE
PARTS, IN THE COMPRESSOR SHIPPING CONDITIONS, SUBDIVIDED ACCORDING TO "LINES", ARE
FOUND IN THE INSPECTION CARD INCLUDED IN THE QUALITY DATA BOOK. WHEN ONE OR MORE
PARTS OF A «LINE» REQUIRE REPLACEMENT, IT MUST BE ENSURED THAT, AFTER REPLACEMENT,
BALANCING IS NOT ALTERED. A TOLERANCE ON THE TOTAL WEIGHT OF THE MASSES OF THE
VARIOUS «LINES» NOT EXCEEDING THE VALUE GIVEN IN THIS CARD IS ACCEPTABLE.
7.2.3 Assembling the reinforcing beams

Assembly shall be carried out using the torque wrench. The torque tightening value is given in the
FRAME ASSEMBLING DATA Table included in the PART LISTS Volume of the Manual.
In carrying out this procedure, follow the numerical order (1-2-3) shown in Figure 28 a) and b).
Figure 28
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7.3 SHAFT AND MAIN BEARINGS
7.3.1 Shaft
7.3.1.1 General information
The crankshaft is built in a single piece. Holes for the passage and distribution of the lube oilre made
inside the shaft. For good lubrication, the holes must be clear and clean.
7.3.1.2 Disassembly and reassembly
The procedure for disassembling the shaft is the following.

- Disconnect the shaft from the drive components and remove the flywheel, if any.
- DIsconnect and remove the connecting rods.
- Disassemble the reinforcing beams (if any).
- Disassemble the main bearing caps.
- Support and lift the shaft with an appropriate lifting system, operating with due care.
- For reassembling, proceed in reverse order
WARNING
IF, WHEN DISASSEMBLING THE SHAFT, THE SURFACES OF THE MAIN JOURNAL OR OF THE CRANK
PIN SHOULD BE DAMAGED, IT WILL BE NECESSARY TO REPAIR THESE SURFACES. IF, AFTER REPAIR,
THE CLEARANCE BETWEEN PIN AND NEW BEARING EXCEEDS THE MAXIMUM VALUE GIVEN IN THE
FRAME ASSEMBLING DATA TABLE (SEE PART LISTS VOLUME OF THIS MANUAL), IT WILL BE
ADVISABLE TO CONTACT THE NUOVO PIGNONE ENGINEERING DEPARTMENT.
7.3.2 Main bearings
The main bearings are built in two halves made of steel, with inner lining made of anti friction metal.
The bearings are installed without adjustment of any kind.
7.3.2.2 Clearance check
During shaft disassembly, this measurement will be made simply using a micrometer gauge. For this
purpose, the bearings must be reassembled and the relevant cap bolts tightened to the torque shown
in the above mentioned FRAME ASSEMBLING DATA Table. Then the measurement shall be taken on
the inner diameter of each bearing and on the corresponding main journal.
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The following procedure ensures reliable measurement of clearance and does not require shaft
disassembly.
a. Remove the frame cover.
b. Remove the reinforcing beams, if any on the bearing.
c. Remove the main bearing cap.
d. Referring to Figure 29 , locate the fixture A in the cap housing.
e. Rotate the shaft until a lubrication hole of the shaft coincides with the hole drilled in the fixture.
f. Insert the pin B (step1).
g. Ensure that the pin is free to rotate inside the bearing seat.
h. Rotate the shaft until the cut of the bearing, fixture side, is 2 to 3 mm lower than the horizontal
plane of the bearing cap seat; in this way, one of the half bearings will be removed.
i. Remove the fixture. Place a thin lead wire on the shaft, at the middle of the highest part, and
reassemble the main bearing cap with the half bearing previously removed. Then tighten the
nuts on the stud bolts to the torque value specified in the FRAME ASSEMBLING DATA Table.
j. With a thin probe, make sure that there is contact between bearing support and cap and
between the two half bearings.
k. Disassemble the cap again and measure the thickness of the lead wire. Its thickness
represents the clearance between shaft and bearing. If the clearance measured is greater
than the one specified in the above mentioned Table, it will be necessary to replace the bearing
(see following paragraph REPLACEMENT). Otherwise, repeat steps a through h in reverse
order to reassemble the bearing in its previous position.
l. Tighten the stud bolts, fastening the cap to the torque values shown in the above mentioned
Table.
WARNING
WHEN REASSEMBLING THE BEARING CAPS, MAKE SURE THAT THE HOLES FOR INSERTING THE
THERMOCOUPLES ARE ON THE MAIN DRIVER SIDE AND ENSURE THAT THE REFERENCE MARK
STAMPED ON THEM COINCIDES WITH THE SAME MARK STAMPED ON THE FRAME (SEE FIGURE 30 ).
7.3.2.3 Replacement
WARNING
IF THE CLEARANCE BETWEEN MAIN JOURNALS AND NEW BEARINGS IS GREATER THAN OR VERY
CLOSE TO THE MAXIMUM VALUE SHOWN IN THE ABOVE MENTIONED TABLE, NUOVO PIGNONE
CAN SUPPLY BEARINGS WITH AN APPROPRIATELY SMALLER INSIDE DIAMETER. CONSULT NUOVO
PIGNONE ENGINEERING DEPARTMENT BEFORE ORDERING THE NEW BEARINGS.
12-2010 1003084 Page 1-156

Referring to Figure 29 , proceed as follows for replacing the bearing:

- Carry out steps a through h of the preceding paragraph CLEARANCE CHECK.
- Remove the fixture and the upper half bearing (Step 2).
- Position again the fixture and the first new half bearing D (Step3).
- Rotate the shaft by 180° looking that the bearing cut, fixture side, is 2 to 3 mm lower than the
horizontal plane of the bearing cap seat.
- Remove the fixture, the other worn half bearing and the pin (Step 4).
- Position the other new half bearing, the pin and the fixture (Step 5).
- Rotate the shaft to bring the cuts of the bearing onto a vertical plane. With the bearing in this
position, the pin should be positioned in coincidence with the slanting hole of the fixture.
- Pull the pin out ((Step 6).
- After having checked the correct axial position of the bearing, remove the fixture, assemble
the cap and tighten the tie rods to the torque value shown in the above mentioned table
WARNING
WHEN REASSEMBLING THE BEARING CAPS, MAKE SURE THAT THE HOLES FOR INSERTING THE
THERMOCOUPLES ARE ON THE MAIN DRIVER SIDE AND ENSURE THAT THE REFERENCE MARK
STAMPED ON THEM COINCIDES WITH THE SAME MARK STAMPED ON THE FRAME (SEE FIGURE 30 ).
7.3.3 Shaft axial positioning

Two shoulder half rings are interposed at the end of the first bearing (driver side). The clearance
between half rings and shaft allows for small axial displacements of the shaft. When it is observed
that the clearance does not comply with the values specified in the above mentioned Table, it will
be necessary to replace one or both shoulder half rings.
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Figure 29
LEGEND
A FIXTURE
B PIN
C FRAME
D NEW HALF BEARING
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Figure 30
LEGEND
A BEARING CAP REFERENCE

B FRAME REFERENCE
C HOLE FOR THERMOCOUPLE ASSEMBLY LOCATED ON DRIVER SIDE
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7.4 CONNECTING ROD AND BEARINGS

The connecting rod big end bearing is built in two halves; it is made of steel with inner lining of anti
friction metal. The bearing is installed without shims and without adjustment of any kind.
The connecting rod small end bearing, or small end bush, is made of steel, with inner coating of anti
friction metal.
A hole runs through the connecting rod body for its entire length, to allow lube oil passage from the
big end bearing to the small end bush.
For good lubrication, the hole must be clear and clean.
7.4.2 Connecting rod

During connecting rod assembly and disassembly, protect the sliding surfaces of the crosshead
extensions using thick sheets of rubber or equivalent material, to avoid impact and consequent
damage. Similarly, if these procedures are carried out with the shaft assembled, protect the shaft's
crank pin as well.
7.4.2.1 Disassembly
To disassemble the connecting rod, after having removed the crankcase cover and the covers of
the crosshead extensions, proceed as follows.
- Rotate the shaft to bring the big end to the top and arrange wooden stops to prevent the
crosshead from moving in any way.
- Unscrew the nuts from the connecting rod big end tie rods and remove the cap with the half
bearing.
- Sling the connecting rod in its body and, after having removed the wooden stops, slowly rotate
the shaft to the outer dead centre.
- Remove the crosshead pin, through the procedure described in the CROSSHEAD Chapter.
- Rotate the shaft again to the inner dead centre. Remove the connecting rod big end tie rods.
- Pull the connecting rod out of the crankcase, orienting it during lifting in such a way as to avoid
impacts. It is advisable to protect the crank pins with thick sheets of rubber or other suitable
material.
7.4.2.2 Assembly
For reassembling, carry out the above procedure in reverse order. Take into consideration marks on
connecting rod body and cap. Tighten the nuts to the torque value specified in the FRAME
ASSEMBLING DATA Table, included in the PART LISTS Volume of the Manual.
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7.4.3 Big end bearing
If unusual noise is heard coming from inside the frame, indicating the possibility of excessive wear
on the connecting rod big end bearings, it will be necessary to check their clearance.
The clearance between big end bearing and crank pin is obtained as the difference between the
diameter of the bearing installed in the connecting rod big end (after the nuts locking the cap have
been tightened to the required torque value) and the diameter of the relevant crank pin. These two
diameters shall be measured using a micrometer gauge (for outside and inside) at three points and
two planes as a minimum.
This reliable and precise method has the disadvantage that the connecting rod must be
disassembled each time such measurement is required. To avoid this, measurement may be made
using probes, if allowed by the arrangement of the crank shaft inside the frame and by the shape
of the connecting rod big end in respect to the shaft.
This method of measurement, while certainly not as precise as the one above, can however be used
in many cases as a check for obtaining values that are generally reliable and that can be used for
deciding, on the basis of this and other parameters, what kind of maintenance shall be performed.
To obtain results that are as reliable as possible using this method, the following procedure is
recommended:
a. Rotate the compressor shaft to position the connecting rod at the lowest point of the turn. In
this position, due to its weight, the clearance coincides with the lower part of the connecting
rod big end.
b. If it is impossible, with this positioning, to insert a feeler gauge to measure this clearance, it
will be necessary to position the connecting rod at the top of the turn. To maintain this position
avoiding any possible shifting, insert stops (e.g. wooden blocks) between crosshead and
crosshead extension. Then force the shaft, so that the contact between connecting rod and
pin takes place on the shaft side half bearing; thus the clearance is entirely on the cap side
half bearing, where it can be measured more easily.
c. Operating either in position a or in position b , insert the gauge alternating from one side to
the other of the connecting rod big end to find the maximum value. Add 0.02 mm to this
measured value to obtain a truer clearance value. Use a feeler gauge of the long and rather
narrow type to avoid false measurement deriving from the camber of the two surfaces
(bearing-crank pin).
If the clearance is greater than the one specified in the FRAME ASSEMBLING DATA Table, replace the
bearing.
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WARNING
IF THE CLEARANCE BETWEEN CRANK PIN AND NEW BEARING IS GREATER THAN OR VERY CLOSE
TO THE MAXIMUM VALUE SHOWN IN THE ABOVE MENTIONED TABLE, NUOVO PIGNONE CAN
SUPPLY A BEARING WITH AN APPROPRIATELY SMALLER INSIDE DIAMETER. CONSULT NUOVO
PIGNONE ENGINEERING DEPARTMENT PRIOR TO ORDERING NEW BEARINGS.
7.4.3.2 Replacement
- Position the connecting rod big end at the top in the turn.
- Sling the connecting rod in its body.
- Remove the big end cap with its half bearing.
- Move the connecting rod big end away from the crank pin, bringing the crosshead to the outer
dead centre.
- Disassemble the second half bearing.
- Move the connecting rod to a suitable position for reassembling the cap.
- Insert the big end's new half bearing.
- Approach the connecting rod big end to the crank pin again.
- Assemble the cap with the new half bearing, tightening the nuts to the torque value specified
in the above mentioned Table; pay attention to the match marks on cap and connecting rod
body.
7.4.4 Small end bush
Using a feeler gauge, measure the total side clearance between the connecting rod small end bush
and the crosshead.
To check the clearance between the small end bush and the crosshead pin, it is necessary to pull
out the pin from the crosshead and measure the diameter of the bush and of the pin (see CROSSHEAD
Chapter).
If one or both clearances are not within the limits specified in the above mentioned Table, it is
necessary to replace the bush.
7.4.4.2 Replacement
WARNING
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IT IS STRONGLY RECOMMENDED NOT TO USE A PRESS AND PUNCH FOR REMOVING THE BUSH
TO BE REPLACED. THIS SYSTEM COULD EASILY CAUSE SEIZING, THUS CAUSING CRACKS ON THE
INNER SURFACE OF THE CONNECTING ROD SMALL END.
The following procedure is recommended.

- Operate with a milling machine at the point indicated in Figure 31 .
- Mill down until close to the seat, i.e. until the bush detaches by itself.
NOTE
After bush disassembly, it is advisable to inspect the surface of the bush seat, so as to identify
any possible fretting which could occur as a consequence of accidental overload. Inspection
should be performed visually and with dye penetrant (or magnetic particles).
- If the surface of the seat has not been damaged in any way, install a standard spare bush.
Otherwise:
- rebore the above mentioned surface, to obtain perfect roundness with a degree of surface
finish not exceeding 1.6 m. Then check the parallelism between the axes of the seat and
connecting rod big end bearing. Any defect in parallelism should not exceed 0.4 mm per metre.
- Accurately measure the diameter of the seat and transmit this information to the NUOVO
PIGNONE "Spare Parts Service" Division, which will arrange to send a bush with suitably
increased outside diameter. If NUOVO PIGNONE sends a bush with outside diameter to be
finished at assembly, see in Figure 32 the sketch of the recommended equipment for correct
machining of the outside surface to the required diameter.
We recommend to assemble the bush after cooling it in liquid nitrogen. Immersion should continue
until the liquid in contact with the bush has stopped boiling.
The installation of the bush in its seat should be carried out as quickly as possible
WARNING
AVOID ANY CONTACT WITH LIQUID NITROGEN. OPERATE IN A WELL VENTILATED AREA TO AVOID
RESPIRATORY DIFFICULTIES OR ASPHYXIA.
In case of problems in obtaining liquid nitrogen, the connecting rod bush can be heated by immersion
in oil having appropriate properties, at a temperature of 150°C, but this way is less practical than
the previous one.
WARNING
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IF THE BUSH LENGTH IS GREATER THAN THE THICKNESS OF THE CONNECTING ROD SMALL END,
PLACE THE CONNECTING ROD ON APPROPRIATE SHIMS SO THAT, WHEN INSERTED, THE TWO
ENDS OF THE BUSH PROJECT FROM BOTH SIDES BY THE SAME AMOUNT.
After the bush has been assembled, check the clearance, as shown above, and check parallelism
between the connecting rod small end bush axis and the big end bearing axis. Any deviation from
parallelism should not exceed 0.4 mm per metre.
Figure 31
LEGEND
A MILLING CUTTER POSITION
12-2010 1003084 Page 1-164

Figure 32
LEGEND
A BUSH
B TAPER PIN
C FLEXIBLE SLEEVE
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7.5 CROSSHEAD

The body is obtained from a steel cast.
The shoes, replaceable type, are coated with antifriction metal; they feature special grooves for lube
oil distribution.
Pressurized oil reaches the upper and lower shoe surfaces through the holes both in the pin
connecting the crosshead to the connecting rod, and in the crosshead body and shoes.
The pin is kept in its seat by 4 tie rods connecting it to a flange, on which the piston rod is hydraulically
tightened.
The adjustment of clearances between piston and cylinder bottoms is performed by machining a
spacer ring at assembly (see Paragraph 5.5 ).
7.5.2 Disassembly
- Remove the slide body doors and take the crank to forward dead centre.
- Release the cylinder bottom and slide the partition cover towards the cylinder, disassembling
any pipes inside the extension that could hinder the cover movement.
- Remove any ballast by extracting it laterally.
- Loosen the nuts of the 4 rod-carrying flange tie rods, and at the same time gradually move
the crosshead towards the aft dead centre until it is released from the flange/rod/piston
assembly, which will be moved towards forward dead centre.
- Unscrew and remove the 4 tie rods from the pin.
- Extract the pin and move away the connecting rod.
- Rotate the crosshead by 90° and extract it from the slide body.
7.5.3 Assembly
For the assembly, perform the operations for disassembly in reverse order.
Tighten the 4 tie rods by means of a torque wrench, to the torque prescribed in Table FRAME
ASSEMBLY DATA belonging to the DETAILS LIST.
7.5.4 Shoes
When the crosshead shoe anti-friction metal is so worn that the clearance between the shoes and
the corresponding slides is greater than the maximum permissible (see above table), it is possible to
restore the clearance in the following ways:
- If the anti-friction metal wear is not excessive, and the shoe can still be used, it is possible to
restore the proper clearance by shimming the shoe.
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CAUTION
The shoe surfaces must be parallel and concentric: the adjustment, therefore, is to
be carried out by a qualified person.
- If the anti-friction metal wear is such as not to allow shoe shimming, it shall be necessary to
replace the shoe with a spare one.
Tighten connecting bolts by means of a torque wrench to the torque prescribed in the above
mentioned table.
After reassembly, check again the clearance between crosshead shoes and guides.
7.5.5 Rod crosshead connection
CAUTION
For safety reasons, personnel must not stand in front of the jack.
7.5.5.1 Assembly
If at assembly the piston/rod/spacer ring/flange/crosshead assembly does not feature new details,
start assembly operations from point h .
a. Machine conic coupling surfaces between spacer ring A (see Figure 33 ) and rod B using the
proper equipment (see DETAILS LIST). Work the surfaces, keeping the rod vertical, until 100%
surface contact is obtained.
b. Insert the rod/piston/spacer ring assembly into the rod carrying flange and manually position
nut C.
c. Mount the flange/rod/piston assembly on the crosshead, manually positioning nuts D on tie
rods E.
d. Measure the clearances between piston and cylinder bottoms at the two ends of stroke and
determine the axial thickness of material to be removed from the spacer ring to obtain the
required values (see the CYLINDER ASSEMBLY DATA TABLE, belonging to the DETAILS LIST).
e. Disassemble the assembly from the crosshead.
f. Machine the spacer ring according to the instructions of drawing Figure 36 , removing the
thickness determined at point a .
g. Verify the contact on 100% of conic surfaces using the equipment mentioned at point a .
h. Insert the rod/piston/spacer ring assembly into the flange.
i. If the cylinder bottom is not mounted, check that reference TOP on the piston is as in Figure
34 . If the cylinder bottom is mounted, check that reference TOP on the rod is as in Figure 35 .
j. Position nut C to the rabbet.
k. Position lock nut C to the rabbet.
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l. Mount cage A (see Figure 37 ), screw the hydraulic device on the rod until it butts against the
cage, checking that planes P1 and P2 are at the same level; if not, drain the oil from pipe union
B, pressing the drain valve and screwing the device piston.
m. Ensure that pressure gauge D is correctly calibrated.
n. Ensure that there are no air bubbles inside the pump (see pump instructions for use supplied
with the pump).
o. Screw the hose end to the device pipe union.
p. Screw to the rabbet knob G of pump F.
q. Pressurize the device pumping until the pressure indicated in the FRAME ASSEMBLY DATA
TABLE is shown on the pressure gauge.
r. If instability in the pressure gauge shows presence of air, empty the system by unscrewing
the knob, then pressurize again after having retightened the knob.
s. Screw lock nut C with a rod through the cage windows.
t. Unscrew knob G to depressurize.
u. Repeat operations from p to s two more times.
v. Screw the device piston to the rabbet to drain the oil contained in it.
w. Release the hose end and unscrew the device.
x. mount the piston/rod/ring/flange assembly on the crosshead and tighten tie rods E by means
of a torque wrench to the values indicated in the above Table.
y. Check again the clearance values between piston and cylinder bottoms at the end of stroke;
if necessary, repeat operations from point d .
7.5.5.2 Disassembly
- Repeat all the operations described for assembly, bearing in mind that to unscrew lock nut
C’ it is necessary to pump up to a pressure about 50 bar higher that the one prescribed for
assembly; avoid higher pressures so as not to overload tightened parts.
NOTE
After releasing the crosshead from the piston rod, and before retightening, it is advisable to check
the efficiency of the device seal rings, and to replace them if necessary.
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Figure 33 -
LEGEND
A SPACER RING
B ROD
C ROD FASTENING NUT
C' LOCK NUT
D FLANGE FASTENING NUT
E TIE ROD
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Figure 34 -
LEGEND
F PISTON
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Figure 35 -
LEGEND
A SPACER RING
B ROD
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Figure 36
LEGEND
A BEVEL = 0.5MM
B REMOVE MATERIAL ON THIS SIDE
C BEVEL = 1.0MM
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Figure 37
LEGEND
A CAGE
B PIPE UNION
C' LOCK NUT
C NUT
D PRESSURE GAUGE
E PISTON ROD
F PUMP
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7.6 PARTITION COVER

The partition cover, located at the end of the crosshead extension, prevents the oil to be carried out
of the frame by the piston rod. This action is performed by a number of scraper rings housed in the
cover. Anyhow, some oil may leak out and must be removed through suitable drains located in the
space between crosshead extension and cylinder.
The partition cover can also house seal rings which prevent the gas that leaks through the stuffing
box from entering the frame.
The assembly drawing of the partition cover installed on the compressor is included in the PART
LISTS Volume of this Manual.
7.6.2 Maintenance
If an excess of oil should be observed on the piston rod, such as to show abnormal wear of the
scraper rings or their jamming in the housing, it is necessary to check the rings immediately and to
replace them if required.
7.6.2.1 Disassembly
The scraper rings can be checked or replaced, by skilled personnel, without detaching the piston rod
from the crosshead (the procedure is carried out through the openings on the crosshead extension).
Proceed as follows:
- Unscrew the nuts on the flange of the scraper rings housing.
- By sliding on the rod, remove the flange, the scraper rings, the seal rings (if any) and the cups.
- Detach the garter springs that hold the ring segments together and then remove them.
7.6.2.2 Assembly
a. Clean the rings and the cups with solvent.

b. Reassemble the first cup with the relevant ring and then the next box, following the order
specified on the assembly drawing. Make sure that the scraper ring lip is positioned toward
the crosshead.
c. Check that the dowels freely engage within their housings.
d. Make sure that the oil drain holes are positioned downward.
e. Check that the clearance between ring and cup is within the limits specified in the assembly
drawing.
f. Repeat procedures b through e for the other boxes and relevant rings.
g. Reassemble the flange and tighten the nuts with a torque wrench to the required torque value
(see MAINTENANCE Section).
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7.7 INTERMEDIATE PARTITION PACKING

For special requirements, an additional separation chamber may be interposed between cylinder
and frame. This distance piece is equipped with packing that prevents the gas that may leak through
the stuffing box from reaching the frame.
The assembly drawing of the intermediate packing, if installed on the compressor, is included in the
PART LISTS Volume of this Manual.
7.7.2 Maintenance
Any abnormal gas leakage through the packing is to be attributed to excessive wear of seal rings
or to poor surface conditions of the piston rod.
In the first case, it is necessary to install new rings. In the second case, which is much less frequent,
it is necessary to grind the piston rod (if its features permits) and to use undersized rings, if necessary.
Note that it will never be possible to obtain adequate seal of the packing if the piston rod is not
perfectly finished or if it presents defects of roundness or taper (see CYLINDERS ASSEMBLIES Section,
PISTONS - PISTON RODS paragraph).
7.7.2.1 Disassembly
The disassembling procedures are carried out through the openings on the distance piece, without
disconnecting the piston rod from the crosshead.
- Unscrew the nuts on the stud bolts fastening the packing flange.
- Remove the piston rod packing from its housing, pulling it by the flange, until being in front of
the distance piece openings.
- Unscrew the nuts on the tie rods of the packing.
- Pull the flange out of the tie rods and move it along the rod.
- Pull out the first packing cup from the tie rods and disassemble the packing rings, detaching
the garter spring that hold them together.
- After having removed the rings, move the cup away and repeat for the other cups of the
packing.
7.7.2.2 Assembly
To assemble the packing, carry out the steps described for disassembly in reverse order.
WARNING
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LOOK CAREFULLY AT THE ASSEMBLY DRAWING OF THE PACKING, BOTH AS REGARDS THE
POSITION OF THE RINGS INSIDE OF THE CUPS AND AS REGARDS THE POSITION OF THE CUPS IN
THE PACKING.
Prior to reassemble, check that the clearances between the various parts of the assembly are within
the limits specified in the assembly drawing. Tighten the nuts with a torque wrench, to the required
torque value (see MAINTENANCE Section).
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7.8 BARRING GEAR

A compressor may be equipped with a special device, called BARRING GEAR, to be used for actuating
slow rotations of the shaft.
If the compressor subject of this Manual is equipped with this device, the relevant FUNCTIONAL P&I
DIAGRAM will be found in the REFERENCE DRAWINGS Volume of the Manual.
The barring gear (basically a piston mechanism) can be actuated either by air or by oil. In the former
case, the barring gear sketch is shown in Figure 38 .
Standard design provides for a barring with cylinders of the compressor at atmospheric pressure;
consequently prior to start the barring ensure that the compressor is fully depressurized.
Barring of the unit when cylinders are pressurized is allowed only if clearly stated in the relevant
FUNCTIONAL P&I DIAGRAM In this instance pay attention to the following safety instruction.
WARNING
WHEN BARRING THE PRESSURIZED COMPRESSOR, CHECK THE COMPRESSOR SELF ROTATION
EACH HALF SHAFT REVOLUTION.
To rotate the compressor shaft, proceed as follows:

- Through bar A, move the barring gear cylinder until wedge B engages with the flywheel
- Open the air check valve C.
- To actuate the barring gear, operate the four-way valve D, moving it alternatively forward and
backward so as to move the device's piston between the two dead centers.
WARNING
THE SYSTEM IS EQUIPPED WITH A LUBRICATOR. THE OIL REACHES THE CYLINDER AFTER HAVING
BEEN ATOMIZED BY THE AIR. PRIOR TO OPERATING THE BARRING GEAR, MAKE SURE THAT OIL IS
PRESENT IN THE LUBRICATOR AND THAT ITS VISCOSITY IS WITHIN 30 TO 60 ISO VG.
In the case of drive by oil, first start the oil pump, and then proceed as explained above.
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Figure 38
LEGEND
A BAR
B WEDGE
C AIR CHECK VALVE
D 4 WAY VALVE
E AIR IN
F AIR OUT
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7.9 FLYWHEEL

In most machines, a flywheel is assembled on the crankshaft. The way for fastening the flywheel to
the shaft depends on the shaft design at the coupling end. Among the alternatives given below, the
user will take into consideration the one that refers to the compressor subject of this Manual. For a
clearer understanding of this subject, see the assembly drawing of the flywheel shaft system, or the
assembly drawing relevant to the frame, included in the PART LISTS Volume of the Manual.
7.9.2 Flanged shaft end, coupled connection
7.9.2.1 Disassembly
- Screw in and tighten the two temporary screws.

- Remove the locking device and the gauged bolts.
- Sling and support the flywheel.
- Remove the temporary screws and release the flywheel. If it is forced onto the spigot, push it
by temporary screws located in the threaded holes provided for this purpose on the flange.
7.9.2.2 Assembly
- Lift the flywheel and take it to the spigot of the shaft flange, so as the two threaded holes of
the flywheel match the corresponding holes on the flange.
- With the two temporary screws, fasten the flywheel to the flange.
- Insert the gauged bolts and tighten them, crosswise two by two. Tighten to the torque value
specified in the FRAME ASSEMBLING DATA Table, included in the PART LISTS Volume of the
Manual. After having tightened the bolts, install the provided locking devices (lock nuts, split
pins, etc.).
- Remove the temporary screws.
7.9.3 Flanged shaft end, coupling with single journal driver

For this type of coupling, the flywheel installation is a part of the compressor shaft/driver shaft
alignment and coupling procedures. For this reason, the procedure has been included in the
INSTALLATION Section. After having tightened the gauged bolts, install the provided locking devices
(lock nuts, split pins, etc.).
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7.9.4 Parallel shaft end
7.9.4.1 Disassembly
- Support the flywheel/adapter.

- Loosen by a few threads all the screw in the RINGFEDER device.
- Remove the screws close to the part threaded holes of the front thrust ring, and screw them
into these holes (see Figure 40 ). By means of these screws, the front and rear thrust rings are
pushed in such a way that the locking unit loosens and can be removed.
- Disassemble the flywheel/adapter from the compressor shaft.
7.9.4.2 Assembly
- Clean the surfaces of the shaft and of the hub.

- Clean and oil all the mating surfaces of the tightening unit, including the threads of the screws
and the contact face of the screw heads.
WARNING
USE COMMON LUBRICANTS. DO NOT USE PARTICULAR OILS SUCH AS, FOR EXAMPLE,
LUBRICANTS CONTAINING MOLYBDENUM DISULPHIDE.
- Properly sling by the holes, lift and position the flywheel/adapter on the compressor shaft.
- Install the RINGFEDER locking device, after having removed the small protection blades
located in slits of the inner and outer rings (see Figure 39 ).
- Tighten the locking screw by hand, evenly and in diametrically opposite sequence.
- While rotating the flywheel /adapter with the shaft, check with dial gauges its truing and axial
position (see Figure 41 ).
Maximum permissible values (dial gauge reading):
RADIAL = 0.10 mm AXIAL = 0.20 mm
- Tighten the locking screws to the torque value specified in the FRAME ASSEMBLING DATA Table.
Tighten to the required torque value in three or more stages, always tightening evenly in
diametrically opposite sequence.
- Check again the position of the flywheel/adapter. If necessary make corrections by adjusting
the screws of the RINGFEDER device.
- Check that all the screws have been tightened to the required torque value.
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Figure 39
LEGEND
A REAR THRUST RING

B OUTER RING
C LOCKING SCREW
D FRONT THRUST RING
E INNER RING
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Figure 40
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Figure 41
LEGEND
A FRAME
B/D DIAL GAUGE
C FLYWHEEL/ADAPTER
E RINGFEDER LOCKING ASSEMBLY
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8 - CYLINDER ASSEMBLY

2 CYLINDER BODIES ..........................................................................................................................................189 1-189
2.1 Components data .........................................................................................................................................189 1-189
2.2 Cylinder removal and reassembly ........................................................................................................189 1-189
2.3 Cooling jackets maintenance .................................................................................................................189 1-189
2.4 Wear, ovalization and reboring ..............................................................................................................190 1-190
2.4.1 Wear M: .............................................................................................................................................................191 1-191
2.4.2 Relative wear R: .............................................................................................................................................191 1-191
2.4.3 Ovalization P: ..................................................................................................................................................191 1-191
2.4.4 Reboring ............................................................................................................................................................191 1-191
2.5 Liner removal and assembly procedure ............................................................................................192 1-192
2.5.1 Liner fitted without interference ............................................................................................................192 1-192
2.5.2 Liner fitted with interference ...................................................................................................................193 1-193
2.6 Instructions for hydraulic tightening of tie rods on head ..........................................................195 1-195
2.6.1 Assembly ...........................................................................................................................................................195 1-195
2.6.2 Disassembly ....................................................................................................................................................196 1-196
3 PISTONS - PISTON RODS .............................................................................................................................203 1-203
3.2 Pistons maintenance ..................................................................................................................................203 1-203
3.3 Piston rod disassembly and reassembly ...........................................................................................203 1-203
3.3.1 Disassembly ....................................................................................................................................................203 1-203
3.3.2 Reassembly .....................................................................................................................................................204 1-204
3.3.3 Rod-Spacer Ring polishing .......................................................................................................................204 1-204
3.4 Assembling piston with piston rod .......................................................................................................204 1-204
3.5 Rider ring wear - Run-out .........................................................................................................................206 1-206
3.5.1 Rider ring wear ...............................................................................................................................................206 1-206
3.5.2 Run-out ..............................................................................................................................................................207 1-207
3.6 Procedure for applying white metal coating ...................................................................................207 1-207
3.6.1 Coating applied with oxyacetylene torch ..........................................................................................207 1-207
3.6.2 Coating applied with spray gun .............................................................................................................209 1-209
3.6.3 Finishing ............................................................................................................................................................210 1-210
3.7 Piston rings ......................................................................................................................................................210 1-210
3.8 Wear on piston rods - Grinding ..............................................................................................................210 1-210
3.8.1 Wear ...................................................................................................................................................................210 1-210
3.8.2 Grinding .............................................................................................................................................................211 1-211
4 PISTON ROD PACKING ..................................................................................................................................215 1-215
4.2 Maintenance ...................................................................................................................................................215 1-215
4.2.1 Disassembly ....................................................................................................................................................215 1-215
4.2.2 Assembly ...........................................................................................................................................................216 1-216
5 VALVES ................................................................................................................................................................218 1-218
5.1 Description .......................................................................................................................................................218 1-218
5.1.1 Operation ..........................................................................................................................................................218 1-218
5.1.2 Components ....................................................................................................................................................218 1-218
5.1.3 Types ...................................................................................................................................................................219 1-219
5.2 Maintenance ...................................................................................................................................................219 1-219
5.2.2 Valve assembly preliminary check ......................................................................................................220 1-220
5.2.3 Checking and restoring valve components ......................................................................................220 1-220
5.2.4 Checks on assembled valves prior to installation .........................................................................222 1-222
5.2.5 Nut tightening and loosening equipment .........................................................................................223 1-223
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5.3 Disassembly from cylinder and reassembly ....................................................................................223 1-223
5.3.1 Disassembly ....................................................................................................................................................224 1-224
5.3.2 Reassembly .....................................................................................................................................................224 1-224
6 REVERSE-ACTION GAS OPERATED DEVICE FOR VALVE UNLOADER CONTROL ...................239 1-239
6.1 Operation ..........................................................................................................................................................239 1-239
6.2 Maintenance ...................................................................................................................................................239 1-239
7 DIRECT-ACTION GAS OPERATED DEVICE FOR CLEARANCE POCKET VALVE CONTROL241
................................................................................................................................................................................. 1-241
7.1 Operation ..........................................................................................................................................................241 1-241
7.2 Maintenance ...................................................................................................................................................241 1-241
8 CHECKING PISTON ROD OSCILLATION SAFETY DEVICES FOR WEAR OF PISTON RIDER243
RINGS ................................................................................................................................................................... 1-243
8.2 Piston rod oscillation check .....................................................................................................................243 1-243
8.3 Safety devices for rider rings wear .......................................................................................................243 1-243
8.3.1 Magnetic induction proximity probe ...................................................................................................243 1-243
8.3.2 Melting or rolling device ............................................................................................................................245 1-245
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This Section of the Manual is intended for the personnel in charge of maintenance and repair work
on the machine. For easier reference, the material has been divided into two Sections. This Section
regards CYLINDERS ASSEMBLIES and contains a brief description of the cylinders, the recommended
procedures for disassembling, checking, repairing or replacing and assembling the various parts.
Another Section of the Manual is dedicated to the FRAME AND CRANK GEAR.
NOTE
For disassembly and reassembly of the various components of the frame, special equipment
may be required, in addition to the usual tools. Refer to the appropriate Section in the PART LISTS
Volume of the Manual. Both the use of such equipment and its identification such as parts list,
code number, possible assembly drawings, are shown in this Section.
Personnel are often required to work in different ways by the conditions of the job site. Also for this
reason, the recommended procedures normally indicate the general description of the work to be
carried out, without going into more details that might be useless and that would, in any case, make
the Manual less concise.
NOTE
A data plate containing identification information as well as some pertinent technical data is
fastened to each cylinder.
CAUTION
When performing maintenance work on the machine, comply with the special warnings
highlighted in the various paragraphs of this Section, those shown in the paragraph entitled
SAFETY PRECAUTIONS - MAINTENANCE PROGRAM in the MAINTENANCE Section, and the rules
shown in the GENERAL INFORMATION Section, relevant to the GENERAL SAFETY PRECAUTIONS.
When disassembling any parts of a cylinder, check their status carefully. If defects are discovered,
either repair or replace those parts. Any scratching, scoring, etc. on mating surfaces will be eliminated
with fine emery cloth, fine stone, etc. Protect unpainted disassembled parts with a light film of lube
oil, except where not suitable (e.g. in non lubricated cylinders).
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CAUTION
During maintenance work, before reassembly, check the conditions of any gaskets and replace
those not in perfect state. If parts of gaskets remain attached to the coupling surfaces, do not
use a chisel to remove them, as this could damage the metal. Operate by inserting a wide, flat
wedge and, starting from this point, carefully slide a blade between gasket and surface.
CAUTION
Deformation caused by tightening or by thermal expansion can result in a defective seal between
metal surfaces without interposed gaskets. To compensate for these defects, special sealant
pastes can be used successfully. For this reason, when carrying out disassembly work on the
various parts of the cylinders, check for the film made by these pastes, remove it and then restore
it during reassembly.
Ge Oil & Gas NUOVO PIGNONE has had good results using the sealant «MOTORSIL - D» produced
by AREXONS Company. To apply this paste, proceed as follows:
- Clean and degrease the surfaces to be sealed.
- Using a spatula, apply a thin, even layer of paste on one of the surfaces.
- After the time specified in the instructions on the paste container has elapsed (indicatively,
about 10 minutes), proceed with assembly and tightening of the parts.
Should it be difficult to find this paste (or an equivalent) on the market, paper gaskets prepared on
site can be used as a replacement; note however that their use is not recommended for the following
duties:
- inside cylinder heads with capacity control device;
- between head and cylinder;
- between cylinder and stuffing box.
CAUTION
In case that abrasive solid particles should enter a cylinder (for example, breakage of valve
components), once the damage and its causes have been rectified and before starting the
machine again, perform thorough cleaning of the cylinder to avoid further damage.
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CAUTION
When the cylinders are opened, take all precautions to avoid entrance of foreign matters. All
openings must be appropriately protected (covers made with wood, cardboard, cloth, etc.). In
any case, clean thoroughly unless absolutely certain that no dirt has entered.
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8.2 CYLINDER BODIES
8.2.1 Components data

See Compressor Data Sheets found in the REFERENCE DRAWINGS Volume of this Manual.
8.2.2 Cylinder removal and reassembly

To remove the cylinder from the frame, proceed as follows:
- Remove the piping connected to the cylinder.
- Disconnect the piston rod from the crosshead (see CROSSHEAD paragraph in FRAME AND
CRANK GEAR Section).
- For the purpose of protection, shield the threaded end of the piston rod with the proper sheath
or wrap with PTFE tape, then disassemble the partition cover and the intermediate partition
packing, if any.
- After having slung the cylinder and tensioned the lifting device, remove the cylinder supporting
system.
- Unscrew the nuts for fastening to the crosshead extension or distance piece. Move the cylinder
away.
To reassemble the cylinder, carry out the above procedure in reverse order.
If a completely assembled cylinder is to be installed, it is advisable to carry out the procedure after
having disassembled the partition cover. This will ensure that there are no impacts between piston
rod and cover, if cylinder lifting and positioning should be performed without the necessary
experience or using inadequate means.
Refer to the paragraph CONNECTING CYLINDERS TO FRAME (INSTALLATION Section). Specifically,
prior to tightening the nuts on the stud bolts connecting cylinder to frame, check that the mating
planes (cylinder frame) are parallel. If required, act on the shims inserted under the cylinder support.
8.2.3 Cooling jackets maintenance

During compressor operation, check for any gas leakage to the environment.
Any leakage of gas into the coolant will be verified by observing the fluid through the sight flow
glasses.
It is advisable to start the coolant circulation prior to starting the machine, as it is highly dangerous
to start cooling after the machine was started and had time to warm up. In contact with cold fluid,
the hot cylinders can easily crack, especially those made of cast iron. It is also advisable to let the
fluid circulate for several minutes after the machine has been stopped, to ensure even temperatures
in the cylinder during cooling.
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During the Winter, it should be taken into consideration that freezing of the coolant in the jackets
can be a severe risk for the cylinders. Consequently, during idleness, when the ambient temperature
is low enough to fear that this may happen, proceed to emptying the cylinder jackets.
For cooling with water (depending on its nature and especially in open circuits) it should be
considered that muddy or solid deposits are always left in the cooling jackets and in the coolers.
These deposits can severely impair the efficiency of the system. For this reason the cylinder jackets
must be inspected at appropriate intervals, and cleaning and descaling must be performed as
required.
For muddy deposits, the procedure to be followed is very simple, and can be carried out with a jet
of pressurized water towards the zones where mud has collected. In general, mud tends to deposit
in recessed areas and in the bottom of the system.
In case of fouling by carbonates or sulphates, the deposits should not be removed by mechanical
action such as, for example, using chisels or other percussion tools. Such procedures would not only
be inadequate in many cases, but could irreparably damage the cylinder walls, especially if made
in cast iron.
The deposits on walls bearing shall instead be subjected to chemical treatment with specific
products, available on the market. A typical treatment consists of the following:
- Degreasing with solvent
- Descaling and deoxidizing, if necessary
- Washing with water
- Killing the residual acids with passivating agent
- Phosphating for rust-proofing.
For details on the procedures listed above, refer to the detailed prescriptions supplied by the various
suppliers of the specific products.
If a water monoethylene glycol solution is used for cooling, refer to Table 15 when adding coolant
or replacing it.
WARNING
DO NOT USE COOLING FLUIDS THAT ARE CORROSIVE TOWARDS THE COMPONENTS OF THE
SYSTEM. FOR EXAMPLE, AVOID USING NON-INHIBITED MONOETHYLENE GLYCOL.
8.2.4 Wear, ovalization and reboring

Periodically, cylinders should be subjected to measurement of maximum wear, relative wear and
ovalization, hereinafter defined by use of the coefficients X, Y and Z, given as a function of the specific
weight of the gas () and of the type of piston rings, in Table 16 . In the following formulas Ø (mm) is
the original bore of the cylinder.
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8.2.4.1 Wear M:
Represents the increase in bore of the section of the cylinder subjected to sliding of piston rings.
Measurement will be performed at several appropriately selected points.
M =( X • ø)/ 1000 (mm)
8.2.4.2 Relative wear R:
Represents the difference between maximum and minimum diameters, measured at several points
on planes containing the cylinder axis. The check shall be performed on at least two planes at right
angles to each other (see Figure 42 ).
R = (Y • ø) / 1000 (mm)
8.2.4.3 Ovalization P:
Represents the difference between maximum and minimum diameters, measured at several points
on planes perpendicular to the cylinder axis. The check shall be repeated on at least three planes
(see Figure 43 ).
Z = (Y • ø) / 1000 (mm)
8.2.4.4 Reboring
If during a check it is found that one or more of the values specified above are greater than the
calculated M, R, P values, it is advisable to restore the surface of the bore, proceeding as described
in Paragraph 2.4.4.1 and Paragraph 2.4.4.2 . below.
Note that, to ensure satisfactory life of seals and rider rings, it will be necessary to limit the roughness
of the sliding surface. For this reason we recommend that in general, when reconditioning bores, Ra
roughness values should be as follows:
0.4 to 0.8 µm for cylinders without liners
0.2 to 0.4 µm for non-coated liners
0.1 to 0.4 µm for coated liners
8.2.4.4.1 Cylinders without liner
For these cylinders (see Figure 44 ), in general, a maximum increase by 3 mm in the diameter øA
can be carried out through reboring. This must be performed complying with coaxiality with the
main axis of the cylinder. The increase in bore makes it necessary to carry out the following steps:
- Check that diameters øB and øC are in any case at least 0.5 mm greater than diameter øA.
Accordingly, if required, the surfaces relevant to øB and øC must be remachined. Consequently,
a metallic coating must be applied to the surface of the head relevant to diameter øD, so as
to restore the required clearance between head and cylinder. If necessary, request the relevant
machining tolerances from NUOVO PIGNONE Service.
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- Due to the new value of the diameter øA, the minimum projection given for rider rings in the
paragraph PISTONS - PISTON RODS shall be increased by a half of the difference between new
and old value of øA.
In this way, excessive lowering and possible interference of the piston rod with packing cups
will be avoided.
- Verify the possibility of replacing the piston rings. We recommend that replacement is carried
out when the increase to the original bore exceeds 0.2% if the piston rings are metallic, and
0.3% if the piston rings are non-metallic.
To facilitate supplying of piston rings, the following standard sizes are generally adopted:
increased bores = original bore
+ 0.25 / 0.5 / 1 / 1.5 / 2 / 2.5 / 3 mm
In any case, contact NUOVO PIGNONE Service in regard to the validity of this scaling.
8.2.4.4.2 Cylinders with liner
For these cylinders it is normally advisable to proceed with liner replacement, as soon as it reaches
the maximum values of wear and/or ovalization specified above. Within these limits, bore surfaces
can be restored (if permitted by liner characteristics).
8.2.5 Liner removal and assembly procedure
8.2.5.1 Liner fitted without interference
8.2.5.1.1 Removal
After having removed the cylinder head, extract the liner using the appropriate pullers.
8.2.5.1.2 Assembly
Prior to reinstalling this type of liner in the cylinder, carefully check the O-rings placed between
liner and cylinder wall. If they have been damaged when removing the liner, install new ones.
Clean and check everything, especially the contact surfaces between liner shoulder and cylinder.
Insert the liner, being careful to ensure that the dowel matches its housing. For cylinders of the
lubricated type, check that the lubrication holes between cylinder and liner coincide with each other.
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8.2.5.2 Liner fitted with interference
8.2.5.2.1 Removal
To remove the liner, proceed to machining it on a vertical lathe or milling machine. During machining,
the liner detaches from the cylinder wall when its thickness has been reduced to 1 to 2 mm. Place
the cylinder correctly on the machine tool, so as not to damage the surface coupling with the frame.
8.2.5.2.2 Assembly
The procedures shown below refer to cylinders of the lubricated type. For non-lubricated cylinders,
the only difference is that there is no need to align the holes for the lube oil. In this case, the correct
positioning of the cylinder liner is given by alignment of the valve ports if these are made on the liner.
Assembling of a force fit liner in the cylinder is performed either by cooling it in liquid nitrogen or by
heating the cylinder in a furnace, in strict accordance with the requirements of the CYLINDER
ASSEMBLING DATA Table (see PART LISTS Volume of this Manual). If both systems are possible, the
choice will be determined by what is available at the jobsite. Consider also that assembly by cooling
the liner offers the advantage of substantially shorter time required for the procedure.
However if this solution is adopted, more specific equipment must be available. The liner lifting
system must be made of stainless steel, due to the brittleness that would be caused in other metals
by the low temperature. Same consideration applies to other devices subjected to the low
temperature. For the nitrogen, it is advisable to have a container of suitable shape available, in order
to minimise the consumption of nitrogen.
WARNING
AS REGARDS THE PROCEDURE FOR INSTALLATION BY HEATING THE CYLINDER, IT SHOULD BE

NOTED THAT HIGH TEMPERATURE CAN CAUSE DEFORMATION AND CONSEQUENT IMPAIRMENT
OF SEALS. CONSEQUENTLY, AFTER ASSEMBLING THE LINER, IT ADVISABLE TO TEST THE SEALING
IN THE VARIOUS PARTS OF THE CYLINDER.
The procedure for installation by heating of the cylinder is described below, since this system is
always possible. Moreover, the procedure for assembly by cooling the liner presents, in comparison
to the previous one, few variations that may be easily deduced.
WARNING
WHEN USING LIQUID NITROGEN, AVOID ANY CONTACT WITH THIS SUBSTANCE. THE AREA IN
WHICH THE PROCEDURE IS CARRIED OUT MUST BE WELL VENTILATED TO AVOID RESPIRATORY
DISTURBANCE AND ASPHYXIA.
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8.2.5.2.2.1 Liner without spacers or with one spacer

a. Mark a fiducial line on the edge of the cylinder and the edge of the liner, paying attention not
to scratch the inner surface. These marks will serve during reassembly to align the lubrication
holes and the valve ports.
b. Remove from the cylinder the plugs that separate chambers subject to different pressure (for
example, plugs separating the cooling jackets from the gas chambers) and that could be
subject to sticking and/or loss of seal during heating. Sling the cylinder and lift it correctly,
making sure to avoid damages. For this procedure, use the stud bolts of the valve covers.
c. Place the cylinder in a furnace, arranging it in the vertical position. Gradually raising the
temperature over a period of 2 to 3 hours, keep it for at least 6 hours at the heating
temperature specified in the above mentioned Table.
d. In the meantime, prepare a perfectly horizontal support, in an ambient that is not cold and
not ventilated. The cylinder will be rested on this support after it has been removed from the
furnace. Prepare the liner, already lifted from the floor and ready to be inserted in the cylinder.
Prepare everything required for the subsequent steps.
e. Remove the cylinder from the furnace and place it vertically on the support.
f. Begin inserting the liner into the cylinder, rapidly checking its coaxiality with the same cylinder.
After inserting the first 100 mm, further advancement should be made rather quickly by letting
the liner drop. Obviously, before and while inserting the liner, special care must be taken to
ensure the correct position of any port and/or lubrication holes, taking into account that the
fiducial lines previously made coincide. Let the liner drop until it rests on the cylinder head.
g. The average time available for the procedures described above, from the moment of
extracting the cylinder out of the furnace, may be approximately 5 minutes. It is preferable to
reduce this time to a minimum, to avoid the risk of blocking the liner in a wrong position.
h. After having inserted the liner, let the cylinder cool naturally down to ambient temperature,
avoiding any forced cooling procedure.
i. If provided, assemble the spacer B, referring to Figure 45 . The spacer shall be inserted into
the cylinder; with the parts at ambient temperature, keeping the spacer pressed against the
liner, measure the dimension "s" taking the mean value of at least 8 measurements made at
equally spaced points. Place a shim having thickness "h" on the spacer, such that:
h (min) = s - 0 mm
h (max) = s + 0.1 mm
If none of the available shims comply with this condition, machine either one ring or the spacer.
j. When the cylinder is cold, screw on and tighten the plugs mentioned in item b, ensuring seal
by applying a sealing compound (e.g. LOCTITE, ARALDITE, etc.).
8.2.5.2.2.2 Liner with two spacers

- See item a above.
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- Insert a temporary (or the original) spacer (see Figure 46 ) into the frame side cylinder end,
fixing it by means of the stud bolts existing on the cylinder head. This spacer should be
positioned so as to be a stop to the liner being installed.
- See items b through e above.
- Begin inserting the liner into the cylinder, rapidly checking its coaxiality with the same cylinder.
After inserting the first 100 mm, further advancement should be made rather quickly by letting
the liner drop. Obviously, before and while inserting the liner, special care must be taken to
ensure the correct position of any port and/or lubrication hole, taking into account that the
fiducial lines previously made coincide. Let the liner drop until it rests on the spacer.
- See items g and h above.
- Assemble the spacer B, referring to Figure 46 . The spacer shall be inserted after the cylinder
has cooled down to ambient temperature, then keeping the spacer pressed against the liner,
measure the dimension "s" taking the mean value of at least 8 measurements made at equally
spaced points. Place the shim having thickness "h" on the spacer, such that:
h (min) = s - 0 mm
h (max) = s + 0.1 mm
If none of the available shims comply with this condition, machine either one ring or the spacer.
This procedure must be repeated also on the frame side of of the cylinder, after having installed
the final spacer.
- See item j above.
8.2.6 Instructions for hydraulic tightening of tie rods on head
WARNING
FOR SAFETY REASONS, PERSONNEL MUST NOT STAND IN THE VICINITY OR IN FRONT OF THE
DEVICES.
8.2.6.1 Assembly
- Ensure that pressure gauge A is correctly calibrated.

- Screw until a nut gets in contact on two opposite tie rods
- Screw the hydraulic device onto the two tie rods, till coming in contact with the head.
- Check that plane P 1 of piston F and plane P 2 of device body E are on the same level.E are on
the same level.
- Screw the pump hose onto the dividerD.
- Screw the divider hoses onto the hydraulic device bodies.
- Tighten the knob C of pump B.
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- With the pump lever, pump oil until a pressure value equal to half the value given in the
CYLINDER ASSEMBLING DATA Table can be read on the pressure gauge.
- If instability in the pressure gauge shows presence of air, empty the system by unscrewing
the knob, then pressurize again after having retightened the same knob.
- With a small rodGthrough the opening in the device body, screw the nuts of the tie rods until
coming in contact with the head.
- After having completed the operations stated above, unscrew the pump knob to release the
pressure. Screw the device piston, to discharge the oil.
- Disconnect the divider hoses from the body of the hydraulic devices.
- Unscrew the hydraulic devices from the tie rods and proceed to tightening the other pairs of
tie rods, following the sequence described in Figure 47 .
- Repeat the above steps, pumping now to the entire pressure value required in CYLINDER
ASSEMBLING DATA Table.
8.2.6.2 Disassembly
- Carry out all of the same steps described for assembly.
NOTE
Keep in mind that, to unscrew the nuts from the tie rods, it will be necessary to reach a pressure
about 3% higher than the pressure required for assembly. Do not apply excessive pressure, to
avoid overstressing the tightened components.
% by weight monoethylene glycol Freezing temperature (°C) Boiling temperature (°C)

10 - 3.5 101.1
20 -8 102.2
30 -15 103.3
40 -24 104.9
50 -36 107.2
60 -50 109.9
70 114.4
80 -47 122.2
90 -29 137.2
100 -13 197.2
Table 15 - FREEZING AND BOILING TEMPERATURES FOR WATER MONOETHYLENE

GLYCOL SOLUTIONS
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X Y Z
SPECIFIC
WEIGHT OF NON-MET. NON-MET. NON-MET.
METALLIC PI METALLIC PI METALLIC PI
GAS (Kg/Nm3) PISTON PISTON PISTON
STON RINGS STON RINGS STON RINGS
RINGS RINGS RINGS
< 0.2 1.4 2.1 0.7 1 0,65 0.9
0.2 < < 1.0 1.8 2.7 1 1.3 0,65 0.9
> 1.0 2.3 3.4 1.3 1.7 0,7 1
Table 16 - COEFFICIENTS FOR CHECKING WEAR AND OVALIZATION ON CYLINDERS
Figure 42
LEGEND
A MEASURING PLANES
B MEASURING POINTS
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Figure 43
LEGEND
A MEASURING PLANES
B MEASURING POINTS
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Figure 44
LEGEND
ØA SLIDING SURFACE DIAMETER

ØB, ØC DIAMETER OF NON-SLIDING SURFACES
ØD DIAMETER OF HEAD FITTING SURFACE
ØE DIAMETER OF PISTON OUTER SURFACES
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Figure 45
LEGEND
A SHIM
B SPACER
C LINER
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Figure 46
LEGEND
A SHIM
B SPACER
C LINER
D TEMPORARY SPACER
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Figure 47
LEGEND
A PRESSURE GAUGE
B HYDRAULIC PUMP
C KNOB
D DIVIDER
E DEVICE BODY
F DEVICE PISTON
G ROD
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8.3 PISTONS - PISTON RODS

The assembly drawing of each piston with rod is included in the PART LISTS Volume of this Manual.
If the piston is not integral with the rod, it is fastened to it by means of a special nut which is prevented
from unscrewing by a setscrew with prick; other systems can be used to avoid unscrewing, such as
caulking the edge of the nut into one of the slots made on the rod. For tightening the nut, see the
relevant paragraph below.
CAUTION
The surface of the rod in contact with the packing rings has been suitably finished to limit wear
of the rings as much as possible. Consequently, all precautions must be taken to ensure that,
during any procedures carried out, the surface is not damaged. In case of rods with tungsten
carbide coating, considering the rather high hardness and consequent brittleness of the material,
it is extremely important to avoid any impacts on the coated zone, both during maintenance and
during storage in the warehouse.
A plastic or rubber ring can be placed on the piston rod, between the partition cover and the piston
rod packing. This ring prevents any oil leaking from the partition cover from entering the cylinder.
As regards the system for fastening the rod to the crosshead, see FRAME AND CRANK GEAR section,
paragraph entitled CROSSHEAD.
8.3.2 Pistons maintenance

Any seizure, which can entail serious consequences, can almost always be attributed to excess load
or to poor cooling of the cylinder or for lubricated cylinders, to insufficiency or poor quality or pollution
of the lube oil. Obviously, seizure can also be caused by metallic or siliceous impurities that have
entered the cylinder during assembly.
Wear on the piston rider rings should be checked as described below in this chapter.
Check also the cleanliness and the condition of the grooves for piston rings and rider rings. Dirt,
fouling and carbon deposits hinder the free movement of the piston rings, impairing operation.
8.3.3 Piston rod disassembly and reassembly
8.3.3.1 Disassembly
- Remove the cylinder head.

- Disconnect the rod from the crosshead (see FRAME AND CRANK GEAR section, CROSSHEAD
paragraph).
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- Prior to withdraw the piston from the cylinder, wrap the rod end thread with suitable adhesive
tape or fasten the appropriate sheath on it.
To be able to pull out the piston it may be necessary, for some types of compressor, to move
the complete partition cover, removing the piping inside of the distance piece which could
obstruct movement.
- Screw the puller onto the threaded hole machined on the rod head and slide the piston, until
it protrudes from the cylinder. From this point on, the piston must be appropriately supported,
by a method to be chosen according to its weight, to the distribution of the piston rod weights,
to its geometry, etc. All precautions must be taken to ensure that, during the procedure, the
various machined surfaces are not damaged or struck, especially sliding surfaces of the
crosshead extension and the cylinder bore, which should be adequately protected.
For periodic checks and inspections, see MAINTENANCE section.
8.3.3.2 Reassembly
Carry out the procedure for disassembly in reverse order, observing the same precautions so as not
to damage the various parts.
When reconnecting the rod to the crosshead, make sure that the linear clearance between piston
and cylinder head or cylinder body is within the limits specified in the CYLINDER ASSEMBLING DATA
table, included in the PART LISTS Volume of the Manual.
In case the spacer ring or the rod (or both) are to be replaced, refer to Paragraph 3.3.3 .
Adjustment of the rod on the crosshead is carried out as described in the CROSSHEAD paragraph in
the FRAME AND CRANK GEAR section. The linear clearance is taken by measuring the thickness of a
lead wire which, inserted into the cylinder through a valve port, is squashed between piston and
cylinder head or cylinder body when it is brought to the head or crank dead centre.
8.3.3.3 Rod-Spacer Ring polishing
Polish the tapered surfaces mating the rod to the spacer ring by means of the equipment shown in
the PART LISTS Volume of the Manual, according to the compressor size.
This operation must be performed with the rod in vertical position, up to 100% contact extension of
the mating tapered surfaces, to be verified with “Prussian Blue”.
8.3.4 Assembling piston with piston rod

This operation may be performed by means of the hydraulic jack; the oil pressure is specified into
the CYLINDER ASSEMBLING DATA table.
WARNING
FOR SAFETY REASONS, PERSONNEL MUST NOT STAND IN FRONT OF THE DEVICES.
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The equipment used for hydraulic tightening of the piston is shown in Figure 48 . The procedure to
be applied is the following:
a. Ensure that the pressure gauge A is correctly calibrated.
b. Inspect and thoroughly clean all the mating surfaces of the rod shoulder, of the piston and of
the nut.
c. Assemble the piston on the rod and check with "Prussian Blue" that the contact area between
rod or shoulder and piston extend for at least three-quarters of the total surface. The contact
area must be uniform and evenly distributed. Grind if necessary.
d. Screw the nut onto the rod and check the contact area between nut and piston as shown in
the previous step. Grind if necessary.
e. Apply a thin film of lubricant containing molybdenum disulphide (e.g. ROCOL, MOLIKOTE, etc.)
to the face of the nut, of the piston, on the screw thread of the rod and of the nut.
f. Tighten the nut by hand until perfect metal to metal contact is ensured.
g. Place the cage F.
h. Screw the hydraulic device onto the piston rod, until it is in contact with the cage.
i. Check that plane P1 of the piston E and plane P2 of the device body D are at the same level.
j. Screw the pump nose onto the hydraulic device piston.
k. Tighten the knob C of pump B.
l. Using the pump lever, pump oil until the pressure specified in the above mentioned table is
read on the pressure gauge.
m. If instability in the pressure gauge shows presence of air, empty the system by unscrewing
the knob, then pressurize again after having retightened the same knob.
n. With a small rod G, through the opening in the cage, screw the nut on the piston rod until
getting in contact.
o. After having completed the above mentioned procedure, unscrew the pump knob to release
the pressure, and screw the device piston to discharge the oil.
p. Repeat steps k through o two more times.
q. Detach the pump nose from the hydraulic device piston.
r. Unscrew the hydraulic device from the piston rod.
s. Remove the cage.
For disassembling, repeat all the steps described for assembly, keeping in mind that, to unscrew the
nut from the piston rod, it will be necessary to reach a pressure about 3% higher than the one required
for assembling. Do not apply excessive pressure, to avoid overloading the tightened components.
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8.3.5 Rider ring wear - Run-out
8.3.5.1 Rider ring wear
If no specific devices for checking are available, wear on the piston rider ring is checked by measuring
the protrusion of the rider ring from the piston. The protrusion is measured with a feeler gauge
inserted into the bottom point between piston and cylinder wall. To do this, remove the cylinder head
and position the piston at mid stroke.
The minimum acceptable value for this protrusion is given in the diagrams shown in Figure 49 .
If the rider ring is of the open type with dowel to prevent rotation, it can still be utilized, after reaching
maximum wear, by turning it 180°. Otherwise, the rider ring will have to be replaced. In both cases,
it is necessary to detach the rod from the crosshead (see relevant paragraph above) and take the
piston partly out of the cylinder until the removal of the ring is feasible. Do not open the rider rings
excessively, during assembly, to avoid breakage.
CAUTION
Do not open excessively the rider rings, at the time are fitted into the piston grooves, to avoid
failure.
NOTE
For non-lubricated cylinders, the first set of rider rings in plastic material has a shorter life than
the next sets. In the first hours of operation, in fact, the rider rings sliding in direct contact with
the metallic surface of the cylinder, wear out easily. During this stage, plastic particles deposit
on the cylinder wall forming a self-lubricating layer between metal and rider rings. When this
layer has been completed, wear of the rider rings stabilizes at substantially lower values. It may
be estimated that the stage of quick wear, (dependent on many factors such as the cleanliness
and the quality of gas, operating parameters, etc.), lasts for approximately 150 hours.
It can also be estimated, still approximately, that at the end of this stage the wear on the rider rings
will have reached 1/1000 of the bore.
CAUTION
Intermittent entrance of liquid particles into the cylinder results in local removal of the plastic
layer. The rider rings come again in contact with the metal; consequently, wear is increased. The
intermittent presence of liquids, or in any case liquids able to dissolve the plastic layer has
therefore harmful effects on the life of the rider rings.
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In the event that it becomes necessary to replace a rider ring of the open type, consider that the
width in mm of the cut on the new ring when inside the cylinder must never be less than the values
shown in the CYLINDER ASSEMBLING DATA table.
The axial clearance between the rider ring and its housing on the piston must comply with the value
shown in the same table.
CAUTION
For tandem pistons, if the rider ring of one piston requires replacement (due to wear or other
reasons), replace also the rider ring of the other one at the same time.
8.3.5.2 Run-out
The term "RUN-OUT" indicates the oscillation of the axis of the piston rod in horizontal cylinders,
during one complete revolution of the compressor shaft made by manual procedure.
During compressor operation, vertical run-out varies with time also due to wear of the piston rider
rings. The vertical run-out measurement, performed at regular intervals, represents a good way for
indirect check of rider ring wear.
Unless other measurement devices are installed (as those utilising proximitors), the run-out is
measured with a dial gauge in the length of the rod between packing and crosshead or, when two-
compartment distance piece is used, between packing and intermediate partition packing.
Measurement is made in two planes, vertical and horizontal.
8.3.6 Procedure for applying white metal coating
CAUTION
Prior to proceeding to whichever type of heating, ensure that the piston is depressurized. In case
of service with hazardous gas, purge the inside with inert gas after removing the plugs (if any)
on the piston. Purge the piston again, upon completion of the procedure for applying white metal,
immediately prior to reinstalling the vent plugs, if the gas used is explosive.
8.3.6.1 Coating applied with oxyacetylene torch
a. If the piston (made of cast iron or steel) was used for gas containing H2, it is necessary to
proceed to dehydrogenation. For this operation, take the piston in a furnace at a temperature
of 250 to 260 °C for approximately 24 hours. Then proceed to slow cooling, keeping the piston
inside the furnace. If the piston is integral with the rod, it will be advisable to place it in the
furnace in vertical position. When this is impossible, for reasons of size, it can be placed
horizontally, after having made sure to support not only the piston but also the rod in at least
two points, to avoid any possible distortion of the latter.
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b. If the piston is made of cast iron and was not used for gas containing H2, it will be necessary
in any case to perform heating at 100 to 150°C for about 5 hours as a drying process.
c. Remove any traces of oxidation with mechanical means. This can be carried out either using
emery cloth or, when deemed necessary, by turning.
d. Clean thoroughly, using an appropriate solvent, and apply a layer 0.2 to 0.3 mm thick of
"CASTOTIN 1" paste to the surface to be coated ("CASTOTIN 1" paste is a surface beading
manufactured by CASTOLIN). This same product is sold worldwide by the subsidiary
"EUTECTIC", with the name "EUTECTIN WELD 1". In the absence of this product or of another
similar one, the surface may be treated with the tin coating procedure.
e. Using, for example, an oxyacetylene torch, proceed to raising the temperature of the area of
the piston where the coating is to be applied. Heat the surfaces in the vicinity of this area
without involving it directly (heating by conduction). This heating shall be done gradually and
evenly. As soon as it can be observed that the beading paste is evenly melted over the entire
area, suspend heating (the temperature should be approx. 220 °C), and immediately remove
the paste using hot water and a brush.
f. Wait until the temperature of the piston decreases to approx. 120°C, then start application of
the white metal. The white metal is applied using the oxyacetylene torch, adjusted to neutral
flame, keeping the piston temperature always around 120 °C and making sure to apply the
white metal by letting it melt (not burning). The drops of white metal shall drop as close as
possible to the surface involved in the coating, and along lines parallel to the piston axis. If
during the entire coating process, the temperature of the surface involved should go
appreciably below 120 °C, heat again as described in step " e ".
g. After having completed the white metal application procedure, wait for the piston to cool, and
then proceed to a first machining of the white metal to a diameter 0.4 to 0.5 mm greater than
the required one.
h. Check, by ultrasonic inspection if possible, that the white metal has well adhered. Dye
penetrant liquid may also be used to detect any fracture lines in the white metal and in
particular detachment of the white metal along the edges of the coating. If these examinations
reveal small zones in which perfect adhesion of the white metal is uncertain, it will be
necessary to proceed to removing the defects and then repeating the procedure starting from
step " d ". Preheating shall be done only in the zone involved in the new application, to avoid
possible damage to the rest of the white metal that has been found to adhere perfectly. Small
surface blowholes, if any, can be eliminated using a scraper, after which the white metal is
applied again.
i. Complete machining of the white metal to the required diameter.
j. For the white metal to be applied, we recommend the following composition:
80% Tin
11% Antimony
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9% Copper
8.3.6.2 Coating applied with spray gun
a. Carry out steps a and b of Paragraph 3.6.1

b. Normally, the surface involved requires no mechanical preparation. Some operators which
apply this type of coating prefer to carry out a thread on the surface, 1 mm pitch and 0.6 mm
depth, with a tool having a 60° tip and rounded end.
c. Clean the surface to be coated with a proper solvent, making sure to remove all traces of
grease.
d. Sandblast, using "corundum" sand or equivalent, to make the surface as rough and as clean
as possible.
e. Blow on the surface with fully dry and oil free air to remove any residue dust.
f. Heat the part to approx. 60 °C to avoid formation of moist zones on the surface involved. If
using the oxyacetylene torch for this procedure, avoid letting the flame contact directly the
area involved.
g. Proceed immediately applying a layer of anchoring product with the spray gun. The anchoring
material may be "METCO 405" or other having the same properties.
h. After having completed item a, do not tamper with the surface involved and proceed
immediately applying the white metal with the spray gun. For the white metal to be applied,
we recommend the following composition:
90 % Tin
6.5% Antimony
3.5% Copper
The white metal thickness must be such to assure total absence of defects on the entire
surface after machining has been performed.
i. After having completed the coating procedure, let cool naturally and then proceed to
machining in order to obtain the desired dimensions. Next, check by ultrasonic inspection that
the white metal adheres well. The use of dye penetrant liquid is also recommended.
j. To apply the white metal coating to pistons with white metal band on the full circumference
(360°), position the piston on a lathe and, during the procedures described in items " g " and
" h ", rotate it at a speed close to the one specified for final machining of the white metal.
NOTE
Both anchoring metal and coating metal are produced by the manufacturers in wire form for
application with spray gun.
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8.3.6.3 Finishing
After having applied the white metal coating, proceed to finishing as shown in Figure 50 .
For pistons with white metal coating on full circumference, the rated diameter of the cylinder named
Do, the diameter of the rider ring Dp is:
Dp = Do - 0.0012 x Do - 0.04
(tolerance h7, ISO Std)
For pistons with white metal coating covering 1/3 of the circumference, the diameter of the rider
ring Dp is:
Dp = Do
(Tolerance h8, ISO Std)
8.3.7 Piston rings

Piston rings are replaced, in general, when the radial thickness becomes equal to or less than a half
of the original one (the size is shown in the CYLINDER ASSEMBLING DATA table).
This limit may be considered excessive by some users, due to the resulting loss in compressor
capacity. In this case, it will be the user himself to decide closer limits of wear.
When replacing piston rings, keep in mind that the width of the cut of the ring when inside the cylinder,
and that the axial clearance between ring and housing must comply with the value shown in the
CYLINDER ASSEMBLING DATA table.
When requesting spare piston rings, keep in mind what is specified in the CYLINDER BODIES
paragraph in regard to increased bore size.
To remove or insert piston rings from or into the piston, proceed in the same way as described for
rider rings.
CAUTION
Avoid to open excessively the single piece piston rings when assembling on the piston, to avoid
breakage.
8.3.8 Wear on piston rods - Grinding
8.3.8.1 Wear
Wear is checked in the middle section of the length subjected to friction of the packing rings.
Perform measurement on three diameters equally spaced from each other.
Wear that can still allow satisfactory behaviour of the packing rings may reach the values of 0.2%
of the nominal diameter of the rod, provided that surface, although worn, is smooth and free from
scoring.
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It is obvious however that satisfactory behaviour is determined, not only by the condition of the
rod, but also by the wear of the seal rings. Therefore, even when wear of the rod is less than
0.2%, it may be necessary to replace the packing rings.
8.3.8.2 Grinding
A piston rod that is worn beyond the limit specified above must be ground, if its feature permits. We
recommend decreasing the diameter by 0.4 mm and installing rings from our standard, for
undersized piston rods.
After decreasing the rod size, further wear of 0.2% is allowable. When this level of wear has been
reached, it is advisable to replace the rod, if its diameter is equal to or less than 60 mm. If the diameter
is over 60 mm, we recommend grinding again to a value of 0.8 mm below the rated diameter, and
installing standard packing rings designed for the 2nd undersize. After this, a further wear of 0.2%
can be tolerated. Below this level it will be advisable to replace the rod.
The rings of smaller diameter shall be utilised only for undersized piston rods.
Consider that, for satisfactory life of the packing rings, the roughness of the sliding surface of the
rod must be low. We recommend roughness values not exceeding the order of 0.3 to 0.4 m.
The above comments are not valid for rods that have undergone ammonia hardening treatment
(thus having a minimum thickness of hardened metal), or obviously for rods with very thin coating
of hard metal. In these cases, consult GE Oil & Gas NUOVO PIGNONE.
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Figure 48
LEGEND
A PRESSURE GAUGE
B HYDRAULIC PUMP
C KNOB
D DEVICE BODY
E DEVICE PISTON
F CAGE
G ROD
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Figure 49
LEGEND
A WHITE METAL PAD OR BRONZE RIDER RING

B PTFE RIDER RING
C BORE
D MIN PROJECTION
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Figure 50
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8.4 PISTON ROD PACKING

The sealing of the compressed gas, between piston rod and cylinder, is performed by the PISTON
ROD PACKING.
The packing is composed of a series of cups, each one containing one or more sealing rings.
The drawing in Figure 51 shows the types of ring commonly used and the various combinations of
rings that can be housed in the cups, in relation to the cylinder service.
The rings are composed of three segments, held together by a garter spring installed in the groove
running around the circumference of the ring.
The rings with tangential cut are designed to permit the inner circumferences of the rings always to
be in contact with the piston rod, by compensating the progressive wear caused by sliding.
The rings with radial cuts, depending on their function, can have segments with the cuts either
spaced apart or in contact with each other.
Rings of the RT and TT pairs must maintain a clearly determined mutual position; this is ensured by
a dowel.
A progressive number that serves to give the exact order of assembly for the various cups is punched
on each of the packing cups. The numerical progression starts from the innermost cup, i.e. the one
on the pressure side.
The packing assembly drawing is included in the PART LISTS Volume of this Manual.
The types and mutual positions of the rings in each cup and the positions of the various cups are
clearly shown on this drawing.
The entire set of cups is held assembled by stud bolts passing through the pack and tightened with
nuts. Other nuts tighten the end flange of the packing on the same stud bolts.
Channels on the end flange, inside the cups, and between one cup and another, may be made for
gas recovery, cooling, lubrication and temperature measurement.
8.4.2 Maintenance
Excessive gas leakage after a certain period of operation is generally due to packing rings wear or
to poor condition of the piston rod, or to a combination of the two.
If the rings are worn out, replacement is necessary. If the rod is in poor condition (that is much less
frequent) it is necessary to grind it. Take into account that it will never be possible to obtain a good
seal if the piston rod is not perfectly smooth or if presents ovalization or tapering.
8.4.2.1 Disassembly
Given the particular shape of the rings, they could be disassembled through the opening of the
distance piece without removing the cups and the rod. In reality, the repair can be carried out more
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easily on the bench. Therefore we recommend the following procedure, which requires previous
detaching of piston rod from the crosshead and removal of the partition cover seal.
- Detach the piping connected to the packing (oil, vents, cooling).
- Unscrew the nuts on the stud bolts fastening the packing flange.
- Move the crosshead to the inner dead centre and the piston to the outer dead centre. For
some types of compressor it may be necessary to move the complete partition cover towards
the frame, detaching any pipes inside the distance piece which could obstruct movement.
- Withdraw the packing along the rod as far as possible, either pulling it by the flange, or utilising
the pullers, if any.
- Unscrew the nuts from the tie rods assembling the packing.
- After having placed the protective sheath on the threaded end of the rod or, in the absence
of this, after having applied adhesive tape, pull out the packing flange and remove it from the
rod, passing it through the hole of the partition cover (if the flange does not pass, disassemble
the cover).
- Pull out, one at a time, the various cups, extracting them through the opening of the distance
piece.
8.4.2.2 Assembly
To assemble the piston rod packing, carry out the disassembly procedure in reverse order. In general,
when disassembling the piston rod packing, it is preferable to replace the packing rings in any case.
If however it is considered appropriate to reassemble the old rings, they should be well cleaned using
adequate methods, any burrs caused by wear should be removed, and their state of wear should
be checked, to assess whether they can still be used or whether they must be replaced (see also
PISTONS PISTON RODS paragraph, WEAR ON PISTON RODS - GRINDING). Keep in mind that the axial
clearance between rings and cups must be within the limits specified on the assembly drawing of
the packing.
CAUTION
Examine carefully the packing assembly drawing, both as regards the position of the rings inside
the cups and as regards the position of the cups in the packing.
For cooled packing, check and carefully reassemble the O-ring seals.
Using a torque wrench, tighten to the torque value specified in the CYLINDER ASSEMBLING DATA
Table, included in the PART LISTS Volume of the Manual.
The flange should be tightened by operating gradually on the bolts. Defects in parallelism at assembly
of the flange are possible causes of rubbing between rod and cups and of leakage.
After assembly, check with air that various passages (oil, water, vents) are clear.
After a few hours of operation, check the tightness of the pack, checking any yielding of the gaskets.
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Figure 51
LEGEND
A TYPE "P"
B TYPE "TR"
C TYPE "RT"
D TYPE "TT"
E TYPE "RTP"
F CYLINDER SIDE
G FRAME SIDE
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8.5 VALVES
8.5.1 Description
8.5.1.1 Operation
The valves are of the automatic type. They open due to the differential pressure between the cylinder
and the suction or discharge chambers, and close due to the load of springs acting on the shutters,
opposed to the gas thrust which keeps the valve open.
The graphs shown in Figure 55 represent the theoretical compression cycle of a cylinder and the
lift of the suction and discharge valve shutter.
The following phases are shown:
1-2: compression
2-3: discharge
3-4: re-expansion
4-1:suction
as well as the following points:
- (1) The piston is at the inner dead centre and the suction valve has just closed.
- (2) The discharge valve opens (the pressure inside the cylinder has reached the discharge
pressure value).
- (3) The piston is at the outer dead centre and the discharge valve has just closed.
- (4) The suction valve opens (the pressure inside the cylinder has reached the suction pressure
value).
WARNING
THE VALVES OPERATION, AND THUS THE COMPRESSION CYCLE, IS INFLUENCED BY A GREAT
NUMBER OF PARAMETERS TAKEN INTO CONSIDERATION FOR COMPRESSOR DESIGN, WITH THE
AIM OF OPTIMISING VALVE OPERATION, OBTAINING THE BEST PERFORMANCE IN TERMS OF FLOW
RATE AND ENERGY CONSUMPTION AS WELL AS A HIGH COMPRESSOR RELIABILITY DEGREE. THUS,
FOR OPTIMUM COMPRESSOR SERVICE, OPERATION MUST TAKE PLACE IN STRICT COMPLIANCE
WITH THE DESIGN CONDITIONS.
8.5.1.2 Components
The main components of the valves are:

- Seat:
the main body of the valve, which withstands the differential pressure (between discharge
and suction) when the valve is closed; it also distributes the gas flow to the shutters.
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- Counterseat:
the valve component which limits the lift of the shutters and contains the springs.
- Shutter:
the element which, like the seat, withstands the differential pressure when the valve is closed,
ensuring gas seal; it may be shaped as a ring, twin rings, plate or poppet.
- Spring:
the element that acts on the shutter, causing the closure of the valve; it may be either
cylindrical or tapered.
A valve detail in the opened and closed positions is shown in Figure 56 .
8.5.1.3 Types
Assembly drawings of the valves installed on the compressor are shown in the PART LISTS Volume
of the Manual.
8.5.2 Maintenance
Compressor performance is strongly influenced by the condition of the valves. Accordingly, it is

essential that no condition which could alter correct valve operation occur during operation. It is
equally important that maintenance is carried out correctly, by carefully following the instructions
given below.
It is recommended that maintenance is carried out by skilled personnel.
In addition to the scheduled maintenance to be carried out on all valves of the compressor at the
intervals specified in the MAINTENANCE Section, it may at times become necessary to identify and
check the valves whose operation appears to be defective. In this case, an industrial stethoscope or
a sound spectrograph and a portable thermowire can be used to identify valves incorrectly
operating. They are usually distinguished by an increase in noise level and/or temperature of the
relevant covers (keep in mind the information shown for valves in the MAINTENANCE Section, SAFETY
PRECAUTIONS - MAINTENANCE PROGRAM paragraph, GENERAL INFORMATION item.)
WARNING
IF, DURING INSPECTION, ANY COMPONENTS OR PARTS OF THE VALVES (SPRINGS, PLATES, ETC.)
ARE FOUND TO BE MISSING, IT WILL BE NECESSARY TO CHECK THAT THESE ELEMENTS HAVE NOT
REMAINED INSIDE THE CYLINDER; IF NOT REMOVED, THEY COULD DAMAGE THE CYLINDER ITSELF
OR OTHER PARTS.
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8.5.2.2 Valve assembly preliminary check
After the valves have been removed from the cylinder for maintenance, before proceeding to internal
inspection it will be necessary to verify their condition as regards:
- presence of undue substances (solids, liquids)
- presence of lube oil.
The valves should appear clean, free from deposits and liquids. Only those installed on lubricated
cylinders should be covered by a very thin, even film of oil.
If undue substances (condensates, entrained liquids, carbon deposits, polymerization products, etc.)
are present, it will be necessary to remove the causes that have produced them.
8.5.2.3 Checking and restoring valve components
The main checks to be carried out on the component parts of the valves are described hereinafter.
If the life of parts subjected to wear (shutters and springs) is found to be poor, send to NUOVO
PIGNONE the information shown in the card COMMENTS ON VALVES OPERATION (see Figure 52 and
Figure 53 for ring valves, Figure 54 for plate valves).
8.5.2.3.1 Seat
Check for any hammering marks on the mating surfaces with the cylinder and on the cage, and for
signs of gas flowing outside of the valve seat. These defects could be caused by loosening of the
fastening system holding the valve and cage in the cylinder. If necessary, restore these surfaces.
Check the sealing surface with the shutters. If distortion or hammering signs exist, with loss of
planarity, it is necessary to restore the surface by finish-grinding (or as alternative, by hand lapping
using very thin emery paste), proceeding as follows:
a. Remove dowels or guide pins inserted in the seat.
b. Restore the seat, machining only the sealing surface of the plates; all the following conditions
must be complied with (see Figure 57 ):
minimum A: 0.6 X C
minimum B:
- 3 mm for suction valve
- 2 mm for discharge valve
c. After having reassembled the dowels or pins (if any), check that their length protruding from
the seat is exactly the same as before. If necessary, deepen the housing holes, using a drill
with diameter 0.1 mm less than the diameter of the dowels or pins.
d. In suction valves with cast iron valve unloader, with the unloader lowered, the limit stop must
be in point D (see Figure 58 ), and approximately 0.2 mm of clearance must remain between
shutter and counterseat at point E. Obviously, if the restoring procedure has reduced the seat
thickness by more than 0.2 mm, the limit stop is shifted from point D to point E. In this case
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the thrust of the device will be entirely discharged onto the valve unloader fingers and onto
the shutters.
To avoid this, it is necessary to increase the thickness of the ring F by exactly as much as the
thickness of the seat that has been reduced.
8.5.2.3.2 Counterseat
Check the total clearance between shutter (new) and guide. For rings guided on both inside and
outside diameter, the lesser of the two clearances is the one to be taken into consideration. If the
clearance measured is greater than the maximum shown in Figure 59 on the basis of the diameter,
it is necessary to replace the counterseat if the guides are integral with it, or to replace the guide
blocks only, if they are inserted in the counterseat. In this case, comply with dimensions and
tolerances shown in Figure 60 and remove the sharp corners from the guide blocks.
8.5.2.3.3 Shutters and springs
As these are the components subjected to wear, it is advisable always to replace them after the time
of operation specified in the MAINTENANCE Section. However, if the need to inspect the valves arises
after only a brief period of operation, it is advisable to inspect shutters and springs also to verify
whether or not they can be used again.
8.5.2.3.3.1 Shutters
In general, these can be used again on condition that:
- the hammering mark of the seat on the shutter does not exceed 0.2 mm in depth.
- the impressions made by the coils of the springs do not exceed 0.2 mm in depth.
- the impressions made by the unloader fingers do not exceed 0.2 mm in depth.
- the defect of flatness of the metal shutters does not exceed the maximum acceptable value
of 0.05 mm.
WARNING
SHUTTERS TO BE USED AGAIN MUST BE REASSEMBLED IN THEIR PREVIOUS POSITION WITH

REFERENCE TO SPRING SIDE AND SEAT SIDE.
8.5.2.3.3.2 Springs
The check shall be extended to all the springs in the valve. For each shutter one of the following two
cases are possible:
a. One or more springs are broken: replace all the springs of the shutter.
b. All the springs are integral. Only those that pass the following checks can be used again:
- absence of wear;
- the free height of the spring is equal to that of the new springs supplied as spare part
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8.5.2.3.4 Stud bolt
Check the state of the thread engaged with the nut. In case of damage that requires replacement
of the stud bolt, carry out the following procedure.
8.5.2.3.4.1 Caulked stud bolt

- Turn 2 mm in depth over a diameter d = (D - 1) mm and unscrew the stud bolt (1).
- Screw down the new stud bolt, tightening it well (2).
- Caulk to fill the groove C (3).
- Turn to the diameter "D" complying with tolerance and squareness (4).
8.5.2.3.4.2 Stud bolt with pin

- Remove the lock pin by drilling with diam. ø = 4 mm, and unscrew the stud bolt (1).
- Tighten well the new stud bolt (2).
- Carry out a new hole for the lock pin with diam. ø = 3 mm, insert the new pin, caulk the edge
of the hole (3).
- Turn to diameter "D" (4) complying with tolerance and squareness.
8.5.2.3.5 Nut
Check that the self-locking nut has not lost its elasticity. Specifically, ensure that the tapered and
notched part offers resistance when screwed onto the stud bolt.
8.5.2.4 Checks on assembled valves prior to installation
After each inspection or maintenance procedure, the following checks must always be carried out.
8.5.2.4.1 Self-locking nut tightening check
Verify that the self-locking nut has been tightened to the torque value shown in the paragraph
TORQUE WRENCH SETTINGS AND HYDRAULIC TIGHTENING PRESSURES in the MAINTENANCE Section,
as a function of the thread diameter.
8.5.2.4.2 Sealing check on ring type valves
The test, to be performed in case of metal rings only, shall be carried out by filling the valve seat with
liquid having low specific gravity. Two minutes after filling, the amount of liquid still remaining in the
seat must be at least equal to a half the initial amount of liquid. If the test results are negative, the
valve must be disassembled to search for and remove the cause of the poor sealing (for example,
presence of dirt, defects in the seat and/or the shutters, assembly errors). When the valve has been
reassembled, the checks described in Paragraph 5.2.4.1 and Paragraph 5.2.4.2 must be repeated.
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8.5.2.4.3 Unloader check
On suction valves with unloader, except for those with disc-type shutter, it must be checked that,
when the unloader is pressed down, the limit stop is in point D (see Figure 58 ), and that between
shutter and counterseat there is a clearance E = 0.1 - 0.2 mm.
If the result of this check is negative, the valve must be disassembled and checked to see whether
the defect is due to incorrect assembly or to the presence of dirt, or to a dimensional error in the
valve components (see d Paragraph 5.2.3.1 ).
When the valve has been reassembled, checks Paragraph 5.2.4.1 , Paragraph 5.2.4.2 and Paragraph
5.2.4.3 must be repeated.
8.5.2.4.4 Shutters check
All the shutters must be checked to verify that they can move freely.
For this purpose, each shutter must be pressed against the counterseat on at least three equally
spaced points. Use a suitable tool, operating through the slots in the seat.
If free movement is not possible, the valve must be disassembled to search for and remove the cause
of the defect. When the valve has been reassembled again, all the checks described above must be
repeated.
8.5.2.5 Nut tightening and loosening equipment
The equipment (supplied, upon request, by NUOVO PIGNONE) is shown in the drawing in Figure 63 . It can be easily us
WARNING
DO NOT CLAMP VALVES DIRECTLY IN THE VICE. OPERATE ON THE NUT EXCLUSIVELY WITH A
TORQUE WRENCH.
8.5.3 Disassembly from cylinder and reassembly
WARNING
THE VALVES REMOVED FROM THE CYLINDER SHOULD BE REASSEMBLED WITH MAXIMUM CARE.
INCORRECT ASSEMBLY CAN CAUSE SEVERE HAZARD. AMONG OTHER THINGS, ENSURE THAT THE
VALVES ARE REASSEMBLED IN THE RIGHT HOUSING. TO DO THIS, COMPARE THE CODES PRINTED
ON THE VALVE BODIES WITH THOSE SHOWN ON THE CYLINDER DATA PLATE, TO FIND THE TYPE
(EITHER SUCTION OR DISCHARGE) AND THE CYLINDER ON WHICH THEY SHALL BE INSTALLED.
VERIFY ALSO THE POSITIONS OF SUCTION OR DISCHARGE SIDE OF EACH CYLINDER (TOP OR
BOTTOM), REFERRING TO THE COMPRESSOR DATA SHEETS OR THE GENERAL ARRANGEMENT
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DRAWING (REFERENCE DRAWINGS VOLUME OF THIS MANUAL). THE DATA PLATES SHALL BE KEPT
INTEGRAL AND CLEARLY LEGIBLE.
The fixture shown in the drawing of Figure 64 can be used to facilitate disassembly and assembly
of heavy valves especially when located in the bottom ports of the cylinder.
The equipment, supplied upon request by NUOVO PIGNONE, consists of welded plates and sections,
and an extraction system housed in a guide bush of the structure.
The main components, listed with reference to the above mentioned drawing are:
1 - Guide bush
2 - Handwheels
3 - Plate
4 - Nut
5 - Lock nut
6 - Channel section
7 - Puller
When disassembling and reassembling valves with this equipment, follow the instructions shown
below.
8.5.3.1 Disassembly
- Place the plate 3fixing it to the stud bolts of the valve cover by means of nuts9.
- Assemble the puller 7 with the guide bush and screw it onto the valve stud bolt; fasten valve
and cage together by means of the channel 6, the nut 4 and the lock nut 5, verifying that the
two hand wheels 2a and 2b, screwed onto the puller rod, are placed as shown in the Figure
64 .
- Loosen the setscrew 8 locking the cage or remove other existing fastening systems.
- Rotate alternatively the two handwheels by a few turns at a time, starting from the one closest
to the cylinder, until valve and cage have been completely extracted.
- Remove the puller, with all the connected parts, from the guide bush.
- Disassemble valve and cage, by unscrewing the lock nut, the nut and the puller.
- Disassemble the plate from the cylinder stud bolts.
8.5.3.2 Reassembly
- Place the plate 3 fixing it to the stud bolts of the valve cover by means of nuts 9.
- Screw the puller 7 to the valve stud bolt and assemble valve and cage by means of channel
6, nut 4 and lock nut 5. Screw the handwheel 2b onto the puller rod.
- Insert the puller into the guide 1of the plate, verifying that the handwheel is located between
guide and cage.
- Rotate the handwheel 2b until valve and cage have been completely inserted into the port.
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- Screw the setscrew 8of the cage or insert other existing fastening systems.
- Unscrew the lock nut and nut and remove the channel. Unscrew the puller from the valve stud
bolt.
- Disassemble the plate from the valve cover stud bolts.
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Figure 52 - COMMENTS ON OPERATION OF RING TYPE VALVES - Sheet 1 of 3
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Figure 53 - COMMENTS ON OPERATION OF RING TYPE VALVES - Sheet 2 of 3
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Figure 54 - COMMENTS ON OPERATION OF PLATE TYPE VALVES - Sheet 3 of 3
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Figure 55
LEGEND
A STROKE
B SUCTION PRESSURE
C DISCHARGE PRESSURE
D OUTER DEAD CENTER
E INNER DEAD CENTER
F DISCHARGE VALVE LIFT
G SUCTION VALVE LIFT
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Figure 56
LEGEND
A CLOSED VALVE
B OPEN VALVE
C SEAT
D SHUTTER
E SPRING
F COUNTERSEAT
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Figure 57
LEGEND
A SUCTION
B DISCHARGE
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Figure 58
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Figure 59
LEGEND
A MAX. CLEARANCE
B SHUTTER DIAMETER
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Figure 60
LEGEND
A SUCTION
B DISCHARGE
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Figure 61
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Figure 62
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Figure 63
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Figure 64
LEGEND
A VIEW FROM A
B SECTION B-B
C SECTION C-C
D VIEW FROM D
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8.6 REVERSE-ACTION GAS OPERATED DEVICE FOR VALVE UNLOADER

CONTROL
8.6.1 Operation
The movement of the suction valve unloader is carried out by a reverse-action actuator, with remote
control through the pressure of a gas.
CAUTION
The gas used for control must be absolutely dry, to avoid the possibility of moisture blocking the
device.
Check at regular intervals that the gas pressure is at the required value. A pressure value lower
than the required one can hinder the full stroke of the stem, with consequent fluttering of the
valve shutters on the unloader. Damage may occur as a consequence.
The actuator, shown in the drawing in Figure 65 included in this paragraph, is designed to obtain
the following operations:
a. - Actuating gas in (through C).
- The stem is up.
- The valve is loaded.
b. - Actuating gas out.
- The stem is down.
- The valve is unloaded.
8.6.2 Maintenance
WARNING
DURING DISASSEMBLY/ASSEMBLY OF THE ACTUATOR, HOLD THE SPRING SECURELY TO AVOID A

SUDDEN RELEASE THAT COULD CAUSE INJURIES.
During each overhaul of the actuator, check all gaskets and seals, ensure that worn out or damaged
ones are replaced.
After reassembly of the actuator, check the stroke length of the stem and verify that it slides freely.
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Figure 65
LEGEND
A STEM
B VENT
C GAS IN
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8.7 DIRECT-ACTION GAS OPERATED DEVICE FOR CLEARANCE POCKET VALVE

CONTROL
8.7.1 Operation
The movement of the clearance pocket valve unloader is carried out by a direct-action actuator,
with remote control through the pressure of a gas.
CAUTION
The gas used for control must be absolutely dry, to avoid the possibility of moisture blocking the
device.
At regular intervals check that the pressure of the actuating gas is at the required value. A
pressure value lower than the required one can hinder the full stroke of the stem, with consequent
fluttering of the valve shutters on the unloader. Damage may occur as a consequence.
The actuator, shown in the drawing in Figure 66 included in this paragraph, is designed to obtain
the following operations:
- actuating gas in (through A):
the stem is down: the valve is open, clearance pocket and cylinder are connected.
- actuating gas out:

the stem is up: the valve is closed, clearance pocket and cylinder are disconnected.
CAUTION
During operation, periodically drain any liquid that may have accumulated in the clearance
pocket.
8.7.2 Maintenance
During each overhaul of the actuator, check all gaskets and seals, ensure that worn out or damaged
ones are replaced.
After reassembly of the actuator, check the stroke length of the stem and verify that it slides freely.
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Figure 66
LEGEND
A GAS IN
B VENT
C STEM
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8.8 CHECKING PISTON ROD OSCILLATION SAFETY DEVICES FOR WEAR OF

PISTON RIDER RINGS

An excessive oscillation of the piston rod may indicate defects, even severe, in operation. For this
reason, the compressor can be equipped with special instrumentation for checking and measuring
rod oscillation.
Excessive wear on the piston rider ring can result in harmful direct contact between the piston itself
and the cylinder.
For protection against this trouble, the compressor can be equipped with special devices designed
to check the wear of rider rings, either sending a signal or stopping the machine when wear reaches
certain set limits.
8.8.2 Piston rod oscillation check

If the compressor is equipped with rod drop detection devices, the relevant procedure is shown in
Section VARIOUS DOCUMENTS.
CAUTION
The device positioning and the monitor calibration and tuning will be performed and/or verified
by the customer after compressor installation and prior to startup.
8.8.3 Safety devices for rider rings wear
8.8.3.1 Magnetic induction proximity probe
This device is used to detect lowering of the piston rod during operation and, indirectly, the wear on
the rider ring causing such drop. With reference to Figure 67 , it is:
da = dp x (L - L1) / L
where dp is the drop of the piston due to the rider ring wear and da is the corresponding drop of the
rod measured by the probe.
where: dp is the drop of the piston due to the rider ring wear and da is the corresponding drop of
the rod measured by the probe.
The ROD DROP AND RUN-OUT DATA Table or the CYLINDER ASSEMBLING DATA Table, included in the
PART LISTS part of the Manual, gives the maximum value of rod drop dx due to the maximum value
dq of wear of the rider ring. The value of dx has been calculated on the basis of the thickness of the
new rider ring, of the depth of the rider ring groove in the piston, of the minimum projection of the
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rider ring (see graphs in PISTONS - PISTON RODS paragraph), and of the geometry of the piston rod-
crosshead assembly. The table also shows the values of L andL1.
For calculating dx, the clearance between crosshead and sliding surfaces of the crosshead extension
must be considered. This clearance has been considered either at the top or at the bottom, depending
on the direction of rotation of the shaft (clockwise or counterclockwise) and on the position of the
crosshead in relation to the shaft (right or left).
Being:
dq = Sn - Sm
where:
Sn = projection of the new rider ring
Sm = minimum projection of the worn rider ring,
we have:
dx = dq x (L - L1) / L
The positioning of the probe at assembly must be carried out, by the adjusting devices, with the
piston rod positioned at the inner dead centre; the probe will be placed at a distance dy from the
rod;
dy = dx + g
being g the clearance which, in conditions of maximum wear, will prevent direct contact between
rod and probe.
CAUTION
Ensure that, within the range of excursion in the drop of the rod, the instrument operates within
its own linearity range.
The instrument will be calibrated so that the distance read on the monitor coincides with the dy
value measured mechanically.
The wear dp of the rider ring can be checked at any time during operation:
dp = (dy - m) x L / (L - L1)
being m the value read on the monitor.
Maximum wear will be reached when:
m=g
CAUTION
After replacement of the rod or of the probe, it will be necessary to calibrate the device again.
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NOTE
If the compressor is equipped with this check and safety device, the relevant procedure is shown
in Section VARIOUS DOCUMENTS.
8.8.3.2 Melting or rolling device
The melting device is located under the piston rod. The typical diagram for installation and relevant
auxiliaries is shown in Figure 68 . When the rider ring reaches maximum wear, the rod comes into
contact with the device. The heat produced by friction causes melting of a plug fuse inserted in the
device, with the consequent escape of the gas from the circuit. The resulting pressure drop actuates
an alarm or trip system.
In similar way, in the rolling device, the contact with the rod opens a discharge for the gas in the
device.
The gas specifications are shown in a device diagram or in the GAS P&I DIAGRAM (see Volume of
REFERENCE DRAWINGS Volume of the Manual).
WARNING
IN ANY CASE, AVOID USING DANGEROUS GAS FOR FEEDING THE SYSTEM, ALSO IN RELATION TO
THE COMPRESSOR SERVICE.
Positioning of the instrument at assembly shall be carried out using the adjustment devices, with
the piston positioned at the inner dead centre.
The distance of the device from the piston rod at assembly, dx (see also Paragraph 8.3.1 ) is given
by the ROD DROP AND RUN-OUT DATA table or in the CYLINDER ASSEMBLING DATA Table.
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Figure 67
LEGEND
A ROD WITH NEW RIDER RING

B ROD WITH PARTIALLY WORN RIDER RING
C ROD WITH RIDER RING AT MAXIMUM WEAR
D ROD DROP MEASUREMENT DEVICE
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Figure 68
LEGEND
A ALARM/TRIP
B PISTON ROD
C PLUG FUSE
D ORIFICE
E GAS IN
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9 - LUBRICATION
1 CRANK GEAR LUBRICATION .......................................................................................................................249 1-249

1.1 Safety precautions - General information ........................................................................................249 1-249
1.2 Lubrication system .......................................................................................................................................249 1-249
1.2.1 Pumps ................................................................................................................................................................249 1-249
1.2.2 Coolers ...............................................................................................................................................................250 1-250
1.2.3 Filters ..................................................................................................................................................................250 1-250
1.3 Omponents description, usage and maintenance .......................................................................251 1-251
1.3.1 Pumps ................................................................................................................................................................251 1-251
1.3.2 Lube oil pressure control ...........................................................................................................................252 1-252
1.3.3 Cooler .................................................................................................................................................................253 1-253
1.3.4 Filter ....................................................................................................................................................................253 1-253
1.3.5 Lube oil ..............................................................................................................................................................254 1-254
2 CYLINDERS AND PISTON ROD PACKING LUBRICATION .................................................................260 1-260
2.1 Safety precautions - General information .......................................................................................260 1-260
2.2 Lubricator .........................................................................................................................................................260 1-260
2.3 Lube oil ..............................................................................................................................................................260 1-260
2.3.1 General information and specifications .............................................................................................260 1-260
2.3.2 Lube oil rate .....................................................................................................................................................261 1-261
3 LUBRICATION OF AUXILIARIES ..................................................................................................................262 1-262
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9.1 CRANK GEAR LUBRICATION
9.1.1 Safety precautions - General information

The lubrication system supplies the compressor crank gear with a lube oil of a grade suitable for the
service and with adequate conditions of:
- pressure
- temperature
- cleanliness.
WARNING
THE LUBRICATION SYSTEM OF THIS MACHINE OFFERS THE MOST COMPLETE PROTECTION FOR
OPERATION FREE FROM ANY PROBLEM AT THIS REGARD. IT SHOULD NEVER BE FORGOTTEN
HOWEVER THAT, IF DIRT AND FOREIGN MATTERS IN GENERAL ARE ALLOWED TO ENTER THE
SYSTEM, VARIOUS COMPONENTS, BEARINGS IN PARTICULAR, MAY BE SEVERELY DAMAGED EVEN
IN A VERY SHORT TIME.
WARNING
PRIOR TO CARRYING OUT ANY PROCEDURE ON THE SYSTEM, REFER TO THE INFORMATION GIVEN
IN THE GENERAL INFORMATION SECTION, RELEVANT TO THE GENERAL SAFETY PRECAUTIONS AND
THE PARAGRAPH SAFETY PRECAUTIONS - MAINTENANCE PROGRAM IN THE MAINTENANCE
SECTION.
9.1.2 Lubrication system

The particular characteristics of the lube oil system and the operating characteristics of its
components always depend on many factors. Some comments on the various types of pumps,
coolers and filters that can compose the lube oil systems are given below. For the configuration of
the lube oil system of this compressor, refer to the COMPRESSOR FRAME LUBE OIL P&I DIAGRAM in
the REFERENCE DRAWINGS Volume of this Manual.
Regarding instrumentation, see also the FIELD INSTRUMENT LIST AND SETTING VALUES included in
the above mentioned part and the AUXILIARIES Volume of the Manual.
Regarding description, usage, and maintenance of the various components, see Paragraph 1.3 of
this paragraph.
9.1.2.1 Pumps
The solutions generally chosen are the following:
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- Main pump driven by compressor shaft, plus prelube hand operated pump for start-up.
- Main pump driven by compressor shaft, plus auxiliary motor driven pump for prelubrication
at start-up and as standby.
- Single motor driven pump.
- Two motor driven pumps, one of them as standby.
9.1.2.2 Coolers
The system may include a cooler or two identical coolers. In the latter case, each of the coolers may
be in service in turn. A proper system of valves ensures cooling continuity during switching. Thus
maintenance can be carried out on a cooler, while the other ensures normal operation.
9.1.2.3 Filters
A filter is placed close to the inlet of the frame lube oil manifold.
If a dual filter is used, its sections can be connected in turn by means of a system of valves that
ensures continuity of the flow during switching. In this way, the filter cartridge of one section may
be replaced or cleaned, while the other provides for normal operation.
The suction strainer is located inside the sump, at the inlet of the pump suction piping, or in the first
length of the same. This strainer carries out initial rough filtering of the oil, preventing impurities of
larger size from entering the system and damaging the pump.
WARNING
THE COMPRESSOR IS EQUIPPED WITH A TEMPORARY FILTER PLACED ON INLET TO THE FRAME'S
OIL MANIFOLD. THIS FILTER RETAINS ANY DIRT LEFT IN THE SECTION OF THE SYSTEM
DOWNSTREAM OF THE MAIN FILTER. IT MAY HAPPEN THAT ITS CLOGGING CAUSES EXCESSIVE
PRESSURE DROP IN THE OIL. IN THIS CASE, STOP THE MACHINE AND CLEAN THE FILTER. IN ANY
CASE, INSPECTION SHOULD BE MADE DURING THE FIRST OIL CHANGE (SEE RELEVANT
INSTRUCTIONS BELOW). IF THE FILTER IS CLEAN, SINCE IT IS NOT DESIGNED FOR CONTINUOUS
SERVICE, REMOVE IT. OTHERWISE, INSTALL IT AGAIN AFTER HAVING CLEANED AND INSPECT IT
AGAIN AT THE NEXT OIL CHANGE. IF ON THIS OCCASION TOO IT SHOULD BE FOUND DIRTY, IT IS
ADVISABLE TO MAKE A CAREFUL INSPECTION OF THE SYSTEM TO IDENTIFY AND DEFINITIVELY
REMOVE THE ORIGIN OF THE DIRT. IT IS ADVISABLE TO INSTALL THIS FILTER AGAIN, WHENEVER
MECHANICAL PROCEDURES ARE CARRIED OUT ON THE PIPING AND/OR EQUIPMENT UPSTREAM
OF IT, AND TO FOLLOW A PROCEDURE SIMILAR TO THE ONE DESCRIBED HERE ABOVE.
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9.1.3 Omponents description, usage and maintenance
9.1.3.1 Pumps
9.1.3.1.1 Frame shield built-in pump
9.1.3.1.1.1 Description and operation

This is a gear pump driven by the compressor shaft (see Figure 69 ). It is sized for a flow rate higher
than that required in normal operation. The pump cover is equipped with a safety and control valve
(generally of the type shown in Figure 70 ), which protects from overpressure and determines the
oil flow rate and pressure in the system (see LUBE OIL PRESSURE CONTROL, in this paragraph). If the
compressor is equipped with this type of pump, part list and assembly drawing are included in the
PART LISTS volume of the Manual.
9.1.3.1.1.2 Maintenance
The lube oil pump is usually overhauled when the machine is subjected to general overhaul.
Wear and defects in the components of the pump are revealed by a change in the discharge pressure
and by troubles in its control. If oil leakage out of pump should occur, replace the seal ring.
After having removed the pump from the frame, disassemble the various parts, marking the two
gears so as to be sure to reassemble them in the correct position. Clean all the parts thoroughly with
solvent, check the valve seals and replace them if necessary.
9.1.3.1.2 Pump installed onto the shield
9.1.3.1.2.1 Description and operation

This is a gear pump (see Figure 71 ): driven by the compressor shaft through a coupling connecting
the shaft to the pump. The pump is equipped with a safety valve, protecting it from overpressure.
This valve is factory-calibrated to the value specified on the COMPRESSOR FRAME LUBE OIL P&I
DIAGRAM. If the compressor is equipped with this type of pump, see the volume of the Manual
relevant to AUXILIARIES, for identification data and technical documentation.
9.1.3.1.2.2 Maintenance
See Paragraph 1.3.1.1.2 and the technical documentation.
9.1.3.1.3 Motor driven pump
If the compressor is equipped with this type of pump, see the volume of the Manual relevant to
AUXILIARIES, for identification data and technical documentation.
Generally, the pump is a gear pump and is driven by an electric motor, whose characteristics are
shown in the COMPRESSOR FRAME LUBE OIL P&I DIAGRAM. It is equipped with a safety valve, as
described in Paragraph 1.3.1.2.1 .
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Keep in mind that the pressure at the pump suction shall not normally be lower than -0.2 bar and
the pressure in the pump seal casing shall be positive, in the order of a few tenths of a bar (refer to
specific instructions provided by the pump manufacturer). To control the correct operation of the
pump components and of the oil system, a vacuum gauge is to be used. It can be preassembled on
console or on skid, or can be assembled at site. This instrument will be assembled through two
connections, one at the suction, the other at the pump casing. A three-way valve will allow reading
the pressure at suction or in the pump casing.
For further data and for pump maintenance, refer to the technical documentation.
9.1.3.1.4 Hand operated pump
This is used exclusively to perform sufficient lubrication at compressor start-up, if no motor driven
pump is installed in the system.
If the compressor is equipped with this type of pump, see the volume of the Manual relevant to
AUXILIARIES, for identification data and technical documentation.
For further data and for maintenance, refer to the technical documentation.
9.1.3.2 Lube oil pressure control
The lube oil pressure must be within the range of values shown in the COMPRESSOR FRAME LUBE
OIL P&I DIAGRAM.
The devices used for controlling the oil pressure are described below. The solution adopted for this
compressor is shown in the above mentioned diagram.
9.1.3.2.1 Relief and pressure control valve integral with the pump
This is used when the main pump is of the type described in Paragraph 1.3.1.1 .
This valve is of the manually operated type and its calibration must be carried out or in any case
checked again at the jobsite with the machine in operation, so that the pressure reading on the
pressure gauge of the frame oil header is at the correct value. See the above mentioned DIAGRAM.
9.1.3.2.2 Pressure control valve external to pump
This valve is appropriately inserted into the lube oil system.

Its calibration must be performed on the jobsite with the machine in operation, as for the valve of
Paragraph 1.3.2.1 .
9.1.3.2.3 Control valve in the piping and control valve at the frame oil header
These valves are appropriately inserted in the lube oil system.

Calibration of these valves must be performed at the jobsite with the machine in operation. The first
valve must be set so as the pressure at cooler outlet is within the limits specified in the above
mentioned diagram. The second one must be calibrated in the same way as the valve described on
Paragraph 1.3.2.1 .
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9.1.3.3 Cooler
9.1.3.3.1 General information and identification
The purpose of the cooler is to maintain the lube oil temperature within the range of values specified
in the COMPRESSOR FRAME LUBE OIL P&I DIAGRAM.
The cooler is generally of the tube bundle type, with oil in shell. It is preferable to have the coolant,
which can produce deposits, in the tubes, being these easily cleaned.
Regarding identification and characteristics of the cooler, see the above mentioned diagram and
the documentation included in the AUXILIARIES Volume of the Manual.
9.1.3.3.2 Maintenance
At time intervals suggested by the results of operation, inspect the cooler and mechanically or
chemically clean the coolant side, if required. On these occasions, verify that the cooler is integral,
so that the coolant and the lube oil cannot come in contact.
If during operation, leakage should occur and if the oil pressure is higher than that of the coolant,
the oil will enter the coolant system and will be entrained away. This defect will be revealed by the
level of oil in the oil sump. If substantial amounts of oil are lost, the pressure switch inserted in the
lube oil circuit may even trip.
When instead the oil pressure is lower than the coolant pressure, the coolant will enter into the oil,
causing contamination and consequent damage, (even very severe), to the crank gear. For these
reasons, we strongly recommend operating with the oil pressure higher than the coolant pressure.
Similarly, when there is an oil heater using a fluid, we recommend operating with the pressure of
the same fluid (e.g. steam) lower than that of the oil.
Consider also that, when the compressor is in the pre-start-up phase or is just stopped, the pressure
of the heating and cooling fluids may exceed that of the oil.
9.1.3.4 Filter
9.1.3.4.1 General information and identification
The filter is designed to remove from the lube oil the various solid pollutants that could damage the
lubricated parts.
Regarding the filter characteristics, see the COMPRESSOR FRAME LUBE OIL P&I DIAGRAM and the
documentation included in the AUXILIARIES Volume of the Manual, in which the data for identification
of the filter and the code number of the filtering element are found, as well as the technical
documentation.
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9.1.3.4.2 Maintenance
The time for the cartridge to become dirty is that elapsing between the time when it is put in service
and that when reaching the maximum permissible pressure drop (see COMPRESSOR FRAME LUBE
OIL P&I DIAGRAM).
This time is approximately 2500 hours. This value is however largely variable, depending on the
amount of pollutants in the system and, in the case of paper cartridges (see below), also on the
amount of water contained in the lube oil.
Therefore, at the first start-up and following maintenance on the crank gear and/or oil replacement
(which always contains pollutants, even when fresh), a shorter fouling time is expected.
For these reasons, the filter cleanliness should be checked frequently by means of differential
pressure gauge or pressure switch. In the absence of this instrumentation, check the pressure gauge
located at the end of the lube oil header of the frame. A too low pressure value may be due just to
clogging of the cartridge.
In any case, we recommend to replace the cartridge midway between an oil change and the next.
The cartridges are, in general, made of wire mesh or paper.
Wire mesh cartridges
These can be regenerated. Regeneration is performed according to the manufacturers'
specifications (see AUXILIARIES Volume of this Manual). Consider however that a reduction in the
actual filtering surface occurs at each cleaning, so a reduction in the fouling time may be expected.
For this reason, after a certain number of regenerations, it may be necessary to replace the cartridge,
even if it is apparently integral.
WARNING
IN ANY CASE, CLEANING BY IMMERSION IS TO BE AVOIDED BECAUSE DIRT PARTICLES CAN REACH
THE INTERIOR OF THE CARTRIDGE, BY THE SOLVENT.
Paper cartridges
These cannot be regenerated, but must always be replaced with new cartridges. As mentioned
above, these cartridges are sensitive also to the amount of water contained in the lube oil. In general,
the maximum permissible water content is 100 p.p.m. (=0.01%). With greater values, there is a
pressure drop through the new cartridge much greater than expected, and the increase is very rapid.
The maximum permissible value may be reached even after only a few hours of operation.
9.1.3.5 Lube oil
9.1.3.5.1 General information
The main functions carried out by the oil are the following:
- Reducing friction between surfaces with mutual sliding.
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- Removing the heat produced by friction.

- Providing protection against aggressive agents.
The use of an appropriate lube oil is of maximum importance for satisfactory operation of the
compressor.
Regarding the specifications of the oil recommended for this service, see the COMPRESSOR FRAME
LUBE OIL P&I DIAGRAM and the CHARACTERISTICS OF LUBRICATING OIL FOR «NUOVO PIGNONE»
RECIPROCATING COMPRESSORS Table, included in the Section VARIOUS DOCUMENTS. During
compressor operation, check at least daily that the oil pressure and temperature are within the limits
specified in the COMPRESSOR FRAME LUBE OIL P&I DIAGRAM (see also the item relevant to FILTER).
9.1.3.5.2 Lube oil replacement
The properties of a lube oil can be significantly altered by the presence of pollutants or by aging,
which results in oxidation.
It is advisable to replace the oil after about the first hundred hours of operation (see OPERATION
Section, STARTUP AND LOAD-TAKING, RUNNING-IN UNDER LOAD Paragraph).
Subsequent oil replacements will be made after 1000 hours, and then every 4000 hours. These time
intervals are purely indicative since consumption, contamination and loss of properties of the oil are
obviously influenced by different factors in the various situations.
As a complement to the information given in the paragraph MAINTENANCE PROGRAM, note that the
factors which must be kept most closely under control for the oils used in this compressor are
viscosity as well as pollution by gas, by liquids and by solid particles of various kind. It should always
be considered that low viscosity values impair the lubricity of the oil. Contamination by gas can cause
not only loss of viscosity, but also lowering of the flash point of the oil, with consequent hazardous
situations. The presence of liquids, besides lowering the viscosity, may cause chemical etching on
compressor parts . The presence of solid particles can cause deterioration of the the sliding surfaces
and obstruction in the oil ducts.
For a correct analysis program (frequency and schedule of operations, acceptance criteria), the
experience of the user and the suggestions of the lubricating oil supplier are always determinant.
The following should always be carried out:
- When replacing the oil, empty the system completely.
- When replacing the oil, inspect the pump suction strainer; if necessary, clean it.
- During general overhaul of the compressor, clean the entire system thoroughly. This procedure
should in any case be carried out when the presence of deposits is observed or suspected.
WARNING
OIL CAN BE REPLACED ONLY WHILE THE MACHINE IS STOPPED. EMPTYING CAN BE CARRIED OUT
MORE RAPIDLY AND THOROUGHLY BY HEATING THE OIL TO A TEMPERATURE OF APPROX. 50 TO
60°C. TO DO THIS, IN THE ABSENCE OF A HEATER, THE COOLER CAN BE USED, LETTING A HOT
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FLUID FLOW THROUGH IT. IN ANY CASE, THE OIL SHALL BE CIRCULATED BY MEANS OF A POWER-
DRIVEN PUMP (EITHER THE MAIN, AUXILIARY OR SERVICE PUMP).
WARNING
PRIOR TO DRAINING THE OIL, SWITCH OFF THE ELECTRIC HEATER (IF PRESENT) TO AVOID
CRACKING. WHEN ADDING FRESH OIL, MAKE SURE THAT THE HEATER IS NOT OVERHEATED, TO
AVOID CRACKING THE OIL.
After having replaced the oil (see above paragraph), it is necessary to take some precautions in
pressurising the system, since air may be left inside. The filter cartridge could be damaged by the
sudden flow of oil, if air is trapped in the system. All air must therefore be thoroughly vented off the
system.
Accordingly, if the prelubrication pump is hand operated, it is necessary to open all the vents in the
systems, to operate this pump, and to close the vents again when the oil begins to flow out of them.
If instead the prelubrication pump is motor driven, it is necessary first to fill the system by hand as
much as possible, particularly the cooler and the filter. Subsequently, start the pump repeatedly for
only a moment, until the immediate response of the differential pressure gauge on the filter (or, in
the absence of this, of the pressure gauge on the oil header) shows that the system is completely
filled.
WARNING
BEING OIL A POLLUTING FLUID, REPLACEMENT AND DISPOSAL SHOULD BE CARRIED OUT IN
COMPLIANCE WITH LOCAL REGULATIONS.
9.1.3.5.3 Oil sump filling - Topping up
Check periodically the oil level.

It is a good rule that, while the machine is running, the level does not drop more than 15 mm below
the middle of the relevant gauge on the oil sump. A lower level could result from poor lubrication,
due to air entering the system.
The oil is added through the special port (see, on this subject, the information supplied in the part of
the Manual containing the description of the frame).
It is recommended that the oil level does not exceed the highest mark on the gauge by more than
15 mm. Even with oil level too high, conditions of poor lubrication could occur, due to foaming made
by the connecting rod big end, if splashing into the oil.
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Figure 69
LEGEND
A RELIEF-CONTROL VALVE
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Figure 70
LEGEND
A ADJUSTING SCREW
B POPPET
C SPRING
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Figure 71
LEGEND
A ADJUSTING SCREW
B POPPET
C SPRING
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9.2 CYLINDERS AND PISTON ROD PACKING LUBRICATION
9.2.1 Safety precautions - General information

If cylinder and piston rod packing are of the lubricated type, the lubrication system supplies these
components with the required amount of lubricant.
In special cases, the lubricant can be indirectly supplied, by injecting it at certain point of the gas
circuit, for example, at the compressor intake.
The main components of this system are:
- lubricator
- instrumentation.
The lubricator can be driven by its own driver or, through a coupling, by the shaft of the crank gear
lube oil pump. In the latter case, a small crank is provided for prelubrication.
The schematic of the lubrication system for the cylinder and packing of the compressor is shown in
the CYLINDERS AND PACKING LUBE OIL P&I DIAGRAM (see part of REFERENCE DRAWINGS Volume of
this Manual).
Regarding instrumentation, see also the FIELD INSTRUMENT LIST AND SETTING VALUES included in
the same part and in the part of the Manual relevant to AUXILIARIES.
WARNING
PRIOR TO CARRYING OUT ANY PROCEDURE ON THE LUBRICATION SYSTEM, REFER TO THE
INFORMATION GIVEN IN THE GENERAL INFORMATION SECTION, RELEVANT TO THE GENERAL
SAFETY PRECAUTIONS AND THE PARAGRAPH SAFETY PRECAUTIONS - MAINTENANCE PROGRAM
IN THE MAINTENANCE SECTION.
9.2.2 Lubricator
The lubricator is designed to send lube oil, at the appropriate flow rate, to specific points of the
machine (see LUBE OIL item in this paragraph).
As regards characteristics, operation and maintenance of the lubricator, see the above mentioned
CYLINDERS AND PACKING LUBE OIL P&I DIAGRAM and the part of the Manual relevant to AUXILIARIES,
in which identification data and technical documentation are given.
9.2.3 Lube oil
9.2.3.1 General information and specifications
The main functions performed by the lube oil are:

- reducing friction between sliding surfaces
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- removing heat produced by friction

- providing protection against corrosion.
The use of the appropriate lube oil is of maximum importance for satisfactory operation of the
compressor.
Regarding the specifications of the oil recommended for this service, see the COMPRESSOR FRAME
LUBE OIL P&I DIAGRAM and the LUBRICATING OIL SPECIFICATIONS FOR NUOVO PIGNONE
RECIPROCATING COMPRESSORS Table, included in the Section VARIOUS DOCUMENTS.
9.2.3.2 Lube oil rate
The oil flow rate per minute for each injection point and for each cylinder is specified in Section
VARIOUS DOCUMENTS under CYLINDERS AND PACKING LUBRICATING OIL FLOW RATE.
WARNING
THE INDICATIONS SHOWN IN SUCH TABLE ARE BASED ON EXPERIENCE ACQUIRED WITH SIMILAR
OR IDENTICAL MACHINES. ANY CORRECTION REQUIRED MAY BE CARRIED OUT DURING
OPERATION, AFTER HAVING PERFORMED THOROUGH INSPECTION OF THE LUBRICATED
COMPONENTS. THE OIL FILM SHOULD BE LIGHT BUT THERE SHOULD BE NO SCORING DUE TO
SHORT LUBRICATION AND NO POINTS WHERE OIL IS TOTALLY MISSING.
During the first period of operation, up to 100 hours of running, it is advisable:

- if piston and rider rings and packing rings are made in plastic, to provide an oil flow rate equal
to 1.5 times that specified in the above mentioned document. Subsequently, the oil flow rate
shall be reduced progressively until reaching, after 250 hours of operation, the specified value
- in presence of metal rings, provide a flow rate double the normal one, reaching the specified
value after 500 hours.
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9.3 LUBRICATION OF AUXILIARIES

The function of the lubrication system for the auxiliaries is the same as that of the system for
compressor lubrication.
As regards schematics, components and instrumentation of this system, see the relevant LUBE OIL
DIAGRAM and the FIELD INSTRUMENT LIST AND SETTING VALUES included in the REFERENCE
DRAWINGS Volume and AUXILIARIES Volume of this Manual.
WARNING
PRIOR TO CARRYING OUT ANY PROCEDURE ON THE COMPRESSION SYSTEM, REFER TO THE
INFORMATION SHWN IN THE GENERAL INFORMATION SECTION, RELEVANT TO THE GENERAL
SAFETY PRECAUTIONS AND THE PARAGRAPH SAFETY PRECAUTIONS - MAINTENANCE PROGRAM
IN THE MAINTENANCE SECTION.
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10 - PROTECTION DURING IDLENESS - PUTTING OUT OF

SERVICE, DISMANTELLING, SCRAPPING

2 IDLENESS NOT EXCEEDING 1 MONTH ...................................................................................................266 1-266
3 IDLENESS FROM 1 TO 6 MONTHS ...........................................................................................................267 1-267
3.2 Compressors with lubricated cylinders ..............................................................................................267 1-267
3.2.1 Frame .................................................................................................................................................................267 1-267
3.2.2 Cylinders ...........................................................................................................................................................267 1-267
3.2.3 Valves .................................................................................................................................................................268 1-268
3.2.4 Piping, equipment .........................................................................................................................................268 1-268
3.2.5 Instrumentation .............................................................................................................................................268 1-268
3.2.6 Auxiliary drivers .............................................................................................................................................269 1-269
3.2.7 Non-painted machined parts .................................................................................................................269 1-269
3.3 Compressors with non-lubricated cylinders ....................................................................................269 1-269
3.3.1 Frame .................................................................................................................................................................269 1-269
3.3.2 Cylinders ...........................................................................................................................................................269 1-269
3.3.3 Valves .................................................................................................................................................................269 1-269
3.3.4 Piston rods and packings ..........................................................................................................................270 1-270
3.3.5 Piston rings, rider rings, seal rings ........................................................................................................270 1-270
3.3.6 Piping, equipment, instrumentation, auxiliary drivers .................................................................270 1-270
4 IDLENESS EXCEEDING 6 MONTHS ..........................................................................................................271 1-271
4.2 Compressors with lubricated cylinders ..............................................................................................271 1-271
4.2.1 Frame .................................................................................................................................................................271 1-271
4.2.2 Cylinders ...........................................................................................................................................................272 1-272
4.2.3 Valves .................................................................................................................................................................272 1-272
4.2.4 Piston rods and packings ..........................................................................................................................272 1-272
4.2.6 Lubricators and relevant tubing ............................................................................................................273 1-273
4.2.8 Safety valves ...................................................................................................................................................273 1-273
4.3 Compressors with non-lubricated cylinders ....................................................................................273 1-273
4.3.1 Frame .................................................................................................................................................................273 1-273
4.3.2 Cylinders ...........................................................................................................................................................273 1-273
4.3.3 Valves, piston rods and packings ..........................................................................................................274 1-274
4.3.6 Safety valves ...................................................................................................................................................274 1-274
5 RECOMMENDED PROTECTIVE AGENTS .................................................................................................276 1-276
5.1 Oils .......................................................................................................................................................................276 1-276
5.2 Dehydrating products .................................................................................................................................276 1-276
5.3 Solvents .............................................................................................................................................................276 1-276
6 PROCEDURES FOR RESTARTING ..............................................................................................................277 1-277
7 DECOMMISSIONING - DISMANTLING - SCRAPPING ........................................................................278 1-278
7.1 Decommissioning .........................................................................................................................................278 1-278
7.2 Dismantling .....................................................................................................................................................278 1-278
7.3 Scrapping .........................................................................................................................................................278 1-278
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The prescriptions relevant to protections that are given in this section apply exclusively to machinery
installed but set idle. As regards preservation of machinery during storage prior to installation, see
the MOVING, HANDLING, STORAGE Section.
These instructions are to be considered adequate for environments of average aggressiveness. They
should therefore be considered significant but neither binding nor limiting. It is therefore
recommended that, especially during the first period of idleness, the machines are subject to
appropriate inspections.
The experience and the capability of the personnel involved, totally responsible for correctly carrying
out the procedures and for the choice of the preserving means, has however a determinant role for
good preservation of the machinery. NUOVO PIGNONE Engineering department is however at
disposal of the customer who, in relation to specific requirements, usual environmental conditions
or other reasons, considers it useful to ask for suggestions.
NOTE
If special procedures for protection are required for the machine subject of this Manual, they will
be found in the GENERAL INFORMATION Section.
The components of the machine, if disassembled, shall be stored in dry, well protected areas.
In case of pressurizing of machine components with inert gas, take the appropriate precautions as
regards defects in gas supply. If nitrogen is not available, sweet gases free from oxygen, moisture
and corrosive agents may be used.
Warning notices shall be placed in the vicinity of pressurised parts, to ensure absolute safety to
personnel.
If machine parts are protected by oil or grease, ensure, immediately prior to use, that they are
perfectly cleaned and dried.
If dehydrating products are used, follow the instructions provided by the supplier, especially as
regards amount to be used, periodic checks and disposal after use, for which local and plant
regulations must be complied with.
WARNING
PRIOR TO UNDERTAKING ANY OF THE PROCEDURES DESCRIBED IN THE VARIOUS PARAGRAPHS

OF THIS SECTION, REFER TO THE RULES GIVEN IN THE GENERAL INFORMATION SECTION,
RELEVANT TO THE GENERAL SAFETY PRECAUTIONS AND THE REQUIREMENTS SPECIFIED IN THE
PARAGRAPH SAFETY PRECAUTIONS - MAINTENANCE PROGRAM IN THE MAINTENANCE SECTION.
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NOTE
In the following part of this Section, recommended protective oils are identified, for the sake of
brevity, by the words "type 1" and "type 2". The meanings of these terms are explained in the
paragraph RECOMMENDED PROTECTIVE AGENTS. As an alternative, other protective agents
having equivalent properties may be used.
Regarding procedures to be carried out on AUXILIARY EQUIPMENT (for example, motor driver), refer
to the relevant documentation in the AUXILIARIES Volume.
NOTE
state of preservation. In any case, Nuovo Pignone's responsibility cannot be extended to cover
any item not included in the Contract.
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10.2 IDLENESS NOT EXCEEDING 1 MONTH

- Isolate the compressor from upstream and downstream plants, by closing all check valves.
- Check that the crosshead extensions, the distance pieces and any other openings in the frame
(drains, gas recoveries, vents, etc.) are closed.
- Thoroughly lubricate the cylinders, if the service allows it.
- Discharge the pressure in the entire piping system, equipment and cylinders.
- If the gas is corrosive or must be removed for other reasons, purge with nitrogen, maintaining
a residual pressure of approx. 100 mm water column (for purging pressure, see OPERATION
Section).
- If the compressor is lubricated cylinder type and nitrogen is not available, lubricate the
cylinders every three days.
- Every three days, rotate the compressor shaft for a few revolutions using the barring device,
or any other available device, after having started the frame lubrication pump if not driven by
the crank shaft.
- In relation to the environmental conditions and to the coolant used, consider the possibility of
emptying completely the cooling system, to avoid damages from freezing.
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10.3 IDLENESS FROM 1 TO 6 MONTHS

As a first step, the compressor must be completely isolated from upstream and downstream plants
by closing all check valves.
With flammable or hazardous gas, prior to starting any procedure on the machine, it is necessary
to apply blind flanges on the piping at the check valves and to thoroughly purge the complete
compressor system with inert gas.
Subsequently, appropriate action will be taken according to the following procedures.
WARNING
IN CASE IDLENESS TIME EXCEEDED SIX MONTHS, PERFORM COMPLETE INSPECTION. IF NO

PROBLEMS ARE FOUND, PROCEED ONLY WITH RENEWAL OF THE PROTECTIVE AGENTS AND OF
THE OIL IN THE FRAME. OTHERWISE CONSIDER THE POSSIBILITY OF APPLYING STRONGER
PROTECTIVE MEASURES.
10.3.2 Compressors with lubricated cylinders
10.3.2.1 Frame
a. Ensure that the openings on crosshead extension and distance pieces are closed. Remove
the breather, detach and carefully plug any vent and drain piping in the distance pieces and
packing. Carefully plug all the holes in the frame, crosshead extensions and distance pieces.
b. Check that the lube oil has been used for less than 6 months and that the water content is
less than 0.01%. Otherwise, replace the oil (see LUBRICATION Section).
c. Protect the inner surfaces of the frame with oil of the type specified in item 1 and in paragraph
RECOMMENDED PROTECTIVE AGENTS.
d. Spread protective oil type 2 on the part of the shaft external to the frame and to all exposed
parts not protected by painting.
e. Approximately once every 5 days, start the crank gear lube oil pump for about 10-15 minutes,
if it is driven by own driver. Otherwise, use the prelubrication hand pump or a service pump
with temporary connection to the lube oil header of the frame. At the same time, turn the
shaft for a few revolutions either by hand or with the barring gear. Avoid stopping the shaft
in the same position in which it was before.
10.3.2.2 Cylinders
a. Remove the valves from the cylinders and put the valve covers back in place.
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b. In relation to the environmental conditions and to the coolant used, consider the possibility
of emptying completely the cooling system, to avoid damages from freezing. If the system is
not emptied and the cooling occurs with water from the water distribution circuit, maintain
moderate circulation. If instead the cooling system is of the closed loop type, with a surge
tank, periodically check the level. If the tank contents is below the level of the cylinders, close
the valve downstream of the pump, after having run the pump for a few minutes to ensure
that the cylinders jackets are completely filled.
c. Protect the inner surfaces with oil type 1.
d. Every 5 days, for 10-15 minutes, lubricate cylinder and packing with lube oil of the type
prescribed for operation, actuating the lubricator either through its driver (if this is the solution)
or through the crank. At the same time, run the pistons for about ten strokes.
e. Spread protective oil type 2 over all exposed surfaces not protected by paint.
10.3.2.3 Valves
- Keep and store the valves assembled and immersed in protective oil type 1.
As an alternative, after immersing in oil bath and dripping, keep them in storage carefully wrapped
in oilpaper or in sealed plastic bag.
10.3.2.4 Piping, equipment
a. Drain and completely empty those parts of the system that may collect condensate
(separators, dampers, accumulation tanks).
b. If, during compressor idleness, equipment and piping can be left completely assembled,
isolate the system and perform, after the procedure described in a , Paragraph 3.2.2 , purging
with nitrogen. Subsequently, after all air has been removed, close all openings and keep
nitrogen at a pressure of approx. 100 mm water column. Pressurise also the distance pieces
placed between crosshead extensions and cylinders.
c. If it is impossible to proceed as specified in b , insert appropriate amounts of dehydrating
product into the various sections of piping and into the equipment, recording where it has
been placed.
WARNING
ESPECIALLY DURING THE INITIAL PERIOD, IT IS ADVISABLE TO CHECK FREQUENTLY THE

CONDITIONS OF THE DEHYDRATING AGENT. REPLACE IF SATURATED OR APPROACHING
SATURATION.
10.3.2.5 Instrumentation
For possible requirements, refer to the part of the Manual relevant to Auxiliaries. In general:
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- Keep the panels carefully closed, after having inserted an appropriate dehydrating agent.
- For electronic components, ensure that the ambient temperature remains within the limits
specified by the manufacturer, during the time of idleness. If necessary, remove the
components and store them in a suitable condition. For these components, temperature
rushes are not tolerated, especially in a damp climate. It is advisable to check daily the
efficiency of the air conditioning system.
10.3.2.6 Auxiliary drivers
For possible requirements, refer to the part of the Manual relevant to AUXILIARIES. In general, if the
bearings are grease-lubricated, fill them immediately after starting the idleness period. Periodically
(for example, once a month), turn the shaft for a few revolutions. The possibility of switching on the
space heaters shall be considered.
10.3.2.7 Non-painted machined parts
Protect with protective oil type 2.
10.3.3 Compressors with non-lubricated cylinders
10.3.3.1 Frame
The same instructions as those given in item Paragraph 3.2.1 . for compressors with lubricated
cylinders are applicable.
10.3.3.2 Cylinders
- Remove the valves from the cylinders and reassemble the valve covers.
- If, during compressor idleness, piping and equipment can be left completely assembled, the
cylinders protection will be obtained by pressurising the system (see b , Paragraph 3.2.4 ).
- If instead the system is left assembled but nitrogen is not available, disassemble piston/piston
rod and packing, insert dehydrating agent into the valve ports and into the gas ducts and
close again.
- If the system cannot be left assembled, detach the piping from the inlet and outlet flanges,
disassemble piston/piston rod and packing, insert dehydrating agent into the valve ports and
into the gas ducts and close again.
- Spread protective oil type 2 over external, exposed machined surfaces not protected by paint.
10.3.3.3 Valves
Proceed as described in Paragraph 3.2.3 . For oxygen compressors, clean the valves thoroughly,
store them in plastic bags with dehydrating agent and seal. Clean accurately with solvent before
reusing.
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10.3.3.4 Piston rods and packings
- Clean thoroughly all parts of the packing, degrease them and seal them in plastic bags with
dehydrating agent; it is advisable to provide adequate mechanical protection, for example
using wooden boxes. Rods and pistons will be cleaned and degreased, and sealed in plastic
bags with dehydrating agent; mechanical protection is recommended. As an alternative, on
condition that the compressor is not for compressing oxygen, use protective oil type 1, plastic
bags and mechanical protection.
WARNING
THE PREFERRED POSITION FOR STORING PISTON RODS IS VERTICALLY. STORE THE PISTON BY
SIMPLY RESTING IT ON A FLAT SURFACE, IF THE PISTON GIVES A SUFFICIENTLY STABLE BASE;
OTHERWISE, THE UPPER END OF THE ROD MUST BE APPROPRIATELY HOLD TO PREVENT
OVERTURNING. IF NO ADEQUATE AMBIENT IS AVAILABLE FOR STORING IN VERTICAL POSITION,
THE ROD CAN BE KEPT IN THE HORIZONTAL POSITION, SUPPORTED AT 3 POINTS. HOWEVER, THIS
TYPE OF STORAGE DOES NOT OFFER THE SAME SAFETY AS THE PREVIOUS ONE IN REGARD TO
POSSIBLE DISTORTION.
10.3.3.5 Piston rings, rider rings, seal rings
Piston rings, rider rings and seal rings, being made of plastic material, require no special measures.
Wrap in plastic film and store properly.
10.3.3.6 Piping, equipment, instrumentation, auxiliary drivers
Proceed as described in Paragraph 3.2.4 , Paragraph 3.2.5 , Paragraph 3.2.6 .
See Paragraph 3.2.7 of this paragraph.
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10.4 IDLENESS EXCEEDING 6 MONTHS
NOTE
The procedures described in the preceding paragraph, if correctly carried out, are in general
enough to protect the compressor even for longer periods. If however the duration of idleness
is planned to be very long, the possibility of applying the following preservation procedures, more
complicate but undoubtedly more reliable, shall be considered.

As a first step, the compressor must be completely isolated from upstream and downstream plants
by closing all check valves.
With flammable or hazardous gas, prior to starting any procedure on the machine, it is necessary
to apply blind flanges on the piping at the check valves and to thoroughly purge the complete
compressor system with inert gas.
It is advisable to detach the cylinders from the frame. Distance pieces, if any, can be left installed.
Subsequently, appropriate actions will be taken according to the following procedures.
WARNING
DURING THE IDLENESS TIME, INSPECT THE MACHINERY EVERY 6 MONTHS. IF NO PROBLEMS ARE
FOUND, PROCEED ONLY TO RENEWING PROTECTIVE AGENTS; OTHERWISE, CONSIDER THE
POSSIBILITY OF CARRYING OUT STRONGER PROTECTIVE ACTIONS.
10.4.2 Compressors with lubricated cylinders
10.4.2.1 Frame
Using metal flanges with gaskets, plug the openings where the cylinders connect with the crosshead
extensions or distance pieces.
- Carry out the procedures described in List Item and in List Item , Frame relevant to idleness
duration from 1 to 6 months.
- Pour protective oil type 1 (see further) into the frame, in sufficient amount to cover the
lubrication pump intake.
- Plug all openings, except one hole (see following item). Make sure that the openings in the
frame, in the crosshead extensions and in the distance pieces, if present, are equipped with
appropriate covers, that the relevant gaskets are sound and that the bolts are correctly
tightened.
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- Through the hole left open, let dry nitrogen flow into the frame. To facilitate the purging of air,
open and close again the various openings in an appropriate sequence. After having removed
the air, close the hole left open and maintain a nitrogen pressure of about 100 mm water
column.
- If the frame is large enough and dry nitrogen is not available, insert bags of dehydrating
product, in such a position not to be damaged during the procedures described here below
in a .
a. Start the lube oil pump, for about 10-15 minutes, if it is driven by own driver. Otherwise, use
the prelubrication hand pump or a service pump with temporary connection to the lube oil
header of the frame. At the same time, turn the shaft for a few revolutions either by hand or
with the barring gear. Avoid stopping the shaft in the same position in which it was before.
This procedure should be repeated at least once every two weeks.
10.4.2.2 Cylinders
As stated above, these are kept disassembled from the frame and without valves, packing and piston
assembly.
a. Clean thoroughly and spread the bore, the valve and packing housings and the gas chambers
with protective oil type 1.
- With metal flanges and gaskets, close carefully the suction and discharge flanges and the
packing housing. Plug correctly all other holes and connections, including the lubrication
tubing.
- Spread all non-painted exposed surfaces with protective oil type 2.
- Insert the cylinder in a plastic bag together with dehydrating product and seal.
10.4.2.3 Valves
Proceed as described in the paragraph relevant to idleness duration from 1 to 6 months.
10.4.2.4 Piston rods and packings
Clean thoroughly all parts, spread with protective oil type 1, seal them in plastic bags.
It is advisable to provide adequate mechanical protection, for instance using a wooden box.
As an alternative, packing and partition covers can be kept immersed in protective oil.
Also for rods and pistons, cleaning, protective oil and plastic bags are recommended. As regards
storage, proceed as described in the Piston rods and packings relevant to idleness duration from
1 to 6 months.
If piston rings, seal rings and rider rings are made in plastic, no special care is required apart from
wrapping in plastic film and proper storage. If they are made in metal:
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- Thoroughly clean the piston rings and seal rings, spread with protective oil type 1 and place
them in plastic bags.
- As an alternative, they can be immersed in oil.
10.4.2.6 Lubricators and relevant tubing
- Detach the oil tubing from the cylinders and from the packing, actuate the lubricators filled
with oil, until the oil flows out of the tubing ends. Close the tubing carefully.
- Fill again the lubricators with oil.
- If the machine is in a closed area, cover all exposed non-protected parts with protective oil
type 2. Otherwise, disassemble these parts from the compressor and store them in a protected
area. In the latter case, detach the tubing from the lubricator and plug tubing and lubricator
carefully.
Follow the instructions shown in Piping, equipment , Instrumentation and Auxiliary drivers relevant
to idleness duration from 1 to 6 months.
10.4.2.8 Safety valves
a. Disassemble safety valves from their location and pour protective oil type 1 into them.
b. Fill the connections with protective oil type 2 and close with hermetic plugs. Also spread with
oil exposed parts not protected by paint.
c. As an alternative to items a and b , disassemble the valves from their location and seal them
in plastic bags with dehydrating product. Close the connections with hermetic plugs.
In any case, it is advisable to remove the valve plug.
Spread with protective oil type 2. Any rubber elements of couplings will be disassembled and properly
kept in storage separately.
10.4.3 Compressors with non-lubricated cylinders
10.4.3.1 Frame
The recommendations shown in Paragraph 4.2.1 are applicable.
10.4.3.2 Cylinders
- If the process tolerates oil traces, proceed as described in Paragraph 4.2.2 and degrease
thoroughly prior to reassembling.
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- If the process does not tolerate oil traces, pressurise with dry nitrogen, close carefully the
suction and discharge flanges and the packing housing with metal flanges and gaskets, plug
well also all the other connections and holes, except for two of them which shall be used for
purging. For the purpose let dry nitrogen in trough one of the two holes and allow air discharge
through the other one. When it can be considered that the air has been completely removed,
plug the outlet hole and pressurize with dry nitrogen at a pressure approx. 100 mm water
column.
For oxygen compressors, place dehydrating agent also inside cylinder, valve ports, and gas
chambers. Carry out more frequent periodic inspections.
In any case, spread protective oil type 2 over exposed external parts that are machined and not
protected by paint.
10.4.3.3 Valves, piston rods and packings
- If the process tolerates traces of grease, see instructions shown in Paragraph 4.2.3 and
Paragraph 4.2.4 . Degrease thoroughly prior to reassembling.
- If the process does not tolerate traces of grease, make sure that no grease is present, degrease
with solvent if required, then seal in plastic bags with dehydrating product.
WARNING
THE PREFERRED POSITION FOR STORING PISTON RODS IS VERTICALLY. STORE THE PISTON BY
PLACING IT ON A FLAT SURFACE, IF IT IS NOT DISASSEMBLED AND IF THE PISTON GIVES A
SUFFICIENTLY STABLE BASE. OTHERWISE IT WILL BE ADVISABLE TO HANG THE ROD, WITH OR
WITHOUT PISTON, USING AN APPROPRIATE EYEBOLT. IF NO ADEQUATE AREA IS AVAILABLE FOR
STORING IN VERTICAL POSITION, THE RODS CAN BE SEPARATED FROM THE PISTON AND KEPT IN
THE HORIZONTAL POSITION, SUPPORTED AT 3 POINTS. HOWEVER, THIS TYPE OF STORAGE DOES
NOT OFFER THE SAME SAFETY AS THE PREVIOUS ONE IN REGARD TO POSSIBLE DISTORTION.
As these are made in plastic, they require no special protective measures. Wrap in plastic film and
store properly.
Proceed as described in Piping, equipment , Instrumentation and Auxiliary drivers relevant to

idleness duration from 1 to 6 months.
10.4.3.6 Safety valves
Proceed as described in c of Paragraph 4.2.8 .
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Proceed as recommended in Paragraph 4.2.9 .
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10.5 RECOMMENDED PROTECTIVE AGENTS

The products recommended for machine protection are listed below. Obviously, other products
available on the market can also be used, on condition that they offer appropriate qualities and
properties.
Handle these products with care, to avoid any risk of personal harm. Moreover, for their use and
disposal after use, refer to the supplier’s instructions and comply with local and plant regulations.
10.5.1 Oils
Regarding oils «type 1» mentioned in the paragraph SAFETY PRECAUTIONS - GENERAL
INFORMATION in this Section, we recommend:
FUCHS ANTICORIT 77
Regarding oils «type 2», we recommend one of the following products:
FUCHS ANTICORIT 2006
AGIP 7921
IP IDEX FLUID PL
10.5.2 Dehydrating products

We have had satisfactory experience with SILICA GEL manufactured by W.R. GRACE & Co., U.S.A.,
(distributed in Italy by GRACE ITALIANA, Passirana di Rho, Milan).
Regarding the amounts to be used, duration, etc., we recommend contacting directly the supplier.
10.5.3 Solvents
We have had satisfactory experience with the SUPER-DETERGENT T.C. 66, distributed by CHIMISOL
S.R.L. (Corso Nazionale 18, La Spezia, ITALY).
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10.6 PROCEDURES FOR RESTARTING

- Inspect carefully the piping. If piping has been treated as described in the previous paragraphs
of this Section, its preservation state should require no special care. If, on the contrary,
oxidation is found, the piping shall undergo appropriate treatment (see OPERATION Section).
- Inspect the various groups of materials and/or the individual parts kept in storage. Remove
any bags of dehydrating product. Remove the protective oil with solvent from the cylinders to
avoid that, if entrained by the gas, it could impair the correct operation of the compressor, or
even cause damage to some components. If the frame oil has been replaced by protective
oil, prior to starting again flush the circuit with the oil recommended for operation.
- After periods of idleness lasting longer than 6 months, always replace the lube oil for crank
gear and cylinders, and clean the systems.
- Verify that any oil accumulations do not prevent free movement of parts of the machinery.
This could cause damage, even very severe, at the time of restart.
- Clean and thoroughly degrease all non-lubricated compressor components. Specifically, for
oxygen compressors, see the pertinent recommendations contained in the MAINTENANCE
Section.
- Check that the materials that have been in storage do not show defects, and proceed
immediately to installing them.
- In the absence of specific instructions from the manufacturer check in any case the degree
of insulation between the windings of electric motors. If they are equipped with heater, make
sure that it is not switched on.
- Check the efficiency of the instruments, of the control devices, of each automatic system.
- Prior to proceeding with the start-up stagephase, consider the possibility of performing
blowing out or purging (see OPERATION Section).
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10.7 DECOMMISSIONING - DISMANTLING - SCRAPPING
10.7.1 Decommissioning
To decommission a compressor, proceed as follows:
- Disconnect all various systems (process gas, power supply, coolant, compressed air, fuel gas,
etc.).
- Purge the compressor system. In any case, if the gas handled was poisonous or harmful in
any way, use adequate breathing mask; this precaution is to be applied in general, but
especially when opening cylinders, various devices, piping, etc., where gas pockets may have
been trapped in spite of the purging.
- Refer also to the GENERAL SAFETY PRECAUTIONS in the relevant paragraph of the GENERAL
INFORMATION Section.
- Acting in compliance with local and plant regulations, suitably dispose of all polluting products,
such as lube oil, water/glycol mixtures, various fluids accumulated in the equipment, plastic
materials, etc.
10.7.2 Dismantling
If the machine is to be dismantled:
- Employ suitable personnel for disassembly and handling the various parts (see the information
given on this subject in the Sections relevant to MOVING, HANDLING, STORAGE and
MAINTENANCE).
- If the machine is to be installed in another site, be sure to transmit this Manual, complete in
every part, to the new user.
- In particular, the new user must be aware of the electrical area classification for which the
unit (compressor, auxiliaries, instruments) was designed. This indication is shown in the
COMPRESSOR DATA SHEETS (see REFERENCE DRAWINGS Volume of the Manual).
10.7.3 Scrapping
If the machine is to be scrapped:
- The various components of the machine should be sent for scrapping following the procedures
specified in local and plant regulations.
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Manual
Volume 2
COMPRESSOR PART LIST

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TABLE OF CONTENT
Section1 - FRAME
1 FRAME 4
Section2 - CYLINDERS
1 1ST STG. CYLINDER 8
2 2ND STG. CYLINDER 10
3 3RD STG. CYLINDER 12
Section3 - ASSEMBLY TOOLS
1 ASSEMBLY TOOLS 14
Section4 - MISCELLANEOUS FOR INSTRUMENTATION
1 MISCELLANEOUS FOR INSTRUMENTATION 16
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1 - FRAME
1 FRAME ..................................................................................................................................................................4 2-4
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1.1 FRAME
ASSEMBLY DRA
POS. TITLE PART LIST
WING OR TABLE
ASSEMBLY DATA:
1 FRAME ASSEMBLY DATA SOP3898110
2 CYLINDERS - HEADS - BALLASTS ASSEMBLY LOCATION SOP6236550
3 ROD DROP AND RUN-OUT DATA SOP5693538
CRANKCASE ASSEMBLY:
4 CRANKCASE SNO4510110 SOP20132
ACCESSORIES SNO3970111 "
BOLTS SNO3970066 "
GASKETS SNO3970067 "
CRANKCASE MAIN BEARINGS SNO3970012 "
SHOULDER HALF-RING SNO3950145 "
NAME PLATES "ROTATION ARROW" SNO7671333 "
NAME PLATES "PIGNONE" SNO7671334 "
CRANKSHAFT ASSEMBLY:
SHAFT SNO0962416 "
PLUG SNO0962493 "
DRIVE SIDE SHIELD ASSEMBLY:
SHIELD SNO6916001 "
BOLTS SNO6916002 "
SHIELD OPPOSITE TO DRIVER SIDE:
SHIELD SNO6916004 "
BOLTS SNO6916005 "
ACCESSORIES FOR FRAME:
COVER SNO6655226 "
5 COVER SNO3970014 SOP84079
6 FRAME COVER SNO3970064 SOP19692
GASKET FOR COVER SNO6916015 "
7 “BICERI” SAFETY VALVE SNO4595391 SOP83943
8 CLOSING COVER SNO4595424 SOP09002
CONNECTING ROD ASSEMBLY:
9 CONNECTING ROD SNO1603768 SOP5685857
BOLTS SNO1603769 "
CONNECTING ROD BEARING AND BUSH SNO1670024 "
CROSSHEAD ASSEMBLY:
10 CROSSHEAD BODY SNO6601582 SOP5687867
SHOES SNO6601583 "
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ASSEMBLY DRA
WING OR TABLE
CROSSHEAD PIN SNO6601720 "
11 BALLAST FOR CRANK 1-3 SNO2607891 SOP5687890
12 BALLAST FOR CRANK 5 SNO2607859 SOP5687872
PARTITION COVER ASSEMBLY:
13 FLANGE, CUPS, MISCELLANEOUS SNO2925911 SOP61210
OIL SCRAPER RINGS SNO2925912 "
L.O. PUMP AND ACCESSORIES:
14 GEAR PUMP SNO4813737 SOP5683322
15 COUPLING SNO3602336 SOP5683324
16 PUMP SHAFT GUARD SNO4500027 SOP83947
FRAME INTERNAL PIPING:
17 LUBE OIL SUCTION PIPING SNO8549113 SOP28842
LUBE OIL DISCHARGE PIPING SNO8549114 "
18 OIL HEADER SNO8548816 SOP08800
OIL FILTERS:
19 SUCTION FILTER SNO3310201 SOP84380
20 TEMPORARY FILTER SNO3300061 SOP84727
DISTANCE PIECE ASSEMBLY:
21 DISTANCE PIECE SNO5252530 SOP74053
BOLTS SNO2246433 "
BOLTS SNO5252531 "
COVER SNO5252533 "
DISTANCE PIECE INTERNAL PIPING:
22 DRAIN SNO8921406 SOP08732
23 VENT SNO8921409 SOP08736
24 COUPLING SNO8921696 SOP08730
25 RECOVERY SNO8921402 SOP08741
26 LUBRICATION SNO8922045 SOP08729
CYLINDER & PACKINGS LUBE OIL CONSOLE:
27 LUBRICATOR ASSEMBLY SNO8715679 SOP5697184
28 BRACKET AND ACCESSORIES SNO8715250 SOP5685878
BASEPLATE CONNECTIONS SNO8715254 "
29 ELECTRIC MOTOR WITH ASSEMBLY SCREW SNO8715680 SOP5682760
30 LUBRICATOR MISCELLANEOUS SNO8715681 SOP5697185
TUBING ASSEMBLY FOR CONNECT CONSOLE TO LUBE OIL
31 SNO8715682 SOP5682772
POINT
FLYWHEEL ASSEMBLY:
32 FLYWHEEL SNO8059387 SOP65658
33 BOLTS SNO4692300 SOP65654
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ASSEMBLY DRA
WING OR TABLE
34 BOLTS SNO4595358 SOP19990
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2 - CYLINDERS
1 1ST STG. CYLINDER .........................................................................................................................................8 2-8

2 2ND STG. CYLINDER ........................................................................................................................................10 2-10
3 3RD STG. CYLINDER ........................................................................................................................................12 2-12
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2.1 1ST STG. CYLINDER
ASSEMBLY DRA
WING OR TABLE
ASSEMBLY DATA
CYLINDER ASSEMBLY DATA SOP5693529
BODY ASSEMBLY
CYLINDER SNO2255107 SOP5682504
CYLINDER HEAD SNO2255108 "
COMPONENTS SNO2251658 "
BOLTS SNO2249171 "
BOLTS SNO2246553 "
SUCTION VALVE COVER SNO4150420 "
DISCHARGE VALVE COVER SNO4149909 "
LINER ASSEMBLY SNO2255111 "
CYLINDER MISCELLANEOUS SNO2251659 "
BOLTS SNO2254883 "
SUCTION CAGE SNO4150421 "
GASKET FOR SUCTION VALVE COVER SNO4150389 "
DISCHARGE CAGE SNO4149843 "
GASKET FOR DISCHARGE VALVE COVER SNO4149870 "
LUBE OIL QUILL SNO2700904 SOP84905
PISTON ROD PACKING ASSEMBLY
FLANGE SNO9738124 SOP20680
CUPS SNO9740338 "
SEAL RINGS SNO9742080 "
GASKET SNO9741146 "
PISTON ROD - PISTON ASSEMBLY
PISTON SNO7241419 SOP08975
ROD SNO7241417 "
PISTON RINGS AND RIDER RINGS SNO7241420 "
OIL SEAL RING SNO7232053 "
VALVES
SUCTION VALVE SNO9870800 SOP5699396
DISCHARGE VALVE SNO9870801 SOP5699397
CLEARANCE POCKET VALVE SNO8479846PL SNO8479846
CAPACITY CONTROL DEVICE
VALVE UNLOADER SNO3105293 SOP5697161
STEM SNO4586333
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ASSEMBLY DRA
WING OR TABLE
STEM SNO4586444
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2.2 2ND STG. CYLINDER
ASSEMBLY DRA
WING OR TABLE
ASSEMBLY DATA
BODY ASSEMBLY
BOLTS SNO2255132 "
BOLTS SNO2246553 "
PLUG SNO2247475 "
LINER SNO2247842 "
BOLTS SNO2254883 "
OIL PIPING SNO2250914 "
GASKETS FOR DISCHARGE VALVE COVER SNO4151403 "
CUPS SNO9741572 SOP20678
FLANGE SNO9738124 "
ROD SNO7241406 "
VALVES
STEM SNO4586374
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2.3 3RD STG. CYLINDER
ASSEMBLY DRA
WING OR TABLE
ASSEMBLY DATA
BODY ASSEMBLY
BOLTS SNO2249166 "
BOLTS SNO2246515 "
LINER ASSEMBLY SNO2254754 "
BOLTS SNO2254883 "
OIL PIPING SNO2250914 "
GASKET FOR DISCHARGE VALVE COVER SNO4149642 "
FLANGE SNO9738506 SOP20700
CUPS SNO9742083 "
ROD SNO7241412 "
VALVES
STEM SNO4586333
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3 - ASSEMBLY TOOLS
1 ASSEMBLY TOOLS ...........................................................................................................................................14 2-14
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3.1 ASSEMBLY TOOLS
ASSEMBLY DRA
POS. TITLE PARTS LIST
WING OR TABLE
FOR HYDRAULIC TIGHTENINGS:
1 HYDRAULIC DEVICE FOR ROD-PISTON SNO4542200 SOP81521
2 OLEODYNAMIC PUMP SNO4512003 SOP65659
3 HYDRAULIC DEVICE FOR CONNECTING ROD SNO4595368 SOP83940
FOR FRAME:
4 TOOLS FOR CROSSHEAD SNO1285077 SOP5693535
TOOLS FOR FRAME SNO1283482
5 TOOLS FOR BALLAST SNO1248971 SOP85115
FOR CYLINDERS:
6 TOOLS FOR PISTON INSERTION SNO1284980 SOP85095
SHEAT FOR INSERCTION SNO1284510 SOP85095
LINER FOR PISTON INSERTION SNO1285047 "
LINER FOR PISTON INSERTION SNO1285037 "
7 DEVICE ASSEMBLY FOR ROD-PISTON SNO1284051 SOP85096
TOOLS FOR PISTON INSERTION SNO1285024
8 DISASSEMBLY PISTON/ROD SNO1283414 SOP08744
9 TOOLS FOR VALVE EXTRACTION SNO1285048 SOP85097
10 TOOLS FOR ROD-FLANGE INSERTION SNO1284472 SOP5688266
Table 5 - ASSEMBLY TOOLS
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4 - MISCELLANEOUS FOR INSTRUMENTATION
1 MISCELLANEOUS FOR INSTRUMENTATION ........................................................................................16 2-16
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4.1 MISCELLANEOUS FOR INSTRUMENTATION
ASSEMBLY DRA
WING OR TABLE
1 ACCESSORIES FOR ACCELEROMETER SNO6776586 SOP5688226
2 ACCESSORIES FOR VELOMITOR SNO6776695 SOP5691649
3 SUPPORTS FOR INSTRUMENTS ON LUBRICATOR SNO4702226 SOP83636
4 ACCESSORIES FOR ROD-DROP / RUN-OUT PROBE SNO9864090 SOP5692426
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Manual
Volume 3
AUXILIARY EQUIPMENT AND
INSTRUMENTATION

1003084
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TABLE OF CONTENT
Section1 - AUXILIARY EQUIPMENT AND INSTRUMENTION

1 AUXILIARY EQUIPMENT AND INSTRUMENTATION 4
1.1 PROCESS GAS SYSTEM 4
1.2 CAPACITY CONTROL SYSTEM 10
1.3 FRAME LUBE OIL SYSTEM 11
1.4 MONITORING SYSTEM 13
1.5 CYLINDERS COOLING SYSTEM 19
1.6 CYLINDERS AND PACKINGS LUBE OIL SYSTEM 23
1.7 MAIN ELECTRIC MOTOR SYSTEM 24
1.8 BARRING AND LOCKING DEVICE SYSTEM 26
12-2010 1003084 Page 3-2

1 - AUXILIARY EQUIPMENT AND INSTRUMENTION
1 AUXILIARY EQUIPMENT AND INSTRUMENTATION ...........................................................................4 3-4

1.1 PROCESS GAS SYSTEM ................................................................................................................................4 3-4
1.2 CAPACITY CONTROL SYSTEM ...................................................................................................................10 3-10
1.3 FRAME LUBE OIL SYSTEM ..........................................................................................................................11 3-11
1.4 MONITORING SYSTEM .................................................................................................................................13 3-13
1.5 CYLINDERS COOLING SYSTEM .................................................................................................................19 3-19
1.6 CYLINDERS AND PACKINGS LUBE OIL SYSTEM ................................................................................23 3-23
1.7 MAIN ELECTRIC MOTOR SYSTEM ............................................................................................................24 3-24
1.8 BARRING AND LOCKING DEVICE SYSTEM ...........................................................................................26 3-26
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1.1 AUXILIARY EQUIPMENT AND INSTRUMENTATION
1.1.1 PROCESS GAS SYSTEM
NP CODE INSTRUMENT DESCRIPTION NP TAG PUBLICATION

RVO6100468 PRESSURE SA 1ST STG SUCTION SEPARATOR PSV 1005 06-11IE
FETY VALVE TAI (N.A.)
TYPE: 3111A
RVO6100468 PRESSURE SA 1ST STG SUCTION SEPARATOR PSV 1006 06-11IE
TYPE: 3111A
RTO846047055 PRESSURE 1ST STG. SUCTION PT 1604 00809-0100-4051
(ITN66235) TARNSMITTER ROSEMOUNT (PT 1804)
TYPE: 3051TA
RMO419670833 PRESSURE 1ST STG. SUCTION PI 1603 PM.02-04
(ITN66418.02) GAUGE WIKA (PI 1803)
TYPE: 233.30
RMO51834 DIFFERENTIAL 1ST STG. SUCTION TEMPORARY STRAINER PDI 1601 PM.07-05
PRESSURE WIKA (PDI 1801)
GAUGE TYPE: 732.51
RTO713087050 DIFFERENTIAL 1ST STG. SUCTION TEMPORARY STRAINER PDT 1602 00809-0100-4051
(ITN66187) PRESSURE ROSEMOUNT (PDT 1802)
TRANSMITTER TYPE: 3051CD
RPO33440 THERMOELE 1ST STG. SUCTION TE 1602 00813-0200-2654
MENT ROSEMOUNT (TE 1802)
TYPE: RTD PT 100
RTO744086010 TEMPERATURE 1ST STG. SUCTION TT 1602 00809-0100-4021
(ITN66212) TRANSMITTER ROSEMOUNT (TT 1802)
TYPE: 3144P
RTO563351183 TEMPERATURE 1ST STG. SUCTION TI 1601 TM.55-01
(ITN66506) GAUGE WIKA (TI 1801)
TYPE: 5550/1
RTO846047055 PRESSURE 1ST STG. SUCTION PT 1607/A 00809-0100-4051
(ITN66235) TARNSMITTER ROSEMOUNT (PT 1807/A)
TYPE: 3051TA
RTO563351183 TEMPERATURE RECOVERY LINE CYL.N°6 TI 1605 TM.55-01
TYPE: 5550/1
RPO33440 THERMOELE 1ST STG. DISCHARGE TE 1604 00813-0200-2654
TYPE: RTD PT 100
RTO744086010 TEMPERATURE 1ST STG. DISCHARGE TT 1604 00809-0100-4021
TYPE: 3144P
RPO33440 THERMOELE 1ST STG. DISCHARGE TE 1603 00813-0200-2654
TYPE: RTD PT 100
RTO744086010 TEMPERATURE 1ST STG. DISCHARGE TT 1603 00809-0100-4021
TYPE: 3144P
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RTO846147055 PRESSURE 1ST STG. DISCHARGE PT 1607/B 00809-0100-4051
(ITN66236) TARNSMITTER ROSEMOUNT (PT 1807/B)
TYPE: 3051TG
RVO6100470 PRESSURE SA 1ST STG. DISCHARGE PSV 1601 06-11IE
FETY VALVE TAI (PSV 1801)
TYPE: 3111A
RVO6100470 PRESSURE SA 1ST STG. DISCHARGE PSV 1602 06-11IE
TYPE: 3111A
RVO90015 PRESSURE 1ST STAGE PROCESS GAS PV 1605 EH21000-0109
CONTROL VAL EMERSON (PV 1805)
VE TYPE: 68-21114
VIBROSWITCH 1ST/2ND INTERSTAGE AIRCOOLER MO VSHH SUPPLIED WITH AIR
TOR EM1-100A/B 1611/A COOLER
( VSHH
1811/A)
VIBROSWITCH 1ST/2ND INTERSTAGE AIRCOOLER MO VSHH SUPPLIED WITH AIR
TOR EM2-100A/B 1611/B COOLER
( VSHH
1811/B)
I/P CONVERTER 1ST/2ND INTERSTAGE AIRCOOLER TY 1605 SUPPLIED WITH AIR
E-100A/B (TY 1805) COOLER
RVO6100471 PRESSURE SA 1ST/2ND INTERSTAGE SEPARATOR PSV 1603 06-11IE

TYPE: 3111A
RVO6100471 PRESSURE SA 1ST/2ND INTERSTAGE SEPARATOR PSV 1604 06-11IE
TYPE: 3111A
ANTICONDEN 1ST/2ND INTERSTAGE AIRCOOLER MO EHM1-100 SUPPLIED WITH AIR
SATION HEA TOR EM1-100A/B A COOLER
TER ( EHM1-100
B)
ANTICONDEN 1ST/2ND INTERSTAGE AIRCOOLER MO EHM2-100 SUPPLIED WITH AIR
TER ( EHM2-100
B)
RTO846147055 PRESSURE 2ND STG. SUCTION PT 1615 00809-0100-4051
(ITN66236) TARNSMITTER ROSEMOUNT (PT 1815)
TYPE: 3051TG
RMO419700833 PRESSURE 2ND STG. SUCTION PI 1614 PM.02-04
TYPE: 233.30
RMO452280101 DIFFERENTIAL 2ND STG. SUCTION TEMPORARY STRAI PDI 1612 PM.07-13
(ITN66422) PRESSURE NER (PDI 1812)
GAUGE WIKA
TYPE: 733.14
RTO713097050 DIFFERENTIAL 2ND STG. SUCTION TEMPORARY STRAI PDT 1613 00809-0100-4051
(ITN66187) PRESSURE NER (PDT 1813)
TARNSMITTER ROSEMOUNT
TYPE: 3051CD
1003084
12-2010 Page 3-5
RPO33440 THERMOELE 2ND STG. SUCTION TE 1606 00813-0200-2654
TYPE: RTD PT 100
RTO744086010 TEMPERATURE 2ND STG. SUCTION TT 1606 00809-0100-4021
TYPE: 3144P
RTO563351183 TEMPERATURE 2ND STG. SUCTION TI 1607 TM.55-01
TYPE: 5550/1
RTO846147055 PRESSURE 2ND STG. SUCTION PT 1616/A 00809-0100-4051
(ITN66236) TARNSMITTER ROSEMOUNT (PT 1816/A)
TYPE: 3051TG
TYPE: 5550/1
TYPE: 5550/1
RPO33440 THERMOELE 2ND STG. DISCHARGE CYL. N°4 TE 1610/A 00813-0200-2654
MENT ROSEMOUNT (TE 1810/A)
TYPE: RTD PT 100
RTO744086010 TEMPERATURE 2ND STG. DISCHARGE CYL. N°4 TT 1610/A 00809-0100-4021
(ITN66212) TRANSMITTER ROSEMOUNT (TT 1810/A)
TYPE: 3144P
RPO33440 THERMOELE 2ND STG. DISCHARGE CYL. N°4 TE 1609/A 00813-0200-2654
TYPE: RTD PT 100
RTO744086010 TEMPERATURE 2ND STG. DISCHARGE CYL. N°4 TT 1609/A 00809-0100-4021
TYPE: 3144P
RTO846157055 PRESSURE 2ND STG. DISCHARGE PT 1616/B 00809-0100-4051
TYPE: 3051TG
RPO33440 THERMOELE 2ND STG. DISCHARGE CYL. N°2 TE 1610/B 00813-0200-2654
MENT ROSEMOUNT (TE 1810/B)
TYPE: RTD PT 100
RTO744086010 TEMPERATURE 2ND STG. DISCHARGE CYL. N°2 TT 1610/B 00809-0100-4021
(ITN66212) TRANSMITTER ROSEMOUNT (TT 1810/B)
TYPE: 3144P
RPO33440 THERMOELE 2ND STG. DISCHARGE CYL. N°2 TE 1609/B 00813-0200-2654
TYPE: RTD PT 100
RTO744086010 TEMPERATURE 2ND STG. DISCHARGE CYL. N°2 TT 1609/B 00809-0100-4021
TYPE: 3144P
RVO6100472 PRESSURE SA 2ND STG. DISCHARGE PSV 1605 07-02IE
TYPE: 3111B
RVO6100472 PRESSURE SA 2ND STG. DISCHARGE PSV 1606 07-02IE
TYPE: 3111B
1003084
12-2010 Page 3-6
RVO90016 PRESSURE 2ND STAGE PROCESS GAS PV 1602 EH41005-0702
VE TYPE: 68-41335
VIBROSWITCH 2ND/3RD INTERSTAGE AIRCOOLER MO VSHH SUPPLIED WITH AIR
TOR EM1-105A/B 1612/A COOLER
( VSHH
1812/A)
VIBROSWITCH 2ND/3RD INTERSTAGE AIRCOOLER MO VSHH SUPPLIED WITH AIR
TOR EM2-105A/B 1612/B COOLER
( VSHH
1812/B)
I/P CONVERTER 2ND/3RD INTERSTAGE AIRCOOLER TY 1611 SUPPLIED WITH AIR
E-105A/B (TY 1811) COOLER
RVO6100473 PRESSURE SA 2ND/3RD INTERSTAGE SEPARATOR PSV 1607 07-02IE

TYPE: 3111B
RVO6100473 PRESSURE SA 2ND/3RD INTERSTAGE SEPARATOR PSV 1608 07-02IE
TYPE: 3111B
ANTICONDEN 2ND/3RD INTERSTAGE AIRCOOLER MO EHM1-105 SUPPLIED WITH AIR
TER ( EHM1-105
B)
ANTICONDEN 2ND/3RD INTERSTAGE AIRCOOLER MO EHM2-105 SUPPLIED WITH AIR
TER ( EHM2-105
B)
RTO846157055 PRESSURE 3RD STG. SUCTION PT 1624 00809-0100-4051
(ITN66236) TRANSMITTER ROSEMOUNT (PT 1824)
TYPE: 3051TG
RTO846157055 PRESSURE 3RD STG. SUCTION PT 1625/A 00809-0100-4051
(ITN66236) TRANSMITTER ROSEMOUNT (PT 1825/A)
TYPE: 3051TG
RMO419740803 PRESSURE 3RD STG. SUCTION PI 1623 PM.02-04
TYPE: 233.30
RMO452330101 DIFFERENTIAL 3RD STG. SUCTION TEMPORARY STRAI PDI 1621 PM.07-13
(ITN66422) PRESSURE NER (PDI 1821)
GAUGE WIKA
TYPE: 733.14
RTO714207050 DIFFERENTIAL 3RD STG. SUCTION TEMPORARY STRAI PDT 1622 00809-0100-4051
(ITN66187) PRESSURE NER (PDT 1822)
TRANSMITTER ROSEMOUNT
TYPE: 3051CD
RPO33440 THERMOELE 3RD STG. SUCTION TE 1613 00813-0200-2654
TYPE: RTD PT 100
RTO744086010 TEMPERATURE 3RD STG. SUCTION TT 1613 00809-0100-4021
TYPE: 3144P
1003084
12-2010 Page 3-7
RTO563351183 TEMPERATURE 3RD STG. SUCTION TI 1612 TM.55-01
TYPE: 5550/1
TYPE: 5550/1
TYPE: 5550/1
TYPE: 5550/1
RPO33441 THERMOELE 3RD STG. DISCHARGE CYL. N°1 TE 1616/A 00813-0200-2654
TYPE: RTD PT 100
RTO744086010 TEMPERATURE 3RD STG. DISCHARGE CYL. N°1 TT 1616/A 00809-0100-4021
TYPE: 3144P
RPO33441 THERMOELE 3RD STG. DISCHARGE CYL. N°1 TE 1615/A 00813-0200-2654
TYPE: RTD PT 100
RTO744086010 TEMPERATURE 3RD STG. DISCHARGE CYL. N°1 TT 1615/A 00809-0100-4021
TYPE: 3144P
RPO33441 THERMOELE 3RD STG. DISCHARGE CYL. N°3 TE 1616/B 00813-0200-2654
TYPE: RTD PT 100
RTO744086010 TEMPERATURE 3RD STG. DISCHARGE CYL. N°3 TT 1616/B 00809-0100-4021
TYPE: 3144P
RPO33441 THERMOELE 3RD STG. DISCHARGE CYL. N°3 TE 1615/B 00813-0200-2654
TYPE: RTD PT 100
RTO744086010 TEMPERATURE 3RD STG. DISCHARGE CYL. N°3 TT 1615/B 00809-0100-4021
TYPE: 3144P
RPO33441 THERMOELE 3RD STG. DISCHARGE CYL. N°5 TE 1616/C 00813-0200-2654
MENT ROSEMOUNT (TE 1816/C)
TYPE: RTD PT 100
RTO744086010 TEMPERATURE 3RD STG. DISCHARGE CYL. N°5 TT 1616/C 00809-0100-4021
(ITN66212) TRANSMITTER ROSEMOUNT (TT 1816/C)
TYPE: 3144P
RPO33441 THERMOELE 3RD STG. DISCHARGE CYL. N°5 TE 1615/C 00813-0200-2654
MENT ROSEMOUNT (TE 1815/C)
TYPE: RTD PT 100
RTO744086010 TEMPERATURE 3RD STG. DISCHARGE CYL. N°5 TT 6115/C 00809-0100-4021
(ITN66212) TRANSMITTER ROSEMOUNT (TT 6115/C)
TYPE: 3144P
RTO846167055 PRESSURE 3RD STG. DISCHARGE PT 1625/B 00809-0100-4051
TYPE: 3051TG
1003084
12-2010 Page 3-8
RVO6100474 PRESSURE SA 3RD STG. DISCHARGE PSV 1609 06-11IE
TYPE: 3211A
RVO6100474 PRESSURE SA 3RD STG. DISCHARGE PSV 1610 06-11IE
TYPE: 3211A
RVO90017 PRESSURE 3RD STG DISCHARGE PV 1612 EH21000-0109
VE TYPE: 68-21714
VIBROSWITCH 3RD STG AIRCOOLER MOTOR EM1-102A/ VSHH SUPPLIED WITH AIR
B 1613/A COOLER
( VSHH
1813/A)
VIBROSWITCH 3RD STG AIRCOOLER MOTOR EM2-102A/ VSHH SUPPLIED WITH AIR
B 1613/B COOLER
( VSHH
1813/B)
I/P CONVERTER 3RD STG AIRCOOLER E-102A/B TY 1617 SUPPLIED WITH AIR
(TY 1817) COOLER
RVO6100469 PRESSURE SA OUTLET TO FLARE PSV 1007 06-11IE

TYPE: 3111A
RVO6100469 PRESSURE SA OUTLET TO FLARE PSV 1008 06-11IE
TYPE: 3111A
ANTICONDEN 3RD STG AIRCOOLER MOTOR EM1-102A/ EHM1-102 SUPPLIED WITH AIR
SATION HEA B A COOLER
TER ( EHM1-102
B)
ANTICONDEN 3RD STG AIRCOOLER MOTOR EM2-102A/ EHM2-102 SUPPLIED WITH AIR
SATION HEA B A COOLER
TER ( EHM2-102
B)
1003084
12-2010 Page 3-9
1.1.2 CAPACITY CONTROL SYSTEM

REO05471 SOLENOID CAPACITY CONTROL XY 1601 ASCO-327
VALVE ASCO (XY 1801)
TYPE: 327
TYPE: 327
TYPE: 327
TYPE: 327
TYPE: 327
TYPE: 327
TYPE: 327
1003084
12-2010 Page 3-10
1.1.3 FRAME LUBE OIL SYSTEM

RPO36234 SCREW PUMP LUBE OIL PUMP AND ELECTRIC MOTOR FL-P2 FL- ALLWEILER MANUAL
WITH ELECTRIC ALLWEILER MP2
MOTOR (FL-P2 FL-
MP2)
RFO38333 FILTER LUBE OIL DUPLEX FILTER FL-F1 FL-F2 A2300-208
FILTERS (FL-F1 FL-
F2)
RRO0110816 ELECTRIC HEA COMPRESSOR FRAME LUBE OIL FL-EH1A 30107-IS
TER FATI (FL-EH1B)
RTO563351083 TEMPERATURE COMPRESSOR FRAME LUBE OIL TI 1625 TM.55-01

TYPE: 5550/1
RTO06465 LEVEL TRAN COMPRESSOR FRAME LUBE OIL LT 1601 MAGNETROL-JUPI
(SOP5696201/4) SMITTER MAGNETROL (LT 1801) TER
TYPE: JUPITER 200
RMO419730803 PRESSURE LUBE OIL HEADER PI 1634 PM.02-04
TYPE: 233.30
RTO846157055 PRESSURE LUBE OIL HEADER PT 1633 00809-0100-4051
TYPE: 3051TG
RTO846157055 PRESSURE LUBE OIL HEADER PT 1632 00809-0100-4051
TYPE: 3051TG
RMO419730803 PRESSURE LUBE OIL CONSOLE AUX. PUMP OUTLET PI 1637 PM.02-04
TYPE: 233.30
RMO419730803 PRESSURE LUBE OIL CONSOLE COOLER INLET PI 1639 PM.02-04
TYPE: 233.30
RMO452330101 DIFFERENTIAL LUBE OIL FILTER PDI 1640 PM.07-13
(ITN66422) PRESSURE WIKA (PDI 1840)
GAUGE TYPE: 733.14
RTO714207050 DIFFERENTIAL LUBE OIL FILTER PDT 1641 00809-0100-4051
(ITN66187) PRESSURE ROSEMOUNT (PDT 1841)
TRANSMITTER TYPE: 3051CD
RVO353555011 SELF REGULA LUBE OIL CONSOLE PCV 1638 FISHER-655EDR
(ITR31914) TING PRESS. FISHER (PCV 1838)
VALVE TYPE: 655EDR
RVO15098 PRESSURE RE COMPRESSOR FRAME LUBE OIL CONSOLE PRV 1630 SEE PART LIST VOLU
LIEF VALVE NP STD (PRV 1830) ME
RVO15098 PRESSURE RE COMPRESSOR FRAME LUBE OIL CONSOLE PRV 1631 SEE PART LIST VOLU
LIEF VALVE NP STD (PRV 1831) ME
1003084
12-2010 Page 3-11
RVO311921000 PRESSURE RE LUBE OIL AUX. PUMP OUTLET PRV 1636 IS-V-3117
(ITR35826) LIEF VALVE CROSBY (PRV 1836)
TYPE: 9811051A
RVO311931000 PRESSURE RE LUBE OIL MAIN PUMP OUTLET PRV 1635 IS-V-3117
(ITR35826) LIEF VALVE CROSBY (PRV 1835)
TYPE: 9911071A
RTO563351083 TEMPERATURE LUBE OIL COOLER INLET TI 1621 TM.55-01
TYPE: 5550/1
RTO563351083 TEMPERATURE LUBE OIL FILTER INLET TI 1624 TM.55-01
TYPE: 5550/1
RPO33439 THERMOELE LUBE OIL FILTER INLET TE 1623 00813-0200-2654
TYPE: RTD PT 100
RTO744086010 TEMPERATURE LUBE OIL FILTER INLET TT 1623 00809-0100-4021
TYPE: 3144P
RVO300325202 THERMOSTA LUBE OIL CONSOLE TCX 1622 AMOT-B
(ITN64078.02) TIC VALVE AMOT (TCX 1822)
TYPE: 2"BR
VIBROSWITCH AIRCOOLER MOTOR FL-EM1A/B VSHH 1620 SUPPLIED WITH AIR
( VSHH COOLER
1820)
VIBROSWITCH AIRCOOLER MOTOR FL-EM2A/B VSHH 1621 SUPPLIED WITH AIR
( VSHH COOLER
1821)
ANTICONDEN AIRCOOLER MOTOR FL-EM1A/B FL-EH- SUPPLIED WITH AIR
SATION HEA EM1A COOLER
TER ( FL-EH-
EM1B)
ANTICONDEN AIRCOOLER MOTOR FL-EM2A/B FL-EH- SUPPLIED WITH AIR
SATION HEA EM2A COOLER
TER ( FL-EH-
EM2B)
1003084
12-2010 Page 3-12
1.1.4 MONITORING SYSTEM

RTO310913000 THERMOELE COMPRESSOR MAIN BEARING TE 1630 00813-0200-2654
(SOP5692374/4) MENT ROSEMOUNT (TE 1830)
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
RTO310910000 THERMOELE CYLINDER N°1 PACKING TEMPERATURE TE 1639 00813-0200-2654
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
RJO04939 VELOMITOR COMPRESSOR FRAME VT 1625 100076-01
(ITN63003) BENTLY NEVADA (VT 1825)
TYPE: 330500
TYPE: 330500
TYPE: 330500
TYPE: 330500
1003084
12-2010 Page 3-13
RJO05826 ACCELEROME CROSSHEAD N°1 PERPENDICULAR TO VT 1632 127088-01
(ITN63003) TER AXIS (VT 1832)
BENTLY NEVADA
TYPE: 330400-01-05
BENTLY NEVADA
TYPE: 330400-01-05
BENTLY NEVADA
TYPE: 330400-01-05
BENTLY NEVADA
TYPE: 330400-01-05
BENTLY NEVADA
TYPE: 330400-01-05
BENTLY NEVADA
TYPE: 330400-01-05
RJO07671 KEY-PHASOR MONIT. SYSTEM COMPR. FLYWHELL XE 1610 146255-01
PROBE BENTLY NEVADA (XE 1810)
TYPE: 330704-000-050-10-02-05
RJO07121 KEY-PHASOR MONIT. SYSTEM COMPR. FLYWHELL XT 1610 146255-01
(ITN63003) PROXIMITOR BENTLY NEVADA (XT 1810)
TYPE: 330780-91-05
RJO07671 POSITION PRO CYL. N.1 PISTON ROD DROP ZE 1613 146255-01
BE BENTLY NEVADA (ZE 1813)
TYPE: 330704-000-050-10-02-05
RJO07121 POSITION CYL. N.1 PISTON ROD DROP ZT 1613 146255-01
(ITN63003) TRANSMITTER BENTLY NEVADA (ZT 1813)
TYPE: 330780-91-05
TYPE: 330704-000-050-10-02-05
TYPE: 330780-91-05
TYPE: 330704-000-050-10-02-05
TYPE: 330780-91-05
TYPE: 330704-000-050-10-02-05
TYPE: 330780-91-05
1003084
12-2010 Page 3-14
TYPE: 330704-000-050-10-02-05
TYPE: 330780-91-05
TYPE: 330704-000-050-10-02-05
TYPE: 330780-91-05
RTO674871216 THERMOELE CYL. N°1 DISCHARGE VALVE COVER TE 1652A 00813-0200-2654
(RT67487/4) MENT ROSEMOUNT (TE 1852A)
TYPE: RTD PT100
RTO674871216 THERMOELE CYL. N°1 DISCHARGE VALVE COVER TE 1652B 00813-0200-2654
(RT67487/4) MENT ROSEMOUNT (TE 1852B)
TYPE: RTD PT100
RTO674871216 THERMOELE CYL. N°1 DISCHARGE VALVE COVER TE 1652C 00813-0200-2654
(RT67487/4) MENT ROSEMOUNT (TE 1852C)
TYPE: RTD PT100
RTO674871216 THERMOELE CYL. N°1 DISCHARGE VALVE COVER TE 1652D 00813-0200-2654
(RT67487/4) MENT ROSEMOUNT (TE 1852D)
TYPE: RTD PT100
RTO674871216 THERMOELE CYL. N°1 SUCTION VALVE COVER TE 1645A 00813-0200-2654
TYPE: RTD PT100
RTO674871216 THERMOELE CYL. N°1 SUCTION VALVE COVER TE 1645B 00813-0200-2654
TYPE: RTD PT100
RTO674871216 THERMOELE CYL. N°1 SUCTION VALVE COVER TE 1645C 00813-0200-2654
TYPE: RTD PT100
RTO674871216 THERMOELE CYL. N°1 SUCTION VALVE COVER TE 1645D 00813-0200-2654
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
RTO674871316 THERMOELE CYL. N°2 DISCHARGE VALVE COVER TE 1653E 00813-0200-2654
(RT67487/4) MENT ROSEMOUNT (TE 1853E)
TYPE: RTD PT100
1003084
12-2010 Page 3-15
RTO674871316 THERMOELE CYL. N°2 DISCHARGE VALVE COVER TE 1653F 00813-0200-2654
(RT67487/4) MENT ROSEMOUNT (TE 1853F)
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
RTO674871316 THERMOELE CYL. N°2 SUCTION VALVE COVER TE 1646E 00813-0200-2654
TYPE: RTD PT100
RTO674871316 THERMOELE CYL. N°2 SUCTION VALVE COVER TE 1646F 00813-0200-2654
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
1003084
12-2010 Page 3-16
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
1003084
12-2010 Page 3-17
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
TYPE: RTD PT100
1003084
12-2010 Page 3-18
1.1.5 CYLINDERS COOLING SYSTEM

SNO4008843 TEMPERED CYLINDERS COOLING WATER CONSOLE LATER
WATER CON NUOVE OFFICINE SAN MAURO
SOLE
RTO713097050 FLOW TRAN CYLINDERS COOLING WATER SYSTEM FT 1620 00809-0100-4051
(ITN66187) SMITTER (PDT) OUTLET (FT 1820)
ROSEMOUNT
TYPE: 3051CD
RPO33439 THERMOELE COOLING WATER OUTLET FROM CYL. N°1 TE 1671 00813-0200-2654
TYPE: RTD PT100
RTO744086010 TEMPERATURE COOLING WATER OUTLET FROM CYL. N°1 TT 1671 00809-0100-4021
TYPE: 3144P
RTO563351083 TEMPERATURE COOLING WATER OUTLET FROM CYL. N°1 TI 1661 TM.55-01
TYPE: 5550/1
RPO33439 THERMOELE PACKING COOLING WATER OUTLET FROM TE 1669 00813-0200-2654
MENT CYL. N°1 (TE 1869)
ROSEMOUNT
TYPE: RTD PT100
RTO744086010 TEMPERATURE PACKING COOLING WATER OUTLET FROM TT 1669 00809-0100-4021
(ITN66212) TRANSMITTER CYL. N°1 (TT 1869)
ROSEMOUNT
TYPE: 3144P
RTO563351083 TEMPERATURE PACKING COOLING WATER OUTLET FROM TI 1677 TM.55-01
(ITN66506) GAUGE CYL. N°1 (TI 1877)
WIKA
TYPE: 5550/1
TYPE: RTD PT100
TYPE: 3144P
TYPE: 5550/1
TYPE: RTD PT100
TYPE: 3144P
TYPE: 5550/1
1003084
12-2010 Page 3-19
ROSEMOUNT
TYPE: RTD PT100
ROSEMOUNT
TYPE: 3144P
WIKA
TYPE: 5550/1
TYPE: RTD PT100
TYPE: 3144P
TYPE: 5550/1
TYPE: RTD PT100
TYPE: 3144P
TYPE: 5550/1
ROSEMOUNT
TYPE: RTD PT100
ROSEMOUNT
TYPE: 3144P
WIKA
TYPE: 5550/1
TYPE: RTD PT100
TYPE: 3144P
TYPE: 5550/1
1003084
12-2010 Page 3-20
RMO419730803 PRESSURE CYLINDERS COOLING WATER SYSTEM IN PI 1645 PM.02-04
(ITN66418.02) GAUGE TLET (PI 1845)
WIKA
TYPE: 233.30
RTO563351083 TEMPERATURE CYLINDERS COOLING WATER SYSTEM IN TI 1660 TM.55-01
(ITN66506) GAUGE TLET (TI 1860)
WIKA
TYPE: 5550/1
RTO713097050 LEVEL TRAN TEMPERED WATER TANK LT 1610 00809-0100-4051
(ITN66187) SMITTER ROSEMOUNT (LT 1810)
TYPE: 3051CD
RMO419730603 PRESSURE TEMPERED WATER PUMP TW-WP1A/B DI PI 1650 PM.02-04
(ITN66418.02) GAUGE SCHARGE (PI 1850)
WIKA
TYPE: 233.30
RMO419730603 PRESSURE TEMPERED WATER PUMP TW-WP2A/B DI PI 1651 PM.02-04
(ITN66418.02) GAUGE SCHARGE (PI 1851)
WIKA
TYPE: 233.30
RTO846157055 PRESSURE TEMPERED WATER COOLERS INLET PT 1652 00809-0100-4051
TYPE: 3051TG
RTO563351023 TEMPERATURE TEMPERED WATER INLET TO PUMPS TI 1683 TM.55-01
(ITN66506) GAUGE WKA (TI 1883)
TYPE: 5550/1
RTO563351023 TEMPERATURE TEMPERED WATER OUTLET FROM CYLIN TI 1680 TM.55-01
(ITN66506) GAUGE DERS (TI 1880)
WKA
TYPE: 5550/1
RTO563351023 TEMPERATURE TEMPERED WATER OUTLET TO CYLIN TI 1685 TM.55-01
(ITN66506) GAUGE DERS (TI 1885)
WIKA
TYPE: 5550/1
RPO33439 THERMOELE TEMPERED WATER INLET TO PUMPS TE 1682 00813-0200-2654
TYPE: RTD PT100
RTO744086010 TEMPERATURE TEMPERED WATER INLET TO PUMPS TT 1682 00809-0100-4021
TYPE: 3144P
RVO300325252 THERMOSTA TEMPERED WATER OUTLET TO CYLIN TCX 1681 AMOT-B
(ITN64078.02) TIC VALVE DERS (TCX 1881)
AMOT
TYPE: 2"BR
RRO0110840 ELECTRIC HEA TEMPERED WATER TANK TW-EH1A 30107-IS
TER FATI (TW-EH1B)
ANTICONDEN TEMPERED WATER MOTOR PUMP TW- TW-EH SUPPLIED WITH WA
SATION HEA WP1A/B MWP1A TER MOTOR PUMP
TER ( TW-EH
MWP1B)
1003084
12-2010 Page 3-21
ANTICONDEN TEMPERED WATER MOTOR PUMP TW- TW-EH SUPPLIED WITH WA
SATION HEA WP2A/B MWP2A TER MOTOR PUMP
TER ( TW-EH
MWP2B)
1003084
12-2010 Page 3-22
1.1.6 CYLINDERS AND PACKINGS LUBE OIL SYSTEM

RLO03180 LUBRICATOR MECHANICAL LUBRICATOR WM-COULTHARD
WM COULTHARD
RMO90083 ELECTRIC MO MOTOR FOR LUBRICATOR CP-ML1 LATER

TOR (CP-ML1)
RJO27119 LEVEL GAUGE LUBE OIL TANK V-1A/B LG 1622 KLINGER-MDR

KLINGER (LG 1822)
TYPE: MDR-DG
RTO713097050 LEVEL TRAN LUBE OIL TANK V-1A/B LT 1621 00809-0100-4051
TYPE: 3051CD
RRO0110847 ELECTRIC HEA LUBE OIL TANK V-1A/B CP-EH3A 30107-IS
TER FATI (CP-EH3B)
RTO563350033 TEMPERATURE LUBE OIL TANK V-1A/B TI 1688 TM.55-01

TYPE: 5550/1
RTO563301203 TEMPERATURE MECHANICAL LUBRICATOR TI 1689 TM.55-01
TYPE: 5550/1
RTO846143035 PRESSURE MECHANICAL LUBRICATOR PT 1653/A 00809-0100-4051
(ITN66236) TRANSMITTER ROSEMOUNT (PT 1853/A)
TYPE: 3051TG
RTO846143035 PRESSURE MECHANICAL LUBRICATOR PT 1653/B 00809-0100-4051
(ITN66236) TRANSMITTER ROSEMOUNT (PT 1853/B)
TYPE: 3051TG
RTO713097050 LEVEL TRAN MECHANICAL LUBRICATOR LT 1620 00809-0100-4051
TYPE: 3051CD
RRO270313833 ELECTRIC HEA MECHANICAL LUBRICATOR CP-EH1A 30107-IS
(SOP09537/4) TER FATI (CP-EH1B)
ANTICONDEN MECHANICAL LUBRICATOR CP-EHM SUPPLIED WITH LU

SATION HEA L1A BRICATOR
TER ( CP-EHM
L1B)
1003084
12-2010 Page 3-23
1.1.7 MAIN ELECTRIC MOTOR SYSTEM

RMO0474248 ELECTRIC MO MAIN ELECTRIC MOTOR MK-1 ABB MANUAL
TOR ABB (MK-1)
TYPE: AMI630L6ABSNH
RGO144130200 COUPLING COUPLING BETWEEN MOTOR AND COM VULKAN-RATO-S
PRESSOR
VULKAN
TYPE: RATO-S 2711 SERIES 2200
THERMOELE MAIN ELECTRIC MOTOR WINDINGS TE 1694 SUPPLIED WITH MAIN
MENT (TE 1894) ELECTRIC MOTOR





THERMOELE MAIN ELECTRIC MOTOR BEARING TE 1690 SUPPLIED WITH MAIN

THERMOELE MAIN ELECTRIC MOTOR BEARING TE 1691 SUPPLIED WITH MAIN

TEMPERATURE MAIN ELECTRIC MOTOR BEARING TI 1690 SUPPLIED WITH MAIN

GAUGE (TI 1890) ELECTRIC MOTOR
TEMPERATURE MAIN ELECTRIC MOTOR BEARING TI 1691 SUPPLIED WITH MAIN

GAUGE (TI 1891) ELECTRIC MOTOR
THERMOELE MAIN ELECTRIC MOTOR HEAT EXCHAN TE 1692 SUPPLIED WITH MAIN
MENT GER (TE 1892) ELECTRIC MOTOR
THERMOELE MAIN ELECTRIC MOTOR HEAT EXCHAN TE 1693 SUPPLIED WITH MAIN
MENT GER (TE 1893) ELECTRIC MOTOR
ELECTRIC HEA MAIN ELECTRIC MOTOR EM-EH1A SUPPLIED WITH MAIN

TER (EM-EH1A) ELECTRIC MOTOR
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ELECTRIC HEA MAIN ELECTRIC MOTOR EM-EH1B SUPPLIED WITH MAIN
TER (EM-EH1B) ELECTRIC MOTOR
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1.1.8 BARRING AND LOCKING DEVICE SYSTEM

RJO20613 LIMIT SWITCH BARRING DEVICE ZSHH 1650 NUOVAASP-PS
NUOVA ASP ( ZSHH
TYPE: PS 202 1850)
RJO20613 LIMIT SWITCH BARRING DEVICE ZSHH 1651 NUOVAASP-PS
NUOVA ASP ( ZSHH
TYPE: PS 202 1851)
RJO20613 LIMIT SWITCH LOCKING DEVICE ZSHH 1652 NUOVAASP-PS
NUOVA ASP ( ZSHH
TYPE: PS 202 1852)
RJO20613 LIMIT SWITCH LOCKING DEVICE ZSHH 1653 NUOVAASP-PS
NUOVA ASP ( ZSHH
TYPE: PS 202 1853)
RVO08722 PNEUMATIC LOCKING DEVICE XV 1650 PNEUMAXMANUAL
(SOP5692344/4) VALVE PNEUMAX (NP STD) (XV 1850)
TYPE: X 224.32.1.1
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Manual
Volume 4
UNIT CONTROL SYSTEM

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TABLE OF CONTENT
Section1 - UNIT CONTROL PANEL

1 UNIT CONTROL PANEL - SCENETRON 4
Section2 - LOCAL CONTROL PANEL
1 LOCAL CONTROL PANEL 6
Section3 - MACHINE MONITORING SYSTEM
1 VIBRATION MONITORING SYSTEM 8
2 TEMPERATURE MONITORING SYSTEM 10
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1 - UNIT CONTROL PANEL
1 UNIT CONTROL PANEL - SCENETRON ...................................................................................................4 4-4
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1.1 UNIT CONTROL PANEL - SCENETRON
UNIT CONTROL PANEL

NUOVO PIGNONE CODE: RQO 5023066
MANUFACTURER: ELETTROMECCANICA M.B.
MANUAL No.: LATER
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2 - LOCAL CONTROL PANEL
1 LOCAL CONTROL PANEL ..............................................................................................................................6 4-6
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2.1 LOCAL CONTROL PANEL
LOCAL CONTROL PANEL MANUAL

NUOVO PIGNONE CODE: RQO14574
MANUFACTURER: ELETTROMECCANICA M.B.
MANUAL No.: LATER
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3 - MACHINE MONITORING SYSTEM
1 VIBRATION MONITORING SYSTEM ..........................................................................................................8 4-8

2 TEMPERATURE MONITORING SYSTEM ..................................................................................................10 4-10
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3.1 VIBRATION MONITORING SYSTEM
VIBRATION MONITORING SYSTEM

BENTLY NEVADA
NUOVO PIGNONE CODE: RJO07502
SUB-
DESCRIPTION DOC N°
SECT.
3500/05 MONITORING SYSTEM 163860-01 1
INSTALLATION AND OPERATING GUIDE
3500/05 MONITORING SYSTEM RACK 129766-01 2
INSTALLATION AND MAINTENANCE MANUAL
3500/15 AC AND DC POWER SUPPLIES 129767-01 3
3500/22 TRANSIENT DATA INTERFACE 161580-01 4
3500/25 ENHANCED KEYPHASOR® MODULE 129770-01 5
3500/33 16 CHANNEL RELAY MODULE 162291-01 6
3500/42 PROXIMITOR®/SEISMIC MONITOR MODULE 129773-01 7
3500/70 RECIP. IMPULSE/VELOCITY MONITOR MODULE 166226-01 8
3500/72 RECIP. ROD POSITION MONITOR 146479-01 9
3500/92 COMMUNICATION MODULE 138629-01 10
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Figure 72 - Bently Nevada 3500 series
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3.2 TEMPERATURE MONITORING SYSTEM
TEMPERATURE MONITORING SYSTEM

BENTLY NEVADA
NUOVO PIGNONE CODE: RJO07504
SUB-
DESCRIPTION DOC No.
SECT.
3500/05 MONITORING SYSTEM 163860-01 1
INSTALLATION AND OPERATION GUIDE
3500/05 MONITORING SYSTEM RACK 129766-01 2
INSTALLATION AND MAINTENANCE MANUAL
3500/15 AC AND DC POWER SUPPLIES 129767-01 3
3500/22 TRANSIENT DATA INTERFACE MANUAL 161580-01 4
3500/25 ENHANCED KEYPHASOR® MODULE 129770-01 5
3500/33 16 CHANNEL RELAY MODULE 162291-01 6
3500/65 16-CHANNEL TEMPERATURE MONITOR 172931-01 7
3500/92 COMMUNICATION MODULE 138629-01 8
12-2010 1003084 Page 4-10

Figure 73 - Bently Nevada 3500 series
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Manual
Volume 5
REFERENCE DRAWINGS OF THE JOB

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TABLE OF CONTENT
Section1 - REFERENCE DRAWING OF THE JOB

1 PROJECT OUTLINE AND DIAGRAM 4
2 DATA SHEETS 5
3 FOUNDATION DRAWINGS 6
4 ELECTRICAL DRAWINGS 7
5 MAINTENANCE 8
6 AUXILIARIES AND INSTRUMENTATION 9
7 MAIN MOTOR 10
8 UNIT CONTROL SYSTEM 11
9 PRESSURE VESSELS 12
10 MISCELLANEOUS 13
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1 - REFERENCE DRAWING OF THE JOB
1 PROJECT OUTLINE AND DIAGRAM ..........................................................................................................4 5-4

2 DATA SHEETS ....................................................................................................................................................5 5-5
3 FOUNDATION DRAWINGS ..........................................................................................................................6 5-6
4 ELECTRICAL DRAWINGS .............................................................................................................................7 5-7
5 MAINTENANCE .................................................................................................................................................8 5-8
6 AUXILIARIES AND INSTRUMENTATION ..................................................................................................9 5-9
7 MAIN MOTOR ....................................................................................................................................................10 5-10
8 UNIT CONTROL SYSTEM ...............................................................................................................................11 5-11
9 PRESSURE VESSELS .......................................................................................................................................12 5-12
10 MISCELLANEOUS ............................................................................................................................................13 5-13
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1.1 PROJECT OUTLINE AND DIAGRAM
POS. TITLE DRAWING N°

1 COMPRESSOR GENERAL ARRANGEMENT SOK2301301
2 PNEUMATIC PLANT ARRANGEMENT SNO2961203
3 FUNCTIONAL P&I DIAGRAM SOP6258790
4 PERFORMANCE CURVES SOP6236591
5 PRIMARY AND PNEUMATIC HOOK-UP SPECIFIATIONS SOP5696989
6 START/STOP SEQUENCE SOP5700065
7 TORSIONAL ANALYSIS REPORT SOP3885132
8 STATIC LOADING DIAGRAM SOP6236561
9 UMBALANCED FORCES AND COUPLES SOP6236566
10 ROD LOAD DIAGRAM SOP3885121
11 STARTING AND BRAKE TORQUE DIAGRAM SOP6044305
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1.2 DATA SHEETS

1 COMPRESSOR DATA SHEET SOK0912989
2 NOISE DATA SHEET SOP6236623
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1.3 FOUNDATION DRAWINGS

1 MACHINERY FOOT PRINT SOK6711953
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1.4 ELECTRICAL DRAWINGS

1 PLANT ELECTRICAL OUTLINE DRAWING SNO2961202
2 FIELD ELECTRICAL HOOK-UP AND WIRING DIAGRAM SOP5692942
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1.5 MAINTENANCE

1 RECIPROCATING COMPRESSOR OIL CHARACTERISTICS "NUOVO PIGNONE" SOP86677
2 PROCEDURE OF POSITIONING OF PISTON ROD-DROP PROBES, CALIBRATION AND SOP24932
SETTINGS OF MONITORING EQUIPMENT
3 LIST OF SPECIAL TOOLS SOP6236791
4 LUBRICANT LIST SOP5696899
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1.6 AUXILIARIES AND INSTRUMENTATION

1 FIELD INSTRUMENT LIST SOP5692937
2 INSTRUMENT DATA SHEET SOP3884912
3 COOLING WATER CONSOLE ARRANGEMENT SOK6705037
4 COOLING WATER CONSOLE FOOT PRINT SOK6711962
5 LOCAL GAUGE BOARD LAYOUT SOP6237008
6 1 STG AIR COOLER SG-8202351
9 WATER AND OIL AIR COOLER SG-8202354
10 1 STG AIR COOLER DATA SHEET SOG7203594
13 OIL AIR COOLER DATA SHEET SOG7203597
14 WATER AIR COOLER DATA SHEET SOG7203598
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1.7 MAIN MOTOR

1 MOTOR DATA SHEET SOP5699476
2 MOTOR GENERAL ARRANGEMENT DRAWING SOP5699478
3 MOTOR WIRING DIAGRAM SOP5699485
4 MOTOR MAIN TERMINAL BOX DRAWING SOP5699483
5 MOTOR AUXILIARY TERMINAL BOX DRAWING SOP5699484
6 MOTOR CARACTERISTIC CURVE SOP5699477
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1.8 UNIT CONTROL SYSTEM

1 UNIT CONTROL SYSTEM LAYOUT SOP5700062
2 SERIAL COMMUNICATION LIST SOP5700084
3 FUNCTIONAL LOGIC DIAGRAM SOP5700101
4 UNIT CONTROL SYSTEM INTERCONNECTING WIRING DIAGRAM SOP5700107
5 UNIT CONTROL SYSTEM I/O LIST SOP5700100
6 LOCAL PANEL LAYOUT SOP5700115
7 CAUSE-EFFECT CHART SOP5700067
8 CONTROL SYSTEM FUNCTIONAL DESCRIPTION SOP5700086
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1.9 PRESSURE VESSELS
POS. TITLE DRAWING

VOLUME BOTTLES:
1 1 STG SUCTION VOLUME BOTTLE SNO4088732
2 1 STG DISCHARGE VOLUME BOTTLE SNO4088733
SEPARATORS:
7 1 STG SUCTION GAS SEPARATOR SNO5954273
9 2 STG SUCTION GAS SEPARATOR (B-SECTION) SNO5954275
12 3 STG SUCTION GAS SEPARATOR (B-SECTION) SNO5954280
13 3 STG DISCHARGE GAS SEPARATOR SNO5954276
TANKS:
14 LUBE OIL TANK AND SUPPORT SNO4697900
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1.10 MISCELLANEOUS

1 CYLINDER NAME PLATES RT-3414112
2 PIPING LINES SPECIFICATIONS SOK6722264
3 SPOOL PIECE FOR TEMPORARY FILTER SNO4088740
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g GE Oil & Gas Nuovo Pignone

Operation & Maintenance

ABB SpA – Process Automation Division

PROJET RECUPERATION DES GAZ TORCHES & REINSTRUMENTATION

Nuovo Pignone N. FORNISSEUR

Projet Numero MR Numero Ordre Feuille Rév.

Customer: ABB FOR SONATRACH

Manufacturer:g GE Oil & Gas

Operation & Maintenance

Customer: ABB FOR SONATRACH

Manufacturer: g GE Oil & Gas

OPERATION AND MAINTENANCE MANUAL

Revision and Status Description

Revision Status Date Prepared Checked Approved Revision Description

00 23.12.10 ISSELnord L. Davini L. Petruzzi AS SHIPPED MANUAL

1.1 AFTER SALES SERVICE

1.1.1 GE OIL & GAS TECHNICAL COMMUNICATION

1.1.2 CUSTOMER SERVICE CENTER

1.1.3 REMOTE MONITORING & DIAGNOSTICS (RM&D)

1.1.4 HOW IT WORKS

PAGE INTENTIONALLY LEFT BLANK

Volume 1 - COMPRESSOR INSTRUCTIONS 1

Operation & Maintenance

Customer: ABB FOR SONATRACH

Section1 - GENERAL INFORMATION

1 DEFINITIONS .....................................................................................................................................................9 1-9

- THE HAZARD LEADING TO THE RISK MENTIONED IN THIS DEFINITION:

A SHROUD CAN ACT:

FORESEEN USE OF THE MACHINE

AS FAR AS THE FORESEEABLE WRONG USE IS CONCERNED, THE FOLLOWING BEHAVIOURS

12-2010 1003084 Page 1-10

1.2 SYMBOLS IN THE MANUAL

THIS SYMBOL INDICATES A PROCEDURE, A PRECAUTION OR A CONDITION THAT, IF NOT

THIS SYMBOL INDICATES A PROCEDURE, A PRECAUTION OR A CONDITION THAT, IF NOT

1.4 IDENTIFICATION OF HAZARDOUS AREAS

SECURING THE MACHINE BEFORE CARRYING OUT MAINTENANCE

1.5 GUARDS (SAFETY DEVICES AND SHROUDS) AND STOP DEVICES

1.6 RESIDUAL RISKS

1.6.1 General residual risks

THE AREA SURROUNDING THE COMPRESSOR OR THE ACOUSTIC HOOD ( PARAGRAPH 4 ), IS AN

IN GENERAL, OPERATORS WILL HAVE TO USE PERSONAL PROTECTION EQUIPMENT ACCORDING

IN CASE OF LONGER STANDSTILL, ADOPT A SUITABLE GUARD IN ORDER TO PRESERVE THE

1.6.2 Mechanical residual risks

IT IS FORBIDDEN TO START THE EQUIPMENT WITHOUT PREVIOUSLY INSTALLING THE FORESEEN

IT IS FORBIDDEN TO USE HOME-BUILT EQUIPMENT (SUPPORTS, BRACKETS, TOOLS, ETC.) THAT

1.6.3 Electric residual risks

MAINTENANCE ON THE ELECTRIC DEVICES MUST BE PERFORMED BY QUALIFIED AND AUTHORIZED

ALWAYS INSTALL THE EQUIPMENT GROUND LEADS AS SHOWN IN THE DRAWINGS.

12-2010 1003084 Page 1-22

DO NOT USE WATER TO EXTINGUISH A FIRE WHEN THE EQUIPMENT IS PRESSURIZED.

1.6.4 Thermal residual risks

1.6.5 Residual risks due to noise

1.6.6 Residual risks due to materials and substances

IF A CARBON DIOXIDE FIREFIGHTING SYSTEM IS USED, DISCHARGE INSIDE A PROTECTED ROOM

WHEN THE FIREFIGHTING SYSTEM IS OPERATED, THE DISCHARGE IS ANNOUNCED BY AN

DO NOT USE ANY FLAMMABLE PRODUCTS TO CLEAN THE MACHINE COMPONENTS.

1.7 HAZARDS INFORMATION IN CASE OF FAILURE

1.8 FORESEEN USE OF THE MACHINE

THE COMPRESSOR CANNOT BE USED TO COMPRESS DIFFERENT TYPES OF GAS. IT CANNOT BE

1.9 GENERAL WARNINGS

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2 - MOVING, HANDLING, STORAGE

1 Moving and handling ...................................................................................................................................32 1-32

SAFETY PRECAUTIONS - GENERAL INFORMATION

K102A&B

K102A&B