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MH WH Instruction Manual PDF
MH WH Instruction Manual PDF
MH WH Instruction Manual PDF
Superior
WH/MH
Compressor
Instruction
Manual
Cooper Energy Services Ajax-Superior
Page a
Page b
Section 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Who We Are...a brief history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Ajax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Superior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Section 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Unit Identification - Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Compressor Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Crankshaft Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Balancing AJAX-Superior Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Compressor System Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Compressor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Section 3
Lubrication And Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Lubricating Oil Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Compressor Frame Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Compressor Cylinder Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Lubrication Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Pump Per Point System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Proportional Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Page c
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Lubricator Worm And Gear Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Section 4
Sour Gas Compressor Applications . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Hazards of Hydrogen Sulfide or Sour Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Concentration Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Section 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Preparing The Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Foundation Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Placement And Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Section 6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Preparation for Initial Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Initial Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Cooper Energy Services Ajax-Superior
Page d
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Normal Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Section 7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Acceptable Tolerance Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Torque Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Critical Bolt Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Page e
Section 8
Parts Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1
Ordering Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Instructions For Ordering Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Parts Listings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Using The Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Page f
Section 1
Introduction
Who We Are...a brief history
AJAX
The first Ajax steam engine was produced in Corry, Pennsylvania, in the late 1870s. This
engine quickly became popular for use in oil well drilling. The company was incorporated as
Ajax Iron Works in 1892, and, in 1895, Ajax was producing its first gas engine.
Both Ajax steam and gas engines were in great demand in the early 1900s as oil finding
operations expanded westward. In the early 1920s, Ajax faced capacity restraints and
decided to discontinue production of its gas engine to focus exclusively on steam engine
production. At this time, the National Supply Co. became the exclusive distributor of the
Ajax steam engine for the oil fields. When oil well drilling slowed during World War II, Ajax
developed a special steam engine used in the marine applications.
After the war, Ajax returned to production of natural gas engines for use in the growing
secondary oil recovery market. Ajax first came in contact with Superiors operations in 1945
when it purchased a line of slow speed horizontal gas engines from the Superior Engine
division of the National Supply Co. In the late 1950s, Ajax introduced its popular integral
gas engine-compressor to meet the market need for a durable, long life product in gas
gathering and boosting applications. Cooper Industries purchased Ajax Iron Works in 1963.
SUPERIOR
Shouvlin Manufacturing Co. was founded in 1889 in Springfield, Ohio, and became the
Superior Gas Engine Co. in the early 1890s. It originally produced gas engines for drilling
rigs and oil pumping units during the development of Ohio and Pennsylvania oil fields. In
1928, Superior was acquired by the National Supply Co., previously Superiors exclusive
agent in the oil production industry.
During the 1920s, the Superior diesel engine line was introduced. This engine was used in
commercial marine applications and in military vessels during World War II. During the
economic boom of the 1940s and 1950s, Superior concentrated on selling diesels for use in
locomotives, power plants, factories, ocean vessels, and other energy-intensive applications.
In 1955, Superior was purchased by the White Motor Co. By the late 1950s, a great number
of Superior engine-generator sets were being sold for military defense use.
Page 1-1
The Superior natural gas compressor was introduced in 1960, and the company rapidly
became one of the leading suppliers of natural gas compression equipment for markets in the
U.S., Canada, and South America. Superior became a part of Cooper Industries in 1976.
Ajax and Superior were previously separate divisions of Cooper Energy Services Group,
with manufacturing locations in Corry, Pennsylvania, and Springfield, Ohio. In 1987, the
Ajax and Superior divisions were consolidated in the Springfield facility to form the AjaxSuperior Operations of CES which in 1995 became a unit of Cooper Cameron Corporations
Cooper-Bessemer Reciprocating Products Division.
Note
This manual contains confidential proprietary information of the Ajax-Superior division of
Cooper Energy Services, an operating division of the Cooper Cameron Corporation. This
manual is provided to you for the limited purpose of providing information to facilitate your
use and maintenance of your equipment. This manual should only be used for the stated purposes, and by receiving this manual you agree not to disclose such information to others.
GENERAL
1. Follow all safety rules and operating procedures put in place by the company that owns
and operates this equipment.
2. Read and understand the instruction manual prior to operating this equipment to become
familiar with the safety, design, and operating features. If you do not have a manual, call
Ajax-Superior at (513) 327-4200.
3. Always wear safety glasses or goggles, steel-toe safety shoes, and hearing protection.
Note
Additional equipment may be required by the equipment owner.
Cooper Energy Services Ajax-Superior
Page Intro-2
4. Do not wear loose fitting clothing, neckties, scarves, watches, rings, etc., near operating
equipment as they can be caught in the moving machinery. Keep long hair tied back.
5. Locate nearest fire extinguisher to area where maintenance is to be performed. Ensure a
clear path to fire extinguisher in case it should be needed for an emergency situation.
6. Do not open cooling or lubrication systems when engine or compressor is hot, as steam or
hot liquids can be released, which can cause severe burns. Be aware that some surfaces
can remain hot for several hours after the unit has been shutdown.
7. When draining the coolant and lubricants, prevent contamination of the environment by
the equipment fluids. Refer to equipment owners material safety data sheets for additional information. (Remember: Antifreeze/Glycol solutions, as well as most lubricants, are
flammable.)
8. Keep the area around the unit clean and orderly with ample space to walk safely around
the unit. Clean up spills and leaks quickly to prevent accidents caused by slipping and
falling.
9. Use only non-flammable, non-toxic cleaning solvents. NEVER USE GASOLINE OR OTHER FLAMMABLE PRODUCTS FOR CLEANING PURPOSES. REFER TO EQUIPMENT
OWNERS MATERIAL SAFETY DATA SHEETS FOR EACH CLEANING PRODUCT
FOR ADDITIONAL PRECAUTIONS.
10. Use fans, blowers, etc. during maintenance and clean-up work in enclosed areas to remove
fumes from cleaning solvents and vented gases.
11. Use ladders, platforms, etc. where possible when working on elevated work surfaces. Always stand on stable surfaces when working on this equipment.
12. Before starting any equipment, make sure all nearby personnel are aware of the start up
and are clear of the equipment.
13. Do not use bare hands when checking for leaks of fluids under pressure, as fluids or particles can penetrate skin. Use cardboard or a similar material to check for leaks.
COMPRESSOR MAINTENANCE
1. Shut down the compressor first, then prevent it from being started before the work is
done. (See ENGINE MAINTENANCE section previously if engine driven.) If electric motor driven, the electric power supply must be disconnected and locked out. THIS IS VERY
IMPORTANT IF THE UNIT HAS REMOTE START CAPABILITY - a remote operations
center may try to start a unit without knowing that work is being performed on it. Suction
and discharge block valves (see site plan for location) must be closed to prevent gas from
flowing into the compressor during maintenance. (Gas pressure could rotate the compresCooper Energy Services Ajax-Superior
Page 1-3
sor and cause injury if not shut off and vented properly - see compressor section of manual.) Note: After maintenance work is done, some adjustments may need to be done with
the compressor running. Stay clear of moving parts and follow instruction manual procedures as required.
2. Before attempting any maintenance or repair on the compressor, vent all gas pressure
from the cylinders, piping, and other pressurized components or chambers. Know the
piping system associated with this compressor. Open discharge blowdown and/or bypass valves to vent system to atmosphere. ALLOW COMPRESSOR TO COOL FOR AT
LEAST 15 MINUTES BEFORE OPENING SUCTION OR INTERSTAGE VENTS. Atmospheric air can be drawn in if a vacuum exists and can create an explosive mixture.
CHECK LOCAL OR PANEL PRESSURE GAUGES FOR ZERO READING BEFORE REMOVING ANY GAS PASSAGE COMPONENTS SUCH AS VALVES, VALVE CAPS, OR
CYLINDER HEADS. Note: UNLOADER CONTROL PRESSURE IS TYPICALLY NOT
SHOWN ON GAUGES. Vent unloader control pressure line by loosening control line tubing fitting.
3. IF POISONOUS OR SUFFOCATING GASES ARE BEING COMPRESSED, FOLLOW ALL
PLANT SAFETY PROCEDURES PRIOR TO AND DURING MAINTENANCE ON ANY
GAS EQUIPMENT OR PIPING TO AVOID INJURY OR DEATH DUE TO INHALATION
OF SUCH SUBSTANCES.
4. Regularly check around compressor and piping gaskets and joints for leaks which could
result in a fire or an explosion.
5. Test all pressure gauges on a periodic basis (see maintenance schedule) to ensure accurate
pressure readings. Likewise, check all relief valves for design opening pressure (see manufacturers data for each relief valve in packaging section of manual).
6. Check all safety shutdown devices (low oil pressure, high and low gas pressures, vibration, etc.) per the schedule in the maintenance section of this manual.
7. Remove electrical lockout function if motor driven when maintenance is completed and
REMOVE MANUAL BARRING DEVICE, if used during maintenance, before starting
unit.
8. Before replacing any studs, measure stud height from machined surface and position replacement stud to the same height.
Page Intro-4
WARRANTY
The Seller warrants to the Buyer that the equipment to be delivered hereunder will be free
from defects in material, workmanship and title and will be of the kind described in the
contract. THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER
WARRANTIES WHETHER WRITTEN, ORAL OR IMPLIED (INCLUDING ANY
WARRANTY OF MERCHANTABILITY OR FITNESS FOR PURPOSE). If it appears within
one year from the date the equipment is placed in service but no later than eighteen (18)
months from the date of delivery to the Buyer, whichever first occurs, that the equipment
does not meet the warranty specified above and the Buyer notifies the Seller promptly, the
Seller shall correct any defect, at the Sellers option, either by repairing any defective part or
parts or by making available, at the Sellers factory, a repaired or replacement part. The
liability of the Seller to the Buyer (except as to title) arising out of the supplying of the
equipment, or its use, whether on warranty, contract or negligence, shall not in any case
exceed the cost of correcting defects in the equipment or part thereof and upon expiration of
the warranty period all such liability shall terminate. The foregoing shall constitute the sole
remedy of the Buyer and the sole liability of the Seller.
The preceding paragraph shall not apply and the Seller assumes no liability whatsoever for
breach of warranty when there is evidence that the defect arose as the result of (a) abuse or
negligence in the operation of the equipment, (b) failure to maintain the equipment properly,
(c) overloading or overspeeding, or (d) use of repair parts not approved by Seller.
The warranty given to the Seller by its supplier of special equipment, including but not
limited to generators, is hereby assigned without recourse by the Seller to the Buyer. AS TO
THIS SPECIAL EQUIPMENT, WHICH GENERALLY BEARS THE NAMEPLATE OF THE
SELLERS SUPPLIER, THE SELLER ASSUMES NO LIABILITY WHATSOEVER FOR
BREACH OF WARRANTY, WHETHER WRITTEN, ORAL OR IMPLIED (INCLUDING ANY
WARRANTY OF MERCHANTABILITY OR FITNESS FOR PURPOSE).
Page 1-5
Page Intro-6
Section 2
Specifications
General Information
Your Ajax-Superior instruction manual has been carefully prepared to assist in the proper
installation, operation, and maintenance of the equipment. It is difficult to accurately
describe every type of installation. However, this manual, along with the drawings included
in the parts list contains sufficient basic information to effectively operate and maintain this
equipment.
This manual represents todays typical design and is subject to change without notice. If
additional help is needed, contact the closest Cooper Energy Services Group Aftermarket
office or the Ajax-Superior Field Engineering Department in Springfield, Ohio.
This manual is divided into sections listed in the Table of Contents. Each begins with a
general description of the equipment or system discussed and includes operating data,
clearances, and information vital to operation.
Reference may be made in the text to other manufacturers literature contained in the
Auxiliary Equipment section which must be consulted, along with drawings or diagrams in
the Parts List, for clarification of specific systems and components. Obtain the most recent
versions of all referenced Engineering Standards and Service Bulletins before using this
equipment.
Sufficient operating manuals, including parts lists for the installation, are included with
every Superior product. Additional copies can be obtained by contacting any Energy
Services Group Aftermarket office. It will not always be possible to duplicate the original
manuals over a period of years due to revisions made in the manuals. However, every effort
will be made to give you information that will be helpful and will closely duplicate the
original manuals.
Page 2-1
Figure 2-1
Frame Nameplate
00744
00743
2. Each Compressor Cylinder has its own serial number which is stamped on a name plate
attached to the cylinder.
3. These serial numbers should be included in all requests as a reference for Ajax-Superior.
Cooper Energy Services Ajax-Superior
Page 2-2
Compressor Description
The Ajax-Superior Compressor has been engineered for reliable, continuous, heavy duty and
long life with trouble free operation. These ruggedly constructed, balanced-opposed type
compressors are built to match the high speed, high precision, high quality, field proven
standards as the Superior Engines. Ready accessibility of all wearing parts mean simplified
maintenance and dependable service. The balance-opposed design, with two crank throws
separated by a crank cheek, has become the modern standard for reciprocating compressors.
Main and connecting rod bearings are of thin wall, steel backed, split, precision design. The
crankshaft can be removed through the top of the base without disturbing the cylinders. The
lube oil pump and the force feed lubricator are gear or shaft driven and mounted on the
auxiliary end cover. Either may be maintained independently.
Lube oil is drawn from the sump through a strainer which protects the lube oil pump. A fullflow lube oil filter with a differential pressure indicator to indicate a plugged filter, protects
all frame running parts.
Although piston and rod lengths may vary according to the stroke and model, all cylinders
will fit interchangeably on the standard crosshead guide. Careful attention has been given to
the cooling of cylinders designed for a 1.5 to 5:1 pressure ratio.
Variable Volume Pockets are furnished as standard equipment on all cylinder classes, except
the model #602 through #605 forged steel cylinders. On these cylinders, other methods of
adding clearance, such as fixed heads (some with center plugs), fixed volume heads, or
valves spaces can be furnished when required.
The purpose of this manual is to familiarize operating and maintenance personnel with the
design and construction of the compressor. Thus, they can understand the functions of the
various parts and know how to care for them in order to obtain the most satisfactory
compressor performance.
The MH6 and WH6 compressors are all of the same basic configuration but vary in size and
rating of certain components. The general configuration of each compressor and various
cylinder head options are shown in Figure 2-3, Figure 2-4 and Figure 2-5.
Page 2-3
Page 2-4
Plate Valve
Variable
Volume
Pocket
Plate
Valve
Piston
Packing
Rod
Connecting Rod
Figure 2-3
00745
Relief
Valve
Breather
Crankshaft
Coupling Hub
Figure 2-4
00746
Page 2-5
Figure 2-6
00748
00747
00749
Page 2-6
Crankshaft Rotation
When facing the oil pump end of the frame, counterclockwise rotation is standard.
! Caution
The maximum allowable variation is two pounds on the reciprocating weights and one
pound on the connecting rod weights for each pair of opposing throws.
This does not apply to adjacent throw pairs, which sometimes vary by 100 lbs. or more,
depending on cylinder sizes.
The estimated balance for the original assembly of a compressor is recorded on the
Compressor Torsional and Balance Data Sheet. A copy of the data sheet for this compressor
is included in the Instruction Manual, and should be referred to in the event a change which
would affect the balance is contemplated. The actual weight of parts can vary from the
estimated weights. Also, when replacing crossheads, connecting rods, pistons, or changing
Page 2-7
piston ring material, the new parts should be weighted in order to reaffirm the actual unit
balance.
! Warning
Failure to verify and correct compressor balance can result in excessive mechanical
vibration, frame cracking, piping vibration, foundation cracking and other damage
to the compressor. It also creates a potentially UNSAFE operating condition for the
operator.
Compressor Specifications
Table 2-1 Compressor Specifications*
Specification
MH6
Number of Throws
2-6
Stroke Inches (mm)
6 (152.4)
Speed Range - RPM
600-1200
Horsepower Per Throw @ 1200 900 (671)
RPM-hp (kw)
Rod Load-kips (kg)
38 (17,237)
Rod Diameter - inches (mm)
2.25 (57.15)
Connecting Rod Length
14.5 (368.3)
Center to Center - inches (mm)
Page 2-8
Type Of Unit
WH6
2-6
6 (152.4)
600-1200
900 (671)
50 (22,680)
2.5 (63.5)
15.0 (381.0)
12.75 (323.85)
4.75 (120.65)
Internal
---397 lbs
Page 2-9
Page 2-10
Section 3
Lubrication And Cooling
General
The responsibility for selecting the proper lubricant is primarily that of the supplier. Use of
only products with field proven reliability and merit, produced by responsible concerns will
provide the best assurance for achieving effective lubrication. Use of such products should
always be accomplished according to the manufacturers recommendations. If a
compounded oil is used, the non-corrosiveness of this oil must be looked into very carefully.
The oil must not contain substances which might be injurious to tin or lead base babbitts and
should be non-corrosive to copper-lead alloys. Similar, synthetic lubricants must be reviewed
for compatibility with compressor materials.
Compressor design, operating conditions, and the gases being handled all have a significant
effect on how well a lubricant performs in the given application. The following will assist
users in selecting the proper lubricant for each application.
Any lubricant that performs satisfactorily in a Superior engine will generally perform well in
a compressor frame. Compressor frame lubricating oils should normally be the same as used
in the engines and should be selected in accordance with Superior Engineering Standards ES
1001 and 1002.
In addition to the above requirements, the frame lubricant must be capable of operating with
the type of gas being handled by the compressor cylinders. For most sweet natural gases and
allied gas services, a lubricating oil with the minimum qualities specified in ES 1001 and 1002
will be suitable. In applications where the compressor cylinders are handling corrosive gases
such as H2S or CO2, a lubricant with a higher TBN or method for adequate retention of the
original TBN is recommended for service in the frame.
In some cases it may be convenient or practical to use the same type oil in the compressor as
is used in the compressor drive engine. This is permissible as long as the engine oil is of
proper viscosity. The oil should be selected per the recommendations of this section.
Figure 3-1
00750
! Caution
Verify that the oil temperature in the sump is heated to at least 40F before attempting to use
compressor.
Prior to start-up, the frame lubrication system should be primed by using the lube oil hand
priming pump or automatic priming pump. Use of this pump will prevent oil starvation in
the bearings during start-up, prolonging compressor life. Compressor design, operating
conditions, and the gases being handled all have a significant effect on how well a lubricant
performs in the given application.
Lube oil header pressure should be 50 psi (345 kPa) and is maintained at this level by the
pressure relief valve. If adjustment is required, it can be done by removing the cap which
provides access to the spring loaded adjusting screw. This should be adjusted while at
normal operating speed and temperature.
Cooper Energy Services Ajax-Superior
When starting the compressor, verify a lube oil header pressure of 20 psi (138Kpa) or greater
occurs within 5 seconds of compressor start-up. To prevent damage to the crankshaft and
other lubricated parts, all compressors are equipped with low oil pressure shutdowns. This
is triggered when the oil pressure falls below 20 psi (138 kPa).
The oil level in the frame is normally at the center of the sight glass. An alarm should sound
if the oil level rises 1 inch during compressor operation, this will submerge the gaskets on the
bottom of the front and rear covers. A shutdown should occur if the oil level rises an
additional 2.5 inches (1.5 on MH62) or if the oil level falls 1 inch from normal level.
Any lubricant that performs satisfactorily in a Superior engine will generally perform well in
a compressor frame. Compressor frame lubricating oils should normally be the same as used
in the engines and should be selected in accordance with Superior Engineering Standard ES
1001.
The frame lubricant must be capable of operating with the type of gas being handled by the
compressor cylinders. For most sweet natural gases and allied gas services, a lubricating oil
with the minimum qualities specified in ES 1001 and 1002 will be suitable. In applications
where the compressor cylinders are handling corrosive gases such as H2S or CO2, a lubricant
with a higher TBN or method for adequate retention of the original TBN is recommended for
service in the frame.
The oil level in the frame sump should be checked while the compressor is running. The
correct level is shown by the round sight gauge on the auxiliary end of the compressor. Oil
level (while running) should be no higher than the top and no lower than the bottom of the
sight gauge. Oil may be manually added through the breather cap hole in the top cover. The
breather cap is designed to be threaded into its bushing by hand and no wrenches should be
used. Make up oil may also be continuously added through an optional, frame mounted oil
level controller connected to an oil supply tank.
Note
The regulator is not designed to make up large quantities of oil in a short time period, such
as refilling the crankcase after oil or filter changes. Its function is to compensate for small
losses that occur during normal operation.
Oil change periods, in general, may be longer than the period required for
compressor drive engines. An initial break-in period of 300 to 500 hours is
recommended. Thereafter, the filter element should be changed and the drainage
periods can be increased to 2000 hours or longer, providing the filter element
remains in good shape and the oil stays reasonably clean. However, if the
oil is badly discolored and loaded with insolubles, it should be drained off
and replaced when the filter element is changed.
00751
IT IS IMPORTANT to provide safe and ample lubrication by the properly adjusting the force
feed lubricator pumps. Observe the detailed instructions, given in Section 5, when first
starting up the compressor. With all lubricator pumps set at full stroke, bring the cylinder
pressure up slowly until the unit is running at full rated speed and load. Watch for any signs
of malfunction. After the first 48 hours at full load, the lubrication rate should be gradually
reduced to the amount necessary for correct lubrication. Adjustment should be made slowly,
a little each day, and should take several days to accomplish.
Because of the variety of gases and operating conditions encountered by Superior
compressor cylinders, the lubricant must be selected with the proper characteristics to be
suitable for the application involved. Contact Superior Engineering for a copy of ES 1002 for
detailed information on selecting lubricants. In all applications, the oil used for compressor
cylinders should have the following qualities:
Lubrication Rate
The lubrication rate may be determined as follows: A fairly generous feed rate for a 6" stroke
compressor running at 1200 rpm will be 1/5 pint per day for each inch of cylinder bore
diameter. Piston rod packing is treated as a separate cylinder and the feed rate is doubled.
That is, a 2-1/2" diameter rod packing is fed at the same rate as a 5" diameter cylinder.
As an approximate setting for the vacuum sight feed type lubricators, the feed rate of 1/5
pint per day per inch of cylinder bore is equivalent to one drop per minute per inch of bore
for a very heavy oil, and ranges up to 2 drops per minute per inch of bore for a light oil.
EXAMPLE:WH62 Compressor with one (1) 10" cylinder and one (1) 20" cylinder
operating at 1200 rpm:
2.5" Packing = 2 x 2.5 x 1/5 pint/day = 5/5 or 1.0 pint/day (5-10 drops per minute)
2.5" Packing = 2 x 2.5 x 1/5 pint/day = 5/5 or 1.0 pint/day (5-10 drops per minute)
10" Cylinder = 10" x 1/5 pint/day = 2 pints/day (10-20 drops per minute)
20" Cylinder - 20" x 1/5 pint/day = 4 pints/day (20-40 drops per minute)
Total Lubrication Rate = 1.0 + 1.0 + 2.0 + 4.0 = 8.0 pints/day
The feed rate specified for break-in and for normal operation may be approximated by
adjusting the pumps as shown on the Cylinder Lubrication Sheet, but a check should
always be made in terms of 24 hour oil consumption.
Pump Per Point System
If a cylinder has more than one feed point, and more than one pump, the requirements for
lubrication should be split evenly. On a normal force feed lubricator, the proper
proportioning of oil to cylinders and packing should, as a first approximation, be adjusted by
the drops per minute method; but a check should be made in terms of actual 24 hour oil
consumption, and the feed rate of all pumps adjusted up or down in the same
proportion as the size of the cylinders being fed.
The check on lubrication rate which takes precedence over any other method
is a visual inspection of the compressor cylinder. This should be done (by removing a valve
at each end) after 48 hours of operation at the final lubrication settings. There should be a
film of oil over the entire circumference of the ring travel section of the cylinder bore.
Separate pumps may be adjusted up or down as indicated by this inspection.
discs that determine the rupture pressure. Refer to rupture disc data sheet inAuxiliary
Equipment section of this manual.
Maintenance
In order to operate properly, the lubrication system must be completely purged of air. This is
done by LOOSENING, BUT NOT REMOVING the nuts of the lube lines at the point of
injection to permit purging of oil and air. The nut at the entry to the distribution block, all pin
indicators and 1/8" pipe plugs in the face of the block must be loosened also, for the same
reason.
! Caution
High pressure oil streams may puncture skin. Use proper wrench and keep hands away from
the immediate point where the system is purging air.
Loosen the vent screws in the top section of the distribution block. Continue to operate the
lubricator pump manually until clear, air-free oil appears at either of the two loosened vent
screws. Retighten this vent screw and continue pumping until air-free oil emerges at the
other vent screw. When this occurs, retighten second vent screw. Continue to operate the
pump manually until air-free oil has emerged from tubing nuts at every injection point.
Then, and only then, tighten the nuts on the tubing lines, the pin indicators, and pipe plugs.
Note
If distribution block must be disassembled for cleaning, observe the following:
(a) Record order of manifold sections and outlet positions in order to facilitate reassembly.
(b) Have a clean work area.
(c) Avoid vise marks; protect ground surfaces, and NEVER grip the ground mating surfaces in a vise.
(d) Pistons are not interchangeable - - each piston is match-honed to its cylinder.
(e) Pistons are removed by hand-punching with a brass rod (either way).
(f) Clean all sections with an approved solvent.
(g) Do not disassemble check valves - - clean with compressed air. Replace defective
parts, as required.
(h) Use all new gaskets when reassembling manifolds.
(i) Torque must be carefully observed when reassembling manifolds, as follows:
Figure 3-3
Upper
Plug
00752
Drain Plug
42,000
MH64/WH64
65,000
MH66/WH66
110,000
Cylinder Cooling
The Ajax-Superior compressors cylinder jackets can be cooled by one of three ways: (1) Dry
jacket, (2) Standpipe, or (3) Circulated water cooling.
1. Dry jacket cooling is generally used where the gas discharge temperature is less than
140F. and gas inlet temperature is greater than 60F. In this form of cooling, the air
present inside the cylinder water jacket is the medium which transfers heat out of the cylinder. The cylinder jackets must be vented when this form of cooling is used.
2. In standpipe cooling, a water with corrosion inhibitor and/or antifreeze solution is
used as the medium for heat transfer. The cylinder jackets are filled with the coolant and
then vented to the atmosphere at their highest point. The vent (or standpipe) should be a
6" long vertical section of pipe which will contain the coolant when it expands. The pipe
must be topped with a vented cap to prevent dirt from entering the coolant. This form of
cooling may be used when the gas discharge temperature is less than 250F. and the rise
between gas suction and discharge temperature is less than 170F. The temperature of the
liquid coolant will reach a mean temperature somewhere between the suction and discharge gas temperatures. Accordingly, a coolant must be chosen whose boiling point is at
least 25F greater than the mean temperature and whose freezing point is at least 25F less
than the suction gas temperature (or ambient, whichever is lower).
3. The third form of cooling is by coolant circulation through the cylinder jackets. This
form of cooling must be used on compressor cylinders having gas discharge temperatures
greater than 250F. or a gas temperature rise greater than 170F.
For maximum performance, it is recommended that the cylinder coolant temperature be
maintained 10F to 15F higher than the suction gas temperature. At lower coolant
temperatures, condensation forms on the cylinder walls. This condensation must be avoided
as it has a tendency to wash the oil film from the cylinder bore, promote corrosion (especially
in non-lubricated cylinders), and cause internal damage by excessive wear on rods, rings,
valves, and the cylinder bore due to lack of lubrication. Also, condensates are incompressible
fluids which can cause damage to any cylinder part by creating forces well beyond the
capability of the machine.
To control condensates and still maintain optimum cylinder performance, the coolant must
be monitored and regulated. This is accomplished by monitoring the coolant in and out
temperatures for each cylinder with thermometers and sight flow indicators. From these
readings, the operator may regulate the water flow to each cylinder by using a water
regulating valve until a coolant temperature differential of 10F (15F maximum) is obtained.
Note
Applications that require low suction temperatures (Below 40F) should be coordinated with
Superior Engineering.
Packing Cooling
In the majority of applications, rod packings will perform satisfactorily without a coolant
being circulated through the packing case and therefore dont have coolant passage. Some
applications, however, do require that the packing cases be cooled in order to achieve
adequate packing ring life. These applications usually involve high pressures and
temperatures, marginal lubrication (characteristically encountered with wet and sour gases),
and unclean gases. On these units, the packing cases are provided with internal coolant
passages. (See Figures 3-4 and 3-5.)
Adequate cooling flow through the packing cases at a satisfactory temperature is required to
properly conduct the heat out of the packing. Inlet coolant temperatures should be as cool as
possible, but no higher than 90F. is recommended to achieve optimal cooling. The coolant
flow required is normally 1 GPM for each inch of rod diameter with a minimum of 2 GPM. A
pressure drop with water coolant of approximately 30 to 50 psig should be expected across
each packing case at the required flows.
Coolant Requirements
The most important consideration for cooling systems is good water quality. The following
chart shows the range of limits for water quality. If raw water is tested and found to have
higher concentrations than the chart allows, it should be treated or de-ionized. If
concentrations are lower, then it should be suitable for use with the addition of inhibitors.
pH
Standard System
Ebullient/Steam
System
7.5 Min.
7.5 Min
Standard System
Ebullient/Steam
System
100-170 Maximum
5.0 Maximum
25 Maximum
25 Maximum
20-100 Maximum
20-100 Maximum
300-400 Maximum
300-400 Maximum
------
50 Maximum
Silica (PPM)
A good industrial-type of antifreeze should be used in all closed-type cooling systems. All
industrial antifreezes have some corrosive inhibitors; however, these inhibitors break down
with heat. This requires periodic adjustments to maintain the corrosive protection of the
coolant.
Corrosion inhibitors vary in their chemical make-up and concentrations, depending on the
manufacturer. Most products will do their job with a good quality water (de-ionized or
demineralized), but will not give adequate corrosion protection with hard or impure water.
The key to good protection is clean water and a reliable water treatment specialist.
Periodic testing of the coolant, whether by the user or the vendor of the treatment system, is
absolutely necessary in order to assure that a proper level of protection is maintained. The
equipment user must obtain the specific instructions for the use and testing requirements of
the inhibitor compounds from the supplier or manufacturer.
A clean system is a prerequisite for establishing protection of any cooling system.
Adequately protected closed cooling systems seldom, if ever, present problems caused by
scaling, corrosion, deposits, or cavitation.
There are three types of cooling systems used for stationary engines and compressors: open,
closed, and combination.
Open systems involve cooling towers, spray ponds, and cool the water by evaporation.
Closed systems involve heat rejection through either shell and tube or radiator type heat
exchangers.
Combination systems have the jacket water in a closed system using shell and tube-type
heat exchangers to transfer the heat to an open system using cooling towers, etc.
Both closed and combination-type systems are commonly used and approved cooling
methods. However, because the open-type systems involves not only large volumes of
make-up water, but also ease air-borne contamination, we do not recommend them.
Superior recommends that the compressor coolant system should be pressurized. To
pressurize the system, all radiators and surge tanks must have a 7 to 10 pound pressure cap.
Figure 3-4
Crosshead Guide and Distance Piece - Lube and Liquid Cooled Package
00753
00754
Figure 3-5
00755
00756
Section 4
Sour Gas Compressor Applications
General Information
This section defines additional compressor hardware and special materials for use when the
compressor is applied in sour gas or corrosive gas service. The requirements listed are based
on API-11P Standards, dated 1989, NACE MRO175, and Ajax-Superior experience.
Additional specifications may apply to pulsation dampers, piping and other equipment used
in conjunction with this compressor. (See API-11P for additional information.)
These specifications apply to equipment only. Follow safe operating and maintenance procedures associated with personnel around sour gas machinery as dictated
by your company procedures. Sour Gas is poisonous and attacks the nervous system
and can cause paralysis, permanent injury or death.
Concentration Levels
Table 4-1 Hydrogen Sulfide Effects
H2S Concentration
1 ppm (.0001%)
Effects
Detectable of Rotten Eggs Odor.
The equipment specifications are based on three levels of sour gas plus additional NACE
requirements as defined by the following percentages of H2S:
Level I
Less than 2% H2S (by volume)
Level 1-11P
2% to 5% H2S
Level 2-11P
Greater than 5% H2S
Enhanced TrimNACE MR0175 Guidelines
Trim Requirements
Hydrogen Sulfide (H2S) Concentrations Up To 2% By Volume:
For any concentration of H2S up to 2% by volume in lubricated service, special trim will
not be required. Standard material is acceptable and special lubrication practices are recommended.
The frame lubricant used must have a total base number (TBN) of 15 or higher to help prevent the lubricant from turning acid and damaging bearings and bushings. This alkalinity
must be maintained during operation in the machine at no less than approximately 30%
of the original TBN number by appropriate timely make-up or complete oil changes.
The frame lubricant must meet or exceed the requirements of MIL-L-2104B, Supplement
No. 1.
A complete oil analysis program on the frame lubricant is required to determine proper
oil change intervals as well as to monitor the condition of the lubricant and the unit.
Compressor cylinder lubricants must adhere to the requirements of Ajax-Superior Engineering Standard ES 1002. Viscosities are to be on the high side of the pressure conditions
normally required and a 3% to 5% compounding (similar to steam cylinder oils) is also required.
The compressor cylinder lubricant rate is to be double the normal rate for equivalent nonsour gas applications.
All brass, bronze, copper and other copper alloys are to be avoided on hardware for all gas
wetted parts.
The distance piece is to be properly vented in accordance with local safety standards to
provide maximum safety to personnel.
Soft iron or aluminum gaskets are to be used between the valve and valve seat.
The O-ring material used for standard equipment is Viton (Spec. 473) and this is also acceptable for H2S service. For lower temperature operations (< 27F) Neoprene (Spec. 479)
can be specified as an option.
Cylinders are to be equipped with a suction flushing system (injection of cylinder lubricating oil into the suction nozzle of each cylinder). This is in addition to the regular cylinder lubrication. This helps to resist the natural solvent action of the sour gas and insures
a thorough distribution of oil for better lubrication. It also helps to better form a barrier to
corrosion by coating all the valve surfaces with an oil film.
Oil slingers are to be used on each compressor rod in the distance piece compartment to
insure that none of the H2S contaminated cylinder or packing lubricant works its way
back into the crankcase and contaminates the frame lubricating system.
Packing and piston ring material shall either be non-metallic or contain no copper bearing
metals.
Cooper Energy Services Ajax-Superior
All carbon steel, alloy steel, or 12CR steel parts which are gas wetted (come into contact
with the process gas stream) are to have a maximum hardness of 22 HRC. This is to include all internal fasteners and V.V. pocket screws as a minimum, but excludes valve fasteners.
The piston rods are 17-4 pH stainless steel with a hardness of 28 - 33 HRC (Heat Treat Spec
ZA).
Forged steel cylinder bodies made of AISI 4142 are to have a maximum hardness of 235
HB. Engineering will evaluate these applications on an individual basis as some cylinder
pressure ratings may have to be reduced because of the mechanical properties restrictions.
All instrumentation that comes into contact with the process stream (liquid level controls,
shutdowns, bourdon tubes, process valving, relief valves, etc.) shall meet the full
requirements of NACE MRO125 except stainless steel tubing fittings. This requirement is the
packagers responsibility.
The distance piece shall be purged with inert gas. The packager is responsible for purging
per these requirements. If other venting or purging systems are desired the details are to be
negotiated between the purchaser and the packager (i.e., vacuum systems or sweet natural
gas purge). The final detailed system should provide for the safety of persons around the
equipment and should prevent contamination of the frame oil with sour gas. Packing cases
will not be purged unless required by the customers.
The cylinders are to be equipped with a suction flushing system (injection of cylinder lubricating oil into the suction nozzle of each cylinder).
Two compartment distance pieces are required. The outer compartment must be purged
with inert gas to a pressure of 3 - 5" of H2O. The inner compartment can either be separately vented as described previously or purged with inert gas to a pressure of 3 - 5" H2O.
Oil slingers are to be used on each compressor rod in the distance piece compartment to
insure that none of the H2S contaminated cylinder or packing lubricant works its way
back into the crankcase and contaminates the frame lubricating system.
The piston rods are Stainless Steel with a hardness of 28 - 33 HRC (Heat Treat Spec. ZA).
Tungsten carbide coating is required in the packing travel area of the piston rods.
The valve components are to be made of carbon steel or AISI 4140 alloy steel with a hardness of 22 HRC maximum (Heat Treat Spec H2S). This reduces the pressure differential
capability of any specific valve design and thus the pressure differential capability of the
cylinders. Engineering will evaluate these on an individual basis and select appropriate
alternative valve designs to meet the application requirements. Compressor valve components may also be made of AISI 416 stainless steel with a maximum hardness of 22 HRC.
This reduced hardness requirement also includes steel valve cages (retainers) when they
are used.
Forged steel cylinder bodies are to be made of AISI 4142 with a maximum hardness of 235
HB. Engineering will evaluate these applications on an individual basis as some cylinder
pressure ratings may have to be reduced.
All steel gas wetted parts are to have a maximum hardness of 22 HRC. This is to include
all internal fasteners and V.V. pocket screws as a minimum.
Valve plates wherever possible are to be plastic to better prevent seat wear against the softer valve seats.
When metal plates are required, 410 stainless steel with a hardness of 17 to 22 HRC shall
be used.
All compressor cylinder and distance piece critical bolting, capscrews, studs, or nuts
which come into contact with the process gas stream shall conform to ASTM A193-B7M
(bolts and studs) and ASTM A194-2HM (nuts).
Section 5
Installation
General
Installation of the compressor will be determined by the fabricator and the end customer.
Since the method employed will vary due to application, the following is offered as a guide
to aid in the installation. These instructions are based on previous installations that have
proven satisfactory.
There are two basic compressor mountings: the baseframe or skid mount and the direct to
block mount. See Figures 5-1 and 5-2. The baseframe/skid mount is most commonly used
whereby the fabricator sets up the complete installation as a package. This package is then
moved to location and placed on a foundation. With the block mounting, there is no
intermediate (baseframe) between the compressor and foundation, thus the compressor is
mounted direct to the foundation (block). This type installation is of a somewhat more
permanent nature.
If you have a choice as to the location of the compressor, select a site where the ground under
and around the unit will be firm and dry at all times. Filled ground, wet clay, unconfined
sand and gravel or similar soils provide poor support. Be sure that sufficient space is
available for necessary maintenance. For instance, there should be ample space to permit
removing the piston and rod assembly out the outboard end of the cylinder. See that
provisions can be made for an overhead hoist, or that a portable crane can be moved into
position as necessary for removal or installation of major parts or assemblies. Electrical
outlets, lighting and cleanliness are other important factors. Adequate ventilation is essential
to safety and the welfare of the operating personnel.
Foundation
The responsibility for an adequate foundation is that of the customer; thus, it is suggested
that a foundation engineer be called in where soil conditions are questionable or where the
location of the compressor is such that transmitted vibration would have detrimental effects
not only to the compressor installation, but on surrounding machinery, buildings, or
personnel. Often times, a neighboring installation on similar soil will serve as a clue to the
soil conditions. However, unless the nature of the ground is well known, it is advisable to
dig several test pits at the proposed site. Ajax-Superior will gladly furnish data on weights
and unbalanced forces required for calculations by a foundation engineer. In any case where
increasing the size of the standard minimum foundation is necessary, the area of the base
should be increased to decrease the soil loading and the possibility of rocking. When
freezing temperatures are likely to occur, the foundation must be carried well below the
lowest expected frostline as determined by the foundation engineer.
00757
00758
Foundation Bolts
To locate the foundation bolts, make a wooden template to temporarily position the bolts
according to the dimensions given on the foundation plan. Set up the template in the exact
position to be occupied by the compressor, allowing space for the grout as indicated. See
Figure 5-3. Fasten the template firmly in position.
The next step is to attach the bolts to the template so that they will extend into the
foundation. There are two important items which should be considered at this point: (1)
Make sure the bolts project far enough through the frame hole to allow two full threads
beyond the nut. Allow for thickness of grout, frame, nut, etc. (2) Provide allowance for
misalignment. A piece of 2.5" to 3" pipe or metal tube positioned around each bolt, as shown
will prevent the bolts from being cemented into a fixed position and thus allow slight
movement of the bolts for alignment with the holes in the frame. Stuff paper or rags around
the bolts at the top of the pipe to prevent cement from entering when the foundation is
poured. The length that the bolts extend into the foundation is indicated on the foundation
plans.
00759
Grouting
The compressor frame may be grouted to a concrete or steel sub-base. In either case a grout
form must be used. Some use a steel grout tray instead of wood. Do not remove stuffing
from foundation bolts pipe casing before pouring grout. The bolts should not be encased so
that they are free to stretch.
Before grout can be poured, a grout form or dam must be constructed on top of the
foundation completely around the baseframe. This form should extend a minimum of 1" to
1.5" beyond the outer perimeter of the compressor baseframe and be deep enough (1.25") so
that at least 1/4" of the grout will come up above the bottom edge. See Figure 5-2 and 5-3.
On a block mounted installation the area under the center of the frame should not be
grouted. Leave the space empty to aid cooling. Also, only the necessary amount of grout
will be needed. A piece of hose or Styrofoam may be used to blank off this area. Whereas
Styrofoam may be left in place, it is important that there is air space under the unit. An
epoxy grout (or non-shrink grout) is recommended in preference to cement. Pour the grout
into the area contained by the grout form so that it comes up at least 1/4" above the bottom
edge of the base. Work the grout up under the inside of the base and into the sleeves around
the anchor bolts. Work grout under frame or baseframe cross-members as well as outside
members. Trowel off for smoothness and allow to set.
! Caution
Responsibility for the grout belongs with the customer or his contractor. Grouting material
instructions should be carefully followed. Failure to comply with this warning may result in
damage to your unit.
When the grout has completely hardened, LOOSEN THE JACKSCREWS and tighten down
all the foundation bolt nuts evenly. Make sure that no stresses are set up when pulling down
the nuts by checking alignment with a dial indicator.
00760
a. Disassemble the flexible coupling. Note the arrangement of bolts, washer, and nuts.
They must be replaced in their original position. Tie a string or wire through one bolt hole
of the laminated rings (A) (Not shown) to retain the dialed position of individual discs.
Note
Laminated rings must be re-assembled in the coupling exactly as received.
b. Mount flange (B) (Not Shown) on engine flywheel. Torque flange screws per Table 5-1
and lockwire together. Mount hub (C) on compressor crankshaft. (See instructions given
in 7.13 DRIVE COUPLING HUB.)
c. With engine and compressor moved into position, as shown on the Outline Drawing,
reassemble coupling. Dimension (D) (Not Shown) must be maintained during the
following alignment procedure.
The recommended procedure for establishing final alignment is called the indicator
method. Proper lining up may take a little time, but it is absolutely essential. Flexible
couplings should not be required to compensate for any misalignment that can be
eliminated. The closer the initial alignment, the greater the capacity of the coupling to take
care of subsequent operational misalignment.
00761
d. After attaching dial indicator as shown in Figure 5-5B, rotate coupling 360 degrees to
locate point of minimum reading on dial; adjust indicator to zero.
e. Rotate coupling 360 degrees. Observe misalignment reading.
f. Move engine or compressor, or both, until dial indicator reading does not exceed .0003"
for each inch of diameter at indicator stem. This is approximately .006" (.15 mm) at outside
diameter of flange B (Figure 5-4). This corrects angular misalignment.
g. Reset indicator to zero and repeat steps d e and f if either the engine or compressor is
moved during aligning trials.
h. The coupling should be turned several revolutions to make sure no end-wise creep
in the crankshaft is measured.
i. Mount dial indicator as shown in Figure 5-5C to check for parallel misalignment. Set
indicator stem on outer diameter surface of flange (B) and adjust to zero.
j. Rotate coupling 360 degrees. Move and/or shim the units until the indicator reading
comes within the maximum allowable variation of .004" (.10 mm).
k. Torque all bolts. See Table 7-2 for recommended torque values.
After several hours of operation, recheck both alignment and bolt torque.
l. When proper alignment is attained within the previously specified limits, the laminated
rings (A) must appear vertical and undistorted. There must be no end thrust due to poor
initial assembly of the coupling.
n. Alignment should be checked periodically. Realign unit when parallel misalignment
exceeds .014" (.36 mm) T.I.R. and/or angular misalignment exceeds .020" (.51 mm) T.I.R.
Bolt Size
Threads/Inch
Torque
(Foot-Lbs)
Dimension-D
Figure 5-4
500
3/4
16
260
8-3/4
550
7/8
14
350
9-7/8
600
14
490
10-7/8
700
1-1/8
12
630
12-7/16
750
1-1/4
12
830
13-1/2
800
1-3/8
12
1100
14-3/4
850
1-1/2
12
1400
15-3/4
Note
Couple bolts are tightened at the factory for shipping purposes only. When installing coupling, the above values apply to bolts and locknuts as they are received from the factory. If
any additional lubricant is used or if the threads are wiped dry, these values must be modified.
Note
Bolt heads should be held and locknut only turned, when tightening coupling bolts.
00762
Cylinder Mounting
Cylinders are normally mounted on the compressor frame when shipped to a location.
Sometimes, because of shipping and packaging restrictions, cylinders may be shipped
separately. If that is your case, remove cylinder head and the piston and rod assembly from
the cylinder body.
When reassembling the cylinder to the crosshead guide, use the nut tightening sequence
shown in Figure 5-7. See Table 7-2 for recommended torque values.
Outer end cylinder supports, if supplied, are intended to support the weight of the cylinder
only. Do not use them to force the cylinder into alignment. If a cylinder cannot be aligned,
check for dirt, burrs, or other irregularities at the mounting surfaces.
! Caution
After the cylinder is mounted and torqued, install the piston and rod assembly and the
cylinder head. See the next paragraph for the proper way to pass the piston rod through the
Cooper Energy Services Ajax-Superior
packing.
The Cylinder Head must be properly indexed on the mounting studs so that Valve Cut-outs
will be aligned with the valve locations in the Cylinder Body.
00763
00764
d. Check the crank end using the same method. For a cold compressor, the crank end
clearance should be .030 to .050 (.76 to 1.27 mm).
e. If any adjustment is needed, loosen the balance nut and screw the piston and rod
assembly in or out of the crosshead. The MH6 and WH6 piston rods both are threaded
with 10 threads per inch. Thus one complete turn of the piston and rod assembly moves it
.100" (2.54 mm).
f. After adjusting the piston and rod assembly, recheck the head end and crank end
clearances.
g. After setting the piston end clearance, re-torque the balance nut. See Table 7-2 for
torque values.
Cooper Energy Services Ajax-Superior
00765
c. Bar over the compressor until reaching the head end dead center position. Record
indicator movement.
d. Compare the vertical run out results with the graph. (See Table 5-2.) The horizontal run
out should not exceed .001" (.025 mm)
e. If the horizontal run out exceeds acceptable limits, loosen the packing and re-torque. If
the crisscross pattern of torquing is not followed this may cause the packing case to seat
at an angle; causing the rod to deflect to one side. If the run out still exceeds limitations,
contact your Energy Services Group Aftermarket facility for assistance.
f. If the vertical run out exceeds acceptable limits, check the packing case as explained for
horizontal run out. Also, check the piping and bottles attached to the cylinder to see if they
are distorting the cylinders. If run out still exceeds limits, loosen the cylinder to crosshead
Guide nuts and re-tighten them. If the run out is still beyond acceptable limits, contact
your Cooper Energy Services Aftermarket facility for assistance.
Cylinder
Number
Rod Run-Out
(At 70F)
6.00"
615
.012 to .030
-.0004 to -.0014)
6.25"
616
.012 to .030
-.0004 to -.0014
6.75"
617
.012 to .030
-.0004 to -.0014
5.75"
618
.012 to .019
-.0005 to .0007
6.25"
619
.012 to .019
-.0005 to .0007
6.75"
620
.012 to .019
-.0005 to .0007
7.25"
621
.012 to .019
-.0005 to .0007
6.00"
659
.014 to .025
-.0004 to .0012
6.50"
660
.013 to .028
-.0005 to .0018
7.00"
661
.016 to .029
-.0005 to .0018
7.50"
625
.015 to .033
-.0005 to .0018
8.00"
626
.016 to .034
-.0005 to .0018
8.50"
627
.017 to .032
-.0002 to .0018
9.50"
628
.019 to .034
-.0002 to .0018
10.25"
629
.019 to .034
-.0001 to .0018
9.00"
630
.019 to .034
-.0001 to .0018
9.50"
631
.019 to .034
-.0001 to .0018
10.0"
632
.019 to .034
-.0001 to .0018
10.5"
633
.019 to .034
-.0001 to .0018
11.0"
634
.019 to .034
-.0001 to .0018
11.5"
635
.019 to .034
-.0001 to .0018
12.0"
636
.019 to .034
-.0001 to .0018
11.0"
637
.022 to .037
.000 to .002
638
.021 to .036
.000 to .002
12.5"
639
.038 to .053
.0013 to .0033
13.0"
640
.039 to .054
.0013 to .0033
14.0"
641
.015 to .033
-.003 to .0019
14.5"
642
.016 to .034
-.003 to .0019
15.0"
643
.017 to .035
-.0003 to .0019
15.75"
644
.018 to .036
-.0003 to .0019
17.0"
645
.030 to .046
.0003 to .0027
18.0"
646
.030 to .046
.0003 to .0027
19.5"
648
.079 to .097
.0032 to .0049
20.5"
649
.079 to .097
.0032 to .0049
22.5"
650
.083 to .101
.0035 to .0052
23.5"
651
.083 to .101
.0035 to .0052
25.5"
652
.083 to .101
.0035 to .0052
26.5"
653
.083 to .101
.0035 to .0052
Section 6
Operation
Preparation For Initial Start-up
The following procedure is suggested before starting the unit for the first time, after an
overhaul of the frame or cylinders, or after an extended (over 6 months) shutdown.
! Caution
Read this manual and familiarize yourself with the compressor, auxiliary equipment, and
your companys safety procedures before attempting to start this equipment.
a. Check the alignment between the driver and the compressor.
b. Verify the proper torquing of the foundation bolts.
c. Remove the top cover of the base and the covers for the crossheads and distance pieces
on each crosshead guide. Thoroughly wipe the interior of the compressor with a lint free
cloth to remove any water or foreign material that may have accumulated during shipment or storage.
d. Check the crankshaft for web deflection.
e. Check the piston rod run out. (See Section 5)
! Warning
Vent the compressor and the process system to the atmosphere before removing any
gas-containing part of the compressor or its associated piping.
f. Remove a valve from each end of every compressor cylinder. (See Section 7)
g. Check the piston end clearances on all cylinders.
h. Add lubricating oil, which meets the proper specifications, to the base and to the lube
oil filter.
i. Check the force feed lubricator for cleanliness and fill to the proper level with oil.
j. Adjust all force feed lubricator pumps to full stroke for cylinder and packing break-in.
k. Disconnect ends of force feed lubricator lines as close as possible to cylinders and crosshead guides. Hand pump the lubricators to fill lines and eliminate air.
Cooper Energy Services Ajax-Superior
! Warning
High pressure oil stream may puncture skin. Use proper wrench and keep hands
away from the immediate point where connection is purging air.
l. Connect the force feed lubricator lines and operate pumps ten more strokes to force oil
into cylinders and rod packing.
m. Prime the frame oil system with the lube oil priming pump. Operate the pump a minimum of 100 strokes. This should fill all empty oil lines.
Note
Oil level in frame should be filled to the level in the Kenco level regualtor NOT the level in
the frame bullseye
n. Hand lubricate the piston rod next to the packing. (This does not apply to non-lubricated applications.)
o. Replace all covers with their respective gaskets and tighten screws according to torque
chart given in Section 1. Distance piece covers may be left off to check for packing leaks
on start up if not using sour gas. For Sour Gas Applications See Warnings In Sour Gas
Trim Section Of Manual.
p. Check to see that all crosshead guides or distance pieces and packings are individually
vented with the proper size of vent lines. Refer to Superior Engineering Standard ES 3 for
the most up-to-date recommendations.
q. Verify that all safety switches, shutdown devices, and relief valves are properly set and
operational. See Section 7 for recommended set points.
r. Visually verify that all guards are in place.
s. Unload the compressor for start-up by placing the bypass line between the first stage
suction and last stage discharge lines.
t. Verify that suction and discharge block valves are open.
Initial Start Up
1. Open the valves supplying water to the compressor cooling system (when required).
2. Start up and operate the unit under no-load conditions at reduced speed where possible
(600RPM for engine driven units). Check the oil pressure. When the compressor is started, an oil pressure of 20 psi (138 kPa) must be experienced within 5 seconds or the com-
pressor must be immediately shut down. Do not restart until adequate oil pressure can be
assured.
3. Run compressor for 2 to 5 minutes at 600 RPM. If driver is a constant speed electric motor run compressor for only 1 to 2 minutes.
! Caution
Running compressor at speeds less than 600 RPM for longer than 12 minutes may result in
unusual wear of the packing and piston rings.
4. Shut system down and check all bearings and packings for high temperatures.
5. Remove crosshead guide covers and check all lubricated surfaces for high temperatures.
6. Check piping for oil or water leaks.
7. Start system and compressor up again and run for approximately 20 to 30 minutes. Add
oil to the crankcase to bring the oil level (while running) up to the middle of the sight glass.
Shut down and recheck as above.
8. Start Unit. Bring unit up to full rated speed. Apply load to compressor by closing the
bypass line between the first stage suction and last stage discharge lines.
9. During the initial period of operation, pay close attention to the machine for any unusual high temperature, pressure, or vibration. In the event of equipment malfunction where
excessive vibration, noise, high temperature, or any other dangerous condition exists, the
compressor should be stopped immediately.
! Warning
Do not immediately remove the equipment covers after the compressor has been
stopped. Allow the unit to cool down to prevent possible explosion due to in rush of
air or injury caused by contact with hot surfaces.
Normal Start Up
Not all of the instructions provided for initial start-ups are required for routine starting. The
following notes comprise the normal starting procedure:
1. Unload the compressor.
2. Operate the force feed lubricator pumps, by hand, for ten strokes. (Be sure the lubricator tank is kept full.)
Cooper Energy Services Ajax-Superior
Normal Shutdown
1. Decrease speed to 600 RPM (Engine driven units only).
2. Unload the compressor by opening the bypass line between the first stage suction and
the last stage discharge lines.
3. Shutdown the compressor driver.
4. Close suction and discharge block valves.
5. Turn off water supply.
6. Relieve pressure by venting compressor cylinders, suction piping, and discharge piping
to remove any remaining gas.
Emergency Shutdown
In an emergency situation, the shutdown devices will shut down the system. In such as case,
the cause of the shutdown must be identified and corrected before restarting the compressor.
Refer to the Troubleshooting Section to troubleshoot compressor.
! Warning
If the compressor has stopped, DO NOT immediately remove the equipment covers.
Allow the unit to cool down first.
! Warning
Improper setting of variable volume pockets, fixed volume pockets, valve unloaders,
or other unloading devices can result in damage and/or injury to equipment and personnel. Operating the system without clearance and loading information can result
in equipment failure due to overload, excessive rod loads, and high temperatures.
Note
Superior attempts to furnish performance curves and/or design performance computer printouts to assist you with compressor operation. If they have been omitted please fill out the
following form and new curves will be provided to you. If compressor operating conditions
change, contact your Cooper Energy Services Aftermarket Sales Office.
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
Section 7
Maintenance
General
The diligent observation of the inspection and maintenance procedure, given in this section,
will go a long way toward insuring satisfactory operation of the compressor. Ajax-Superior
recommends planned periodic inspections of equipment. Regardless of the gas compressors,
malfunctions can occur. Faithful preventative maintenance and the use of Genuine Superior
Parts will help prevent costly down time, repairs, and replacement costs. Planned
shutdowns for doing preventative maintenance will result in minimum maintenance costs
and maximum mechanical efficiency of your equipment. Good preventative maintenance
practice includes a periodic check of critical bolt torques, such as compressor main and
connecting rod bolts and drive coupling bolts.
The following paragraphs contain valuable precautions, tolerance limits, and recommended
torque values.
Precautions
Follow the precautions listed below when any maintenance is performed. Damage to the
equipment, personal injury or death may result if these precautions are not followed.
a. Block the flywheel to prevent rotation of the compressor and driver.
b. Remove all gas by unloading, venting, and then blinding the compressor. Blinding
means to shut off all block valves so there can be no process gas flow to the compressor.
c. Eliminate all internal pressures by removing cylinder indicator plugs or vent through
indicator cocks, if provided.
d. Prevent clogged oil lines or filters by using only lint free cloths.
e. Insure all tools and work areas are clean and free of oil, water, dirt, dust or grit.
f. Never file, grind or scrape any lubricated parts (i.e. bearing shells or saddles).
g. Never distort or mark the piston rod with any tool or device. Rods that are bent or have
burrs will damage the packing or prevent it from sealing. In severe cases, the rod could
break.
h. Never torque or tighten any nut, cap screw or stud if threads or mating threads are
covered with paint or other materials that are not specified by Ajax-Superior for use on
threads.
Cooper Energy Services Ajax-Superior
superior-frame-manual-mhwh-maintenance.fm
Page 7-1
i. It is recommended that genuine Superior parts replace any components which are
changed.
j. Do not refinish worn valve plates.
k. When reassembling parts during maintenance, replace all worn or damaged gaskets
and seals.
l. Always install new cotter pins or lockwire.
m. Check and clean all lubricating oil passages when the unit is down for repair or normal
maintenance.
n. After a long period of shutdown or a major overhaul, frequently check the unit during
the first 300 hours of operation.
o. After completing maintenance, remove any locking or blocking devices before
attempting to rotate the equipment.
! Warning
When work is being done on the compressor, the driving unit must be blocked in such
a way that the compressor cannot turn over. Block valves must be closed on the suction and discharge lines. Air or gas must be bled off from the cylinders. Precaution
must be taken to prevent the opening of any valve which would release pressure
against a piston, causing it to rotate the unit at a critical moment.
Limits
inch (mm)
.004 - .0096
.003 - .004
Page 7.0-2
superior-frame-manual-mhwh-maintenance.fm
.0015 - .003
.017 - .029
.003 - .007
.014 - .022
Torque Recommendations
To insure satisfactory compressor performance and to minimize costly failures, it is
extremely important to tighten all nuts and bolt s to the recommended torque values
specified in Table 7-2. Additional information is given in Service Bulletins 168 and 175.
Follow the following general recommendations.
Torque wrenches should not be used to Break Loose fasteners. Use an appropriate
wrench or breaker bar.
Hand position is critical. Only pull from the hand hold to assure accuracy.
The torque wrench supplied with Superior equipment is a heavy-duty, adjustable click type wrench. It will only torque in the clockwise direction.
Occasionally clean and lubricate the ratcheting head with light oil, NOT GREASE.
Periodic Calibration is essential to ensure accuracy.
! Caution
When tightening nuts and bolts on compressor valve caps, bottles, and flanges care must be
taken to exercised to avoid excessive tightening. Over-tightening can result in unnecessary
stress in the cylinder body and, in the case of valve caps, can result in valve seat distortion.
superior-frame-manual-mhwh-maintenance.fm
Page 7-3
Size
Torque
Ft-Lb (N-m)
3/4 - 10 UNC
185-200 (251-271)
MH6
1" - 8 UNJ
WH6
1" - 8 UNJ
1 1/8" - 7 UNC
7/8" - 9 UNC
7/8" - 9 UNC
MH6
1/2" - 20 UNF
30 - 35
WH6
3/8" - 16 UNC
18 - 22 (24 - 30)
2 1/4" - 10 UNS
Shoe to Crosshead
Balance Nut
MH6
Page 7.0-4
superior-frame-manual-mhwh-maintenance.fm
WH6
2 1/2" - 10 UNS
2650-3250 (3593-4406)
7/8" - 9 UNC
1/4"
4 - 6 (5 - 8)
3/8"
12-18 (16-24)
1/2"
35-45 (47-61)
5/8"
60-70 (81-95)
3/4"
120-140 (163-190)
7/8"
200-220 (271-298)
1"
260-290 (353-393)
1-1/8"
370-410 (502-556)
1-1/4"
520-570 (705-773)
1-3/8"
700-770 (949-1044)
1-1/2"
930-1030 (1261-1396)
Cylinder Number
Cylinder Diameter
615
6.00"
370
616
6.25"
370
617
6.75"
370
618
5.75"
300
619
6.25"
300
620
6.75"
300
621
7.25"
300
superior-frame-manual-mhwh-maintenance.fm
Page 7-5
Base (Crankcase)
The base is made of high strength alloy iron and is heavily ribbed and reinforced for
maximum rigidity. Large spacer bars provide further stability and ease reassembly. The top
and end covers are individually removable to provide easy access to moving parts. Our
open-top design allows the crankshaft to be easily removed. An oil sump is provided in the
lower portion of the base. The line-bored main bearing supports have caps which are matchmarked and numbered and must be assembled accordingly.
! Caution
Only use a pencil for marking on the parting line faces or in the groove of the bearing shells.
After removing the main bearing cap and the upper bearing shell, the lower bearing shell can
be rolled out from underneath the crankshaft with the help of the main bearing removal tool.
This is done by inserting the neck of the tool into the oil passage in the crankshaft journal.
When the compressor is barred over, the tool will push the bearing shell out from underneath
the journal and around to the top where it can be removed. A new bearing shell can be
installed using the same procedure.
Carefully clean the crankshaft, bearing shells and saddles before attempting to replace the
bearing shells. Under no circumstances should any filing, scraping, or other fitting be done
on either bearing shells or saddles. The bearing cap nuts should be tightened uniformly
(using a crisscross pattern) to the proper torque given in Table 7-2.
The main bearing clearance (tolerance value) can be checked by using a dial indicator and a
hydraulic jack. Proceed as follows:
a. Remove the top cover to gain access to the crankshaft.
Page 7.0-6
superior-frame-manual-mhwh-maintenance.fm
! Warning
Take extreme caution to adequately support the rod. If care is not taken during the
bearing removal process, personal injury and equipment damage could result.
With the connecting rod supported, remove the rod cap and its bearing half. In order to get
access to the other bearing half, bar the compressor over so the crankshaft moves slightly
away from the connecting rod.
Install a new bearing half against the back wall of the connecting rod. The tang recess within
the rod should support the bearing until the crankshaft can be moved back into position.
Complete the assembly process by putting the other bearing half and rod cap in position and
tighten the bolts (using a crisscross pattern) per the torque values given in Table 7-2.
The rod cap and crosshead pin must be removed to remove a connecting rod. The crosshead
pin can only be removed when the cross head is in the outer most position. Remove the
Cooper Energy Services Ajax-Superior
superior-frame-manual-mhwh-maintenance.fm
Page 7-7
crosshead pin by removing the retaining ring - external on the MH6 and internal on the WH6
- on one side of the pin. Push the pin through the crosshead far enough to release the
connecting rod. The connecting rod can be eased out of its position when the crankshaft
throw is slightly below the inner most position.
! Warning
Always support the connecting rod so it can not drop and damage equipment or
cause injuries.
A connecting rod can be installed by reversing the above procedure.
Note
The caps and rods are numbered by throw and have their weights stamped on them. Always
install rods with this information displayed up.
Crosshead Guide
The fasteners holding the crosshead guide to the base must be torqued uniformly (using a
crisscross pattern) to prevent cocking of the guide relative to the base and crankshaft. (See
Table 7-2 for torque values). Large side covers on the crosshead guide allow easy access to
the crosshead, connecting rod, and rod packing. The crosshead can be removed through
these openings without disturbing the cylinder mounting.
Lubrication to the crosshead slide areas is handled differently between the MH6 and WH6.
On the WH6, lube oil is sent via an internal oil path.
Page 7.0-8
superior-frame-manual-mhwh-maintenance.fm
and rod assembly out far enough to allow the crosshead to be removed.
h. Remove one of the retaining rings which constrains the crosshead pin.
i. Support the connecting rod and carefully remove the crosshead pin.
j. With the pin removed, slowly bar over the compressor to inner most position. Be careful
to support the small end of the connecting rod so it cannot score or dent the bottom slide.
k. Support the crosshead weight, roll the crosshead the rest of the way over and lift it out.
Care should be used to prevent damage to the shoes or slides.
Any special tools needed for the above procedure are listed in the Bill of Material located at
the rear of this manual.
To install a crosshead, reverse the above sequence. When using the crosshead installation
handles, more care and feel is required. DO NOT USE FORCE as this is the first indication
that the job is being done incorrectly and damaged crosshead shoes may result. The correct
procedure is to stand to one side of the crosshead guide and feed the crosshead across,
attempting to roll it in at short intervals. From the proper position, the crosshead will roll in
easily without damage to the shoes.
During the reassembly procedure, the machined face of the balance nut must be toward the
crosshead. Check piston end clearances and then make sure that the balance nut is torqued
properly against the crosshead. (See Table 7-2.)
Note
Crossheads and balance nuts are stamped with throw numbers and must be replaced accordingly.
superior-frame-manual-mhwh-maintenance.fm
Page 7-9
Page 7.0-10
superior-frame-manual-mhwh-maintenance.fm
exists at dimension X.
b. Mount a steel bar (G) in the manner illustrated. Putting a 1 1/2-6 UNC tapped hole at
its midpoint will permit a standard 1 1/2 UNC cap screw to be used as a jackscrew.
c. Tighten nuts on cap screws (H) per torque values given in Table 7-2.
d. Torque jackscrew (J) up against the crankshaft per the torque values given in Table 7-2.
e. Connect a 10,000 psi hand hydraulic pump to the 3/8 pipe tap (F) in the hub.
f. Operate the hand pump until the hub becomes loose and slides against the lock nut (E).
g. Remove the jackscrew and bar arrangement.
h. Remove nut (E); the hub can then be lifted off by crane or by hand.
If the proper equipment is not available, the most practical method of removing the coupling
hub from the crankshaft is by first removing the crankshaft from the base. The crankshaft
and drive end cover plate may now be taken to a suitable work area where the locknut is
removed, the hub heated and pressed off the crankshaft.
Install the coupling hub onto the crankshaft as follows:
a. When at room temperature, push the hub on the crankshaft taper as far as possible.
b. Push the crankshaft all the way to one side to take up any thrust clearance that may be
present.
c. Use gage blocks and shims to fill the space between the coupling and the compressor
end cover.
d. Remove the amount of shims needed to provide an advance of the hub on shaft of .050.
superior-frame-manual-mhwh-maintenance.fm
Page 7-11
e. Heat the coupling hub and slide it on the shaft until it engages the gage block, reduce
the amount of shims needed as required.
f. Hold hub in position until it is cool enough to engage the crankshaft.
e. When hub has cooled to room temperature, install lock nuts and Nylock setscrews.
Figure 7-1
Removing
Crankshaft
Coupling
Hub
00766
Page 7.0-12
superior-frame-manual-mhwh-maintenance.fm
Figure 7-2
00767
Figure 7-3
00768
Misalignment Failure
Disc is broken adjacent to washer face. Usually indicates excessive shaft misalignment
during operation. This type of disc failure usually starts in the outer discs in the pack and
progresses through the disc pack. Realign equipment and replace disc pack. Make HOT
check of alignment to assure it is within coupling misalignment capacity.
superior-frame-manual-mhwh-maintenance.fm
Page 7-13
Figure 7-4
Misalignment failure
00769
Fatigue Failure
Disc is broken adjacent to the washer face with heavy corrosion along area of break. This
failure is typical of discs that have been in service for years or have been operating in an offshore environment. Breaks will first appear in the outer discs and will progress into the disc
pack. If excessive corrosion exists, they should be replaced with stainless steel plating.
Figure 7-5
Fatigue Failure
00770
Compression.
Disc pack is wavy and dimension between flange faces is smaller that indicated on
installation instructions. This means that the coupling was installed in a compressed
condition or equipment has shifted axially during operation. Check for thermal growth. If
the application is a bearing motor, verify that the operating center line of the motor rotor is
properly positioned.
Figure 7-6
Compression
00771
Elongation
Page 7.0-14
superior-frame-manual-mhwh-maintenance.fm
Figure 7-7
Elongation
00772
! Caution
If bulged or bowed condition only appears in one chordal section there may be a loose bolt
on one side of the distortion. Loosen coupling locknuts and turn bolt slightly to remove
friction. Bulge should flatten out. Re-torque locknuts. If distortion does not disappear,
replace disc pack.
superior-frame-manual-mhwh-maintenance.fm
Page 7-15
Figure 7-8
Torque Overload
00773
Cylinder Body
A wide range of cylinder sizes is available. Each cylinder is conservatively designed for very
low stress at rated working pressures .
All cylinder bodies are provided with drilled water passages, top and bottom, which connect
the water inlet and outlet with the cooling muff, which surrounds the ring travel area of the
bore. Whenever the water jacket covers on the cylinder sides are removed to clean out
deposits, the drilled passages should also be cleaned out. If the pipe plugs in the crank end
of the drilled passages are removed, they should be coated with good waterproof sealer and
replaced. This will prevent water seepage into the atmospheric vent space.
Lube oil, from the force feed lubricator tubing system, passes through a check valve and into
a fitting on the outside should be cleaned out and all steel tubing checked for soundness and
tightness. This paragraph does not apply to non-lube operation.
Plugs are provided, on all size of cylinders, which can be removed and indicator cocks
inserted to take pressure readings, if desired.
Cylinder Head
After removing a cylinder head, examine the O-ring which provides a seal between the
cylinder head and the cylinder body for nicks, tears and compression set. Replace as
required. The water seal grommets should also be checked. It is recommended that a
complete set of O-rings and grommets, for all cylinder sizes used, be kept in stock at all
times.
Page 7.0-16
superior-frame-manual-mhwh-maintenance.fm
! Caution
The cylinder head must be properly indexed on the mounting studs so that the valve cut outs
in the head align with valve locations in the cylinder body.
superior-frame-manual-mhwh-maintenance.fm
Page 7-17
Figure 7-9
00774
The purpose of pressure packing is to prevent the loss of gases from the cylinder along the
piston rod. During initial operation, a packing may leak or tend to overheat. This temporary
condition occurs while the packing rings are adjusting to the piston rod and packing case.
! Warning
As a general guide, temperatures not tolerated by resting your hand on the packing
case flange, after the unit is shut down, indicate to fast of a wear rate. For a lubricated packing, check to see if the lubrication rate is set properly (Section 3).
Definite lubrication rates and time intervals for packing wear in are difficult to prescribe.
Experience has indicated that these factors may vary widely on different applications. If
there is concern about proper lubrication rate, contact the nearest Cooper Energy Service
Group Aftermarket office.
Page 7.0-18
superior-frame-manual-mhwh-maintenance.fm
00775
Ordinarily, packing cases (cups and glands) are not severely worn. Therefore, it is possible to
repair piston rod packings by replacing the packing rings only. It is good practice to keep a
complete set of packing rings on hand for the packing assemblies of all your cylinders.
In order to remove a packing case from a crosshead guide or cylinder, the piston rod must be
pulled out through the assembly out.
Before disassembling a packing case, note all identification marks to insure components are
reassembled properly. If components are not marked, identify each cups position relative to
the adjacent cup or flange by numbering or marking them together. While disassembling a
packing, record the position of each ring and the direction each ring faces for proper
reassembly.
Refer to following figure for aid in identifying packing rings. Knowing your packing rings is
very helpful when ordering new ones.
superior-frame-manual-mhwh-maintenance.fm
Page 7-19
00776
Page 7.0-20
superior-frame-manual-mhwh-maintenance.fm
Note
The rings must be placed in the packing cups in the same position (facing original direction)
as the original set.
Before installing new packing assemblies, it is important that the piston rod be carefully
checked. If the rod is worn, rough, pitted or has a taper, it must be replaced.
The bore for the pressure packing nose cup must be cleaned and examined for burrs. If
found, burrs should be removed. Also, replace the O-ring in the outside diameter of the
wiper packing flange with a new one.
A new metallic gasket should be placed in the groove of the pressure packing nose cup.
Remove the old metallic gasket with a sharp tool - being careful not to damage the groove.
Clean the groove thoroughly and install a new gasket. Tap the gasket into the groove with a
hard rubber mallet. Do not use a steel hammer as this may damage the sealing surface of the
new gasket.
After installing the packing cases and before connecting the oil tubing to the packing flange
(for lubricated packing), hand pump the force feed lubricator (when supplied) until oil runs
from one of the disconnected tubes. Connect this tube to the respective hole in the packing
flange and continue to pump the lubricator 12 to 15 more strokes.
After the piston and rod assembly has been reinstalled, the piston end clearance must be set
(See Paragraph 5.9) and the piston rod run out must be checked (See Paragraph 5.10).
Valve Installation
Suction and discharge valves must be installed in the proper direction. This can be
determined by first inspecting the valve to see which direction the valve plates move while
opening or compressing the springs. Gas will flow in that same direction.
superior-frame-manual-mhwh-maintenance.fm
Page 7-21
00777
Valve Replacement
Proceed with valve removal in the following manner:
Note
Before removing any gas containing part of the compressor or associated gas piping system,
vent compressor and system to atmospheric pressure.
a. Loosen bolts or nuts holding valve cap. DO NOT remove completely until after cap is
pulled out far enough to vent any pressure trapped under cap.
b. Remove valve cap. Inspect O-ring; replace if defective.
c. Loosen setscrew in valve retainer (bottom valves only); insert threaded puller into valve
retainer and remove.
Page 7.0-22
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00778
superior-frame-manual-mhwh-maintenance.fm
Page 7-23
f. Clean the gasket surface on valve and in valve pocket. Use new gasket.
g. Place valve in pocket, FACING PROPER DIRECTION.
h. Locate the retainer on top of the valve assembly and grease or oil the O-ring of the valve
cap before forcing the cap into place by torquing the nuts or screws evenly to the values
listed in the torque tables.
Note
The valve cap flange must not contact the cylinder body. Clearance must exist at this point
to insure that pressure is applied to the valve and retainer gaskets when the relief cap bolts
or nuts are tightened.
To replace a valve in a bottom port (assume that this is a discharge port), proceed as follows:
i. Invert retainer. Place valve on top of retainer with valve guard facing out (away from
the cylinder). Slip gasket on valve assembly.
j. Lift the complete works up into the bottom port, making sure that the valve seat enters
first.
k. Tighten the retainer setscrew just enough to hold everything in place.
l. Lubricate valve cap O-ring, and replace as described in step habove.
Valve Maintenance
For valve maintenance information see the Auxiliary Equipment section of the manual.
Page 7.0-24
superior-frame-manual-mhwh-maintenance.fm
Table 7-3
Alarm/Shutdown
Normal Condition
Alarm Point
Shutdown Point
Oil Pressure
45-55 psig
25
20
Oil Temperature
160-180 F (Out)
185F Out
190F Out
Vibration
Nominal
Gas Temperature
20F above TS or TD
25F above TS or TD
Water Temperature
Tin or Tout
Gas Pressure
5% below PS
5% above PD
10% below PS
10% above PD
Special Tools
Refer to the parts section of this manual for information on special tools.
Table 7-4
System
Daily
Weekly
Monthly
SemiAnnually
Annually
or as
Needed
CONTROLS
superior-frame-manual-mhwh-maintenance.fm
Page 7-25
System
Daily
Weekly
Monthly
SemiAnnually
Annually
or as
Needed
LUBRICATION SYSTEM
Check oil levels, oil level regulator, and oil
sight level.
Replace O-rings.
System
Daily
Weekly
Monthly
Page 7.0-26
superior-frame-manual-mhwh-maintenance.fm
SemiAnnually
Annually
or as
Needed
System
Daily
Weekly
Monthly
SemiAnnually
Annually
or as
Needed
Troubleshooting
Troubleshooting is the process of finding operational problems. This section describes the
difficulties which may arise during operation of a compressor, the typical origins or sources
of these problems and suggestions on how to repair the trouble. The following steps should
be followed in all troubleshooting activities:
a. Determine what general area is affected - frame, cylinders, lubricating system, etc.
b. Analyze the symptoms (clues) to pinpoint the exact location of the problem valves,
bearings, etc.
superior-frame-manual-mhwh-maintenance.fm
Page 7-27
Possible Cause
Potential Damage
Corrective Measure
Compressor Will
Not Turn Over
a. Mechanical Seizure of
Compressor.
b. Tripped shutdown
device.
Defective shutdown
device.
c. Foreign material
(water, non-lube
packing, etc.) in
cylinders.
Page 7.0-28
superior-frame-manual-mhwh-maintenance.fm
a. Opposing cylinders
are out of balance.
b. Worn bearings.
c. Improper compressor
installation and
alignment.
Foundation damage,
foundation bolt failure,
grout cracking, or broken
frame and crankshaft.
d. Gas pulsation
Excessive vibration
causing cracked welds,
foundations, grout, and
parts. Also possible
foundation bolt breakage.
e. Loose valves
Possible Cause
Potential Damage
Corrective Measure
No lube oil
pressure.
Lack of Oil
Scored bearings,
crankshaft, crosshead
shoes and pins. Possible
seizure of compressor.
Clogged strainer or
filters.
Same as above.
Same as above.
superior-frame-manual-mhwh-maintenance.fm
Page 7-29
Same as above.
Scored bearings,
crankshaft, crosshead
shoes, and pins. Seizure of
compressor is possible.
Same as above.
Same as above.
Sticking or maladjusted
pressure relief valve.
Same as above.
Same as above.
Clean cooler.
Insufficient warm
cooling water through
cooler.
Same as above.
Possible Cause
Potential Damage
Corrective Measure
Failure to deliver
gas.
Defective or missing
valves
Deposits on valves.
Page 7.0-30
superior-frame-manual-mhwh-maintenance.fm
Low compressor
cylinder
discharge
pressure.
High compressor
cylinder
discharge
pressure.
Insufficient
capacity.
Open or defective
clearance pocket.
Possible insufficiencies on
rod load reversal and head
mechanism damage.
High discharge
temperatures.
Replace rings.
Defective or missing
valves.
Same as above.
Loose valve(s).
Improper setting of
volume pockets.
Improper positioning in
piping downstream of
the compressor.
Same as above.
Open valve.
Clogged Cooler.
Same as above.
Clean coolers.
Clean scrubber.
superior-frame-manual-mhwh-maintenance.fm
Page 7-31
Replace rings.
Defective or missing
valves.
Same as above.
Suction valve in
discharge or discharge
valve in suction.
Same as above.
! Warning
If all valves are reversed, excessive pressure can build up resulting in cylinder failure and injury.
High interstage
pressure.
Loose valves.
Improper settings of
clearance pockets on the
higher stage heads.
Missing or defective
suction valve(s) on the
higher stage.
Same as above.
Same as above.
Page 7.0-32
superior-frame-manual-mhwh-maintenance.fm
Same as above.
High gas
discharge
temperature
Defective discharge
valves.
High discharge
pressure.
High section
temperature.
Breakdown in cylinder
lubrication causing
overheating, cylinder
scoring, and valve
damage.
Possible Cause
Potential Damage
Corrective Measure
Growling in lube
oil pump.
Chatter in relief
valve.
superior-frame-manual-mhwh-maintenance.fm
Page 7-33
Foreign material in
cylinder (Including
Water).
Piston-to-cylinder end
clearance set incorrectly.
Improperly installed
valve.
Loose valve.
Scored piston or
cylinder.
Piston seizure.
Damage to seating
surfaces in cylinder or on
valve.
Damage to seating
surfaces on packing case.
Loose piston.
Scoured piston or
cylinder.
Excessive carbon
deposits.
Same as above.
Remove carbon.
Foreign object in
cylinder.
Same as above.
Tighten head.
Page 7.0-34
superior-frame-manual-mhwh-maintenance.fm
Worn, broken, or
chipped gear teeth.
Gear damage.
Replace gear.
Improper backlash
setting.
Gear damage.
Possible Cause
Potential Damage
Corrective Measure
Vibration
Piping system
improperly supported.
Same as above.
Tighten nuts.
Piping strain.
Tighten.
Loss of production.
Gas measurement
techniques are not
correct.
Poor mechanical
condition of unit.
Failure of individual
components.
Overload
Poor mechanical
condition of unit.
Distortion of compression
cycle resulting in excess
load.
Causing abnormal
cylinder horsepower
performance.
Low capacity.
High load.
superior-frame-manual-mhwh-maintenance.fm
Page 7-35
Overheated and/or
damaged packing. Scored
cylinder walls.
Same as above.
Plugged vent in
lubricator tank.
Same as above.
Unplug vent.
Same as above.
Same as above.
Incorrect adjustment of
pump stroke.
Same as above.
Same as above.
Damage to cooler.
Defective gauge.
Replace gauge.
High discharge
temperature.
Faulty valves.
Cracked or broken
cylinder; bent rod; or worn
piston rings/packing.
Replace valves.
High discharge
temperature.
Same as above.
Insufficient lubrication
(lubricated cylinder
only).
Same as above.
Increase lubrication.
Same as above.
Same as above.
High discharge
pressure.
Same as above.
Same as above.
High cooler
pressure.
Page 7.0-36
superior-frame-manual-mhwh-maintenance.fm
Rupture disk
ruptures.
Condensate caused by
cold interstage piping.
Same as above.
Liquid in cylinder.
Same as above.
Excessive lubrication.
Same as above.
Reduce lubrication.
Carbon deposits.
Same as above.
Improper assembly.
Same as above.
Reassemble properly.
Insufficient control.
Pressure or leaking seal
in variable volume
pocket unloader.
Same as above.
Overheated and/or
damaged packing. Scored
cylinder walls.
Clogged filter.
Same as above.
Replace filter.
Same as above.
Unblock line.
Same as above.
Unblock line.
Same as above.
superior-frame-manual-mhwh-maintenance.fm
Page 7-37
Page 7.0-38
superior-frame-manual-mhwh-maintenance.fm
Section 8
General Information
Ordering Parts
This section provides directions for ordering parts and illustrations to aid in the assembly of
various sections of the engine.
The right is reserved to change the construction or material of any part without incurring the
obligation of installing such changes on units already delivered.
Part number, part name, and quantity. If a part has no part number then give a complete
description and size of the part.
Service
Cooper Energy Services maintains a large staff of qualified service representatives and
mechanics that are familiar with your equipment and will be able to handle any problems
that may arise. Field Service, diagnostic equipment, tools, and engineering support are
available to assist you upon request. Field service rates are highly competitive; contact the
nearest Aftermarket facility for further details.
superior-frame-manual-mhwh-general.fm
Page 8-1
Replacement Parts
Cooper Energy Services maintains a multi-million dollar inventory of genuine Superior
replacement parts at reasonable prices. These parts are designed and engineered specifically
for your Superior power equipment and are recommended to keep your equipment
operating within design parameters. CES part distribution center makes parts available 24
hours a day, seven days a week.
Parts Listings
Using The Parts List
This parts list is made to conform to the original construction of the unit, and CES does not
assume the responsibility or obligate itself to maintain this catalog to conform to any
subsequent changes made on the unit after it leaves the factory. Complete records of all
changes and service orders for each unit are maintained at the factory and at the CES
Aftermarket Parts Department in an effort to supply the correct parts. Due to occasional part
substitutions in the field and since there is no assurance that parts furnished from the factory
are installed, CES cannot guarantee the furnishing of correct parts. Be aware that this parts
list does not include any subsequent parts supplied by the packaging agent of the equipment.
Below is an example from the parts list. The Item refers to the callout used in the illustration.
P/N is the part number of the item. Qty/ Assy refers to the total number of that part in the
assembly above it. If no assembly is above the part, the Qty/ Assy refers to the quantity of
that part used in the engine. An assembly is listed followed by its component parts, which
are indented to show their relationship to the assembly. Description is the name of the part.
An assembly is index numbered numerically (e.g., 1, 2, 3) and its description will include
the word Assembly.
An assemblys detail parts will be indented two spaces and index numbered using numeric and alphabetic characters (e.g., 1A, 1B, 1C).
If a detail part is in turn an assembly, its detail parts will be indented two spaces further
and are index numbered numerically, alphabetically, and again numerically (e.g., 1A1,
1A2, 1A3).
Page 8.0-2
superior-frame-manual-mhwh-general.fm
In the parts list example, there are 8 Cylinder Head Assemblies (Item Number 1) within the
engine. There are 3 Short Valve Guides (Item Number 1H) to each Cylinder Head Assembly.
Therefore, there are three short valve guides to a cylinder head; the total number of short
valve guides for a 2408G engine is 24 (3 per head x 8 heads).
Some parts that make up an assembly cannot be purchased by themselves. An example of
this is the Crankshaft. The crankshaft can be purchased through the Crankshaft Assembly
part number. Other parts can be purchased individually, but for convenience it may be easier
to purchase the subassembly.
! Warning
Proper length of studs and bolts is important for proper thread engagement. Before
removing any studs, measure stud height from machined surface and position
replacement stud to same height.
DENVER, COLORADO..
Cooper Energy Services
9850 South I-70 Service Road
Wheat Ridge, CO 80033-2267
MIAMI, FLORIDA........................
Cooper Energy Services Intl...
superior-frame-manual-mhwh-general.fm
Page 8-3
BROUSSARD, LOUISIANA
Cooper Energy Services
206 Boncrest
Broussard, LA 70518-3530
SPRINGFIELD, OHIO......
Cooper Energy Services
1401 Sheridan Avenue
Springfield, OH 45501-0540
TULSA, OKLAHOMA.....
Cooper Energy Services
4405 South 74 East Avenue
Tulsa, OK 74145-4727
ALICE, TEXAS...................
Cooper Energy Services
Highway 281 North and Commerce Road
Alice, TX 78332
HOUSTON, TEXAS..........
Cooper Energy Services
1111 Lockwood Drive
Houston, TX 77020
ODESSA, TEXAS...............
Cooper Energy Services
Page 8.0-4
superior-frame-manual-mhwh-general.fm
EVANSTON, WYOMING
Cooper Energy Services
109 Meadow Drive
Evanston, WY 82930
Canada
EDMONTON, ALBERTA
Cooper Energy Services
10685 - 176 Street
Edmonton, Alberta Canada T5S 1G5
South America
Cooper Energy Services International.
5600 S.W. 135th Avenue
Suite 201
Miami, FL
33183-5123
CARACAS.............
Phone: 58 - 2 - 912811
Cooper Energy Services De Venezuela, S.A.
58 - 2 - 912066
Cooper Energy Services Ajax-Superior
superior-frame-manual-mhwh-general.fm
Page 8-5
Apartado 61358
Centro Banaven, 2. Piso
Oficina A-23, Entrada A
Avenida La Estancia, Chuao
Caracas 1060-A, Venezuela
Fax:
58 - 2 - 993 - 0306
ANACO WAREHOUSE...
Phone: 58 - 82 - 22264
Cooper Energy Services De Venezuela, S.A
58 - 82 - 22696
Carretera Negra, KM. 97
Fax: 58 - 82 - 23659
Apartado No. 12
Anaco, Edo. Anzoategui, Venezuela
MARACAIBO WAREHOUSE......
Phone: 58 - 61 - 74831
Cooper Energy Services De Venezuela, S.A
58 - 61 - 70798
Av. 12 Entre Calles 78 Y 79.....
Fax: 58 - 61 - 70839
Edificio Torre 12
Mezanine Norte
Maracaibo, Edo. Zulia, Venezuela
United Kingdom
LIVERPOOL....................................
Cooper Energy Services Intl..
Atlantic Industrial Complex
Dunnings Bridge Road
Bootle, Merseyside L30 4UZ
United Kingdom
Mexico
MEXICO CITY.................................
Cooper Energy Services Intl..
Sierra Mojada No. 626 - 2DO. Piso
Lomas De Chapultepec
Deleg. Miguel Hidalgo
Mexico, D.F. - 11050
Mexico City
Middle East
DUBAI
................................
Cooper Energy Services Intl..
Dubai World Trade Center
Page 8.0-6
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Far East
CHINA.............................................
Cooper Energy Services Intl..
3331 China World Tower
Jianwai, Beijing, 100004
Peoples Republic of China
SINGAPORE ...............................
Cooper Energy Services Intl..
Boon Lay
PO Box 888
Singapore 9164
Courier:
superior-frame-manual-mhwh-general.fm
Page 8-7