Section 4 - Part Replacement For models KBZ:U

Force Feed Lubricator Chain Sprocket Replacement

1. With a good machinist rule, measure exact distance from
inside face of auxiliary end cover to near face of
lubricator sprocket. Note measurement for proper
positioning of new sprocket. Remove chain.
2. Remove sprocket set screw and sprocket. Detach all
tubing from lubricator.
3. Remove mounting bracket cap screws and lubricator.
4. With the lubricator on the bench, remove key from shaft
and file shaft to remove burrs raised by set screw cup
point. Oil and install a new O-ring.
1. Mounting Bracket 4. Shaft Oil Seal
5. Dig out the shaft oil seal with an awl and install a new
Cap Screws (4) 5. Key
one.
2. Auxiliary End 6. Set Screw
6. Install a new key. Verify it fits into the new sprocket (see Cover 7. Sprocket
build book for key type and dimensions). If too thick, 3. O-Ring
polish it with emery cloth on a flat surface until it easily FIGURE 4-48 Force Feed Lubricator
slides into the notch. The top edge may also require a Chain Sprocket
little polishing.
7. After new key installation, verify the new sprocket fits, oil the new O-ring, and remount lubricator to
the end cover.
8. Slide new sprocket onto the shaft and set to dimension measured in step 1. Tighten set screw.
9. Using a straight edge, to within 1/32 inch (1 mm), check alignment to crankshaft drive sprocket with
crankshaft centered in end play. When aligning this sprocket with the idler sprocket, take into
account that the idler sprocket is thinner than the other sprockets. If misaligned, adjust sprocket
position as needed.
10. Install chain and adjust according to “Chain Adjustment” on page 4-48.
11. Re-attach all tubing to lubricator.

Crankshaft Chain Sprocket Replacement

Examine sprocket carefully for wear; sprockets operating for five years or more may require
replacement. To replace a sprocket on a KBZ:U/2:
1. Drill a hole in the sprocket hub parallel to the shaft centerline and big enough to remove most of the
hub cross section (see figure to the right). Multiple smaller holes may be required. DO NOT touch
shaft with drill. Mark the drill with tape to avoid drilling through the sprocket and into the crankshaft
face. The hole relieves most of the shrink, and a few radial strikes with a hammer and chisel opens
the sprocket enough for easy removal.
2. Suspend the new sprocket with a wire and heat it with a small torch to about 400°F (204°C), then
slip it over the auxiliary end of the crankshaft. Hold the sprocket in place and rotate it slightly to
ensure squareness until it cools enough to shrink onto the crankshaft.

For KBZ:U/4/6: Crankshaft sprockets are on a removable adapter. Remove the adapter and sprocket
and replace it with a new adapter and sprocket.

REV: 07/19 Page 4-47 of 49

For models KBZ:U Section 4 - Part Replacement

Chain Adjustment
1. Roll the crankshaft to the tightest position of
the chain. This prevents snugging the chain at
a slack position and breaking rollers, or ruining
the pump and lubricator bearings when the
chain goes through its tightest position.
2. Use a tape measure to measure the longest
most easily accessible span from sprocket
center to sprocket center, where the deflection
will be gauged. Determine allowable deflection
limits for the measured span as defined by the
shaded area in FIGURE 4-50.
3. Measure chain deflection from a straight edge
held on the chain rollers where it wraps over FIGURE 4-49 Typical Chain Deflection
the two sprockets of the span (see FIGURE 4- Measurement
49). Using a machinist’s scale with 0.01 inch or
(1.0 mm) increments, apply finger pressure to
measure the distance from the straight edge to a chain roller at the center of the span. Record the
measurement and check to see if it is in tolerance.
4. If adjustment is required, remove the cap screws and plastic plugs from the eccentric cap. Rotate the
cap clockwise to line up the first two new cap screw holes. If this tightens the chain too much, turn the
cap counterclockwise for a different hole alignment.
5. Replace and tighten the two cap screws hand wrench tight. CAUTION: Over tightening may
result in bent shafts.
6. Roll the crankshaft to check tightness in several positions. At its tightest position, the chain should
deflect within the shaded limits in FIGURE 4-50 . Replace plastic caps to keep the holes clean.

FIGURE 4-50 Allowable Chain Deflection, Inches (mm)

Page 4-48 of 49 REV: 07/19

Section 4 - Part Replacement For models KBZ:U

Component Cleaning & Thread Lube for Non-Lube

Compressor Cylinders
Ariel cleans and protects complete non-lube cylinders to non-lube service requirements. Clean all
internal parts shipped loose, contaminated internal surfaces, and repair parts prior to installation, to
extend the life of rings and non-lube compressors.
Clean cylinder bore thoroughly with denatured alcohol until a clean, alcohol-soaked, white paper towel
removes no more debris. This includes all surfaces of the bore, counter bore, valve pockets, etc. Do not
use Never-Seez on steel gaskets. Apply a light film of oil to cylinder seating surfaces to seal o-rings.

CAUTION: Denatured alcohol presents health and safety hazards. It contains methyl
alcohol and is poisonous if ingested. Avoid eye and skin contact. Keep alcohol away
from heat, sparks, flame, and all other ignition sources. Use adequate ventilation,
neoprene or butyl gloves, mono-goggles or face-mask, and impermeable apron.
Properly handle and dispose of materials resulting from clean-up. See manufacturer's
material safety data sheets for more details.

Do not use any lubricants or anti-seize compounds on parts that may contact the gas stream.
Use very small amounts of Never-Seez regular grade on nut and collar when assembling piston
assembly. Thoroughly clean piston (especially the ring grooves) with denatured alcohol until a clean,
alcohol-soaked towel removes no more debris.
Disassemble packing case. Wipe all surfaces clean with denatured alcohol. Re-assemble. When the
packing case is water cooled, re-assemble and test to “Testing” on page 4-25. Handle cleaned parts
with new or clean "rubber" or new white cotton gloves.
Before piston rod installation, wipe it with denatured alcohol. Be careful not to leave fingerprints on the
rod before it contacts the packing rings. Wipe the rod with denatured alcohol after installation.
Clean the head end head or unloader components with denatured alcohol. Use minimal amounts of oil
for the bolt-holes to ensure oil does not run into the cylinder. Also install the head end steel gasket
without Never-Seez.
Disassemble and clean the valves with denatured alcohol, then re-assemble, wipe them again, and
install. Clean retainers and high clearance assemblies with denatured alcohol. Use only a thin film of oil
for the valve cap O-rings and bolt-holes.
Assemble cleaned parts immediately to avoid contamination and corrosion. If cylinder will not
commence immediate service, contact Ariel for preservation instructions to ER-34.

REV: 07/19 Page 4-49 of 49

Section 5 - Start Up
Warranty Notification - Installation List Data and Start Up Check Lists for
Reciprocating Compressors JGZ:U and KBB:V:Z:U
The following forms are designed to ensure a successful start-up of Ariel reciprocating compressors.
Ariel warranty coverage requires these completed forms be sent to:
Administrative Assistant - Sales, Ariel Corporation
35 Blackjack Road • Mount Vernon, Ohio 43050 USA
Phone: 740-397-0311 • FAX: 740-397-3856
Email: warrantyregistration@arielcorp.com

Warranty Notification - Installation List Data

Date:___________________ Name:_____________________________________________
Unassigned Resale Direct Sale Lease-Purchase Rental/Lease Unit

Compressor Frame
Frame Model:______________________ Frame Serial #:_____________________________
Frame Lubricant Make and Grade:_______________________________________________
Package Startup Date:________________________________

Distributor/Fabricator
Company:______________________________________ Name:______________________
Address:___________________________________________________________________
City:__________________________________________ State:_____ Zip:_______________
Country:__________________________________
Fabricator Unit Number:_______________________________________

REV: 07/19
For models KBZ:U Section 5 - Start Up

Application

Air/Nitrogen CNG/GNC FPSO Gathering Fuel Gas Booster

Refrigeration Pipeline PRC Injection Storage/Withdrawal Miscellaneous

Elevation:_____________________________
H2S%:_____________ CO2%:_____________ Specific Gravity:__________________
Non-Lube: Yes No

Unit Location
Customer Name:_____________________________________________________________
Project/Lease Name: _________________________________________________________
Closest Town:________________________________ State:______ Country:_____________
Offshore: Yes No
Directions to Location or GPS:__________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
Customer Contact Person:________________________ Contact Phone:________________
Contact Email:_______________________________________ OK to contact: Yes No

Driver
Driver Manufacturer:_________________________________ Driver Model:______________
Driver Type:__________________ Applied RPM:_______ Name Plate HP (kW):___________
Coupling Manufacturer:____________________________ Coupling Model:______________

Page 5-2 of 10 REV: 07/19

Section 5 - Start Up For models KBZ:U

Compressor Cylinders and Operating Conditions

Cylinder Stage Throw Serial Bore Dia. Inlet Temp. Inlet Pres. Disc. Temp Disc. Pres.
Class Number Number Number In. (mm) °F (°C) psig (barg) °F (°C) psig (barg)
_________ _________ _________ _________ _________ _________ _________ _________ _________
_________ _________ _________ _________ _________ _________ _________ _________ _________
_________ _________ _________ _________ _________ _________ _________ _________ _________
_________ _________ _________ _________ _________ _________ _________ _________ _________
_________ _________ _________ _________ _________ _________ _________ _________ _________
_________ _________ _________ _________ _________ _________ _________ _________ _________

Cylinder Lubricant Make and Grade:______________________________________________

Documentation and Accessories

Check all items included in the shipment:
Maintenance and Repair Manual Recommended Spares List
Yes No Yes No
Start-Up Spare Parts Unit Start and Stop Procedures
Yes No Yes No
Toolbox w/Ariel Tools Toolbox with Hydraulic Tools (optional)
Yes No Yes No
Unit Parts List Toolbox with SAE Hand Tools (optional)
Yes No Yes No

Commissioning Agent
Name:_______________________ Company:_____________________________________
Address:___________________________________________________________________
City:_______________________________________ State:_______ Zip:________________
Country:_______________________
Phone:_________________________ Email:_____________________________________

REV: 07/19 Page 5-3 of 10

For models KBZ:U Section 5 - Start Up

START-UP CHECK LIST - ITEMS TO CHECK IN THE FIELD AT COMMISSIONING

Description Date Checked Date Verified
1. Confirm receipt of all Ariel supplied components and protection of all con- Customer: Distributor:
tainers and parts against storage-related damage. _________________ _________________
Commissioning Agent:
_________________
2. Check and verify the top cover data plate of the compressor frame for Commissioning Agent: Distributor:
compressor design limitations such as rod load, maximum and minimum _________________ _________________
speed, and maximum lube oil temperature.
3. Check and verify the availability of correct start-up spares, hand tools, Commissioning Agent: Distributor:
special tools, compressor parts list and drawings, and technical manuals at _________________ _________________
installation.
4. Check and verify the Ariel lube sheet and Lubrication Specification Commissioning Agent: Distributor:
matches the recommended oil grade and viscosity for the service. _________________ _________________
5. Check and verify all lube oil piping cleanliness per Ariel lubrication spe- Commissioning Agent: Distributor:
cifications (see “Oil System Cleanliness” on page 3-10). _________________ _________________
6. Verify lube oil storage and supply line cleanliness per “Oil System Commissioning Agent: Distributor:
Cleanliness” on page 3-10. Verify crankcase oil supply isolation valve is _________________ _________________
open.
7. Verify pre-lube piping cleanliness per “Oil System Cleanliness” on Commissioning Agent: Distributor:
page 3-10 and correct circuit operation. _________________ _________________
8. Verify there is an oil cooler and high temperature shutdown for the oil into Commissioning Agent: Distributor:
the compressor frame. _________________ _________________
9. Verify whether the temperature control valve installation is blending or Commissioning Agent: Distributor:
diverting (blending preferred). ______________________ _________________ _________________
10. Check compressor crankcase oil level controller for proper installation, Commissioning Agent: Distributor:
operation, levelness, and venting. _________________ _________________
11. If applicable, check cooling water circuit cleanliness for the oil cooler Commissioning Agent: Distributor:
and cooled packing per Maintenance and Repair Manual. Verify correct rout- _________________ _________________
ing and test pump rotation. Set pressure appropriately per Maintenance and
Repair Manual and leak test.
12. Verify correct filter element installation. Prime the oil filter element and Commissioning Agent: Distributor:
all lube oil piping with oil. _________________ _________________
13. Verify proper compressor crankcase oil level before starting (about 7/8 Commissioning Agent: Distributor:
full in site glass). _________________ _________________
14. Verify correct installation of a low oil pressure shutdown tubed to the Commissioning Agent: Distributor:
downstream side of the oil filter. _________________ _________________
15. Operate pre-lube system. Commissioning Agent: Distributor:
_________________ _________________
16. Tighten frame hold down bolting (see Appendix G - ER-26). Commissioning Agent: Distributor:
_________________ _________________
17. Record “out of plane” readings (pre-grout).
_________ _________ _________ _________ _________ _________
Drive End _________ _________ _________ _________ _________ _________ Auxiliary
End

Flatness measuring device Manufacturer / Model:___________________________________

Date of last calibration:____________________ Calibration Due:______________________
NOTE: See Appendix H - ER-82. Commissioning Agent: Distributor:
_________________ _________________
18. If applicable, check compressor frame mounting grout or chocks for Commissioning Agent: Distributor:
proper installation to top of base frame. Also check for cracks. _________________ _________________

Page 5-4 of 10 REV: 07/19

Section 5 - Start Up For models KBZ:U

START-UP CHECK LIST - ITEMS TO CHECK IN THE FIELD AT COMMISSIONING

Description Date Checked Date Verified
19. If applicable, check compressor skid-to-foundation grouting for proper Commissioning Agent: Distributor:
installation, grout type, and internal support. _________________ _________________
20. Record soft foot readings. Over 0.002 inches (0.05 mm) pull-down on any frame foot requires correction.
_________ _________ _________ _________ _________ _________
Drive End _________ _________ _________ _________ _________ _________ Auxiliary
End

NOTE: See Appendix H - ER-82. Commissioning Agent: Distributor:

_________________ _________________
21. If applicable, re-assemble the guide/cylinder components. Commissioning Agent: Distributor:
_________________ _________________
22. Check and verify connecting rods can move freely without damage Commissioning Agent: Distributor:
before rotating the crankshaft. _________________ _________________
NOTE: Pre-lube compressor before turning crankshaft.
23. Check crosshead guide shimming for correct pre-load and hold down Commissioning Agent: Distributor:
bolt torque. _________________ _________________
24. Record piston end clearances with feeler gages (see Maintenance and Repair Manual, Appendix B).
Throw 1 2 3 4 5 6
Head End ___________ ___________ ___________ ___________ ___________ ___________
Crank End ___________ ___________ ___________ ___________ ___________ ___________

NOTE: Pre-lube compressor before turning crankshaft. Commissioning Agent: Distributor:

_________________ _________________
25. Record rod run out (see Maintenance and Repair Manual, Section 4 for maximum acceptable readings).
Throw 1 2 3 4 5 6
Vertical:
Piston @ CE ___________ ___________ ___________ ___________ ___________ ___________
Mid-Stroke ___________ ___________ ___________ ___________ ___________ ___________
Piston @ HE ___________ ___________ ___________ ___________ ___________ ___________
Horizontal:
Piston @ CE ___________ ___________ ___________ ___________ ___________ ___________
Mid-Stroke ___________ ___________ ___________ ___________ ___________ ___________
Piston @ HE ___________ ___________ ___________ ___________ ___________ ___________

NOTE: Pre-lube compressor before turning crankshaft. Commissioning Agent: Distributor:

_________________ _________________
26. Measure crosshead clearances with cylinders mounted. To check top, Commissioning Agent: Distributor:
insert 0.5 inch (12.7 mm) wide feelers from one side edge across to the _________________ _________________
opposite side, at both ends. See Maintenance and Repair Manual, Appendix
B for limits. To check bottom, insert a 0.0015 inch (0.038 mm) feeler at the
four corners; feeler should insert no more than 0.50 (13 mm). Record val-
ues:
Throw Top Min. Top Max. Bottom Max. (Corners)
1 _________ _________ _________
2 _________ _________ _________
3 _________ _________ _________
4 _________ _________ _________
5 _________ _________ _________
6 _________ _________ _________

REV: 07/19 Page 5-5 of 10

For models KBZ:U Section 5 - Start Up

START-UP CHECK LIST - ITEMS TO CHECK IN THE FIELD AT COMMISSIONING

Description Date Checked Date Verified
27. Record “out of plane” readings (post-grout).
Throw 1 2 3 4 5 6
Head End ___________ ___________ ___________ ___________ ___________ ___________
Crank End ___________ ___________ ___________ ___________ ___________ ___________

Flatness measuring device Manufacturer / Model:___________________________________

Date of last calibration:____________________ Calibration Due:______________________
NOTE: See Appendix H - ER-82. If applicable after reassembly, Commissioning Agent: Distributor:
send readings to Ariel. _________________ _________________
28. For electric motor drivers, check and verify the motor shaft is set at its Commissioning Agent: Distributor:
magnetic center before positioning axial clearance. With the coupling dis- _________________ _________________
connected, check and verify driver rotation matches the compressor rotation
arrow.
29. Check coupling bolt torque to coupling manufacturer Commissioning Agent: Distributor:
recommendations. _________________ _________________
30. Check and verify compressor to driver alignment (installed on site, Commissioning Agent: Distributor:
cold). Record dial indicator readings in inches (mm) at the 3, 6, 9 and 12 _________________ _________________
o’clock positions or attach alignment tool print-out.

If using a laser alignment tool, make a print out and attach it to this doc-
ument.
31. Check and verify compressor crankshaft thrust clearance. The shaft Commissioning Agent: Distributor:
should remain stationary after thrusting each direction (see Appendix B ). _________________ _________________
________________________ ________________________

START-UP CHECK LIST - PROCESS PIPING VENTS AND DRAINS

Description Date Checked Date Verified
1. Verify the bottle and process pipe installation contains no bolt bound Commissioning Agent: Distributor:
flanges or elevation differences that may stress the compressor cylinders _________________ _________________
2. Verify cold adjustment of any bottle or cylinder supports. Commissioning Agent: Distributor:
_________________ _________________
3. Verify correct inlet screen orientation in process piping. Commissioning Agent: Distributor:
_________________ _________________
4. Check, verify, & record process piping orifice sizes & locations. Commissioning Agent: Distributor:
__________________________________________________ _________________ _________________
__________________________________________________
__________________________________________________
__________________________________________________
5. Check and verify piping and instrumentation diagrams are "as built". Commissioning Agent: Distributor:
Check all valves for correct position and easy operation and verify correct _________________ _________________
installation of all identification tag numbers. Verify tag numbers match com-
ponent numbers on the drawing.

Page 5-6 of 10 REV: 07/19