Supply of CNG Compressor Package

–Project Manhattan

Doc. No. JR-APSL-196021-GEN-OMM-01 PO No. APSL/P-M/P&C(P)/LPO/172/2019

Operation & Maintenance Manual

0.1 2020/7/8 Issued For Client Review Yongbin.Gao Zhengda.Yu Yan.Zhang

Rev. Date Description Issued Checked Approved

 Natural Gas Compressor Package

TABLE OF CONTENTS

FOREWORD ........................................................................................................................ 1

CHAPTER 1 SAFETY NOTICE ............................................................................................ 2

CHAPTER 2 MAIN TECHNICAL DATA ............................................................................... 5

2.1 MAIN TECHNICAL DATA .......................................................................................... 5

2.2 COMPRESSOR PACKAGE WORKING CONDITION PARAMETERS ..................... 11

CHAPTER 3 PACKAGE CONTROL SYSTEM ................................................................... 12

3.1 OVERVIEW .............................................................................................................. 14

3.2TECHNICAL DATA ................................................................................................... 14

3.3 ENVIRONMENTAL CONDITIONS ............................................................................ 14

3.4 HMI SCREEN INTRODUCTION ................................................................................ 15

3.5 OPERATION PROCEDURE ..................................................................................... 24

3.6 FAILURE PROTECTION .......................................................................................... 29

CHAPTER 4 MAINTENANCE ............................................................................................ 32

4.1 COMPRESSOR UNIT MAINTENANCE SUMMARY LIST ........................................ 32

CHAPTER 5 MAIN FAILURES AND TROUBLESHOOTING .............................................. 41

5.1 PACKAGE FAILURES AND TROUBLESHOOTING ................................................ 41

5.2 CYLINDER FAILURES AND TROUBLESHOOTING ................................................ 42

 Natural Gas Compressor Package

FOREWORD

Thank you for choosing JEREH products. We will provide you with high-quality and efficient

after-sales service.

The manual is applicable to the natural gas compressor package YSJZ245-330 (Model:

JGA/4) of Nigeria CNG project.

Model description:

The model YSJZ245-330 is determined according to the maximum discharge pressure

and maximum power of the unit.

Model: YSJZ245-330

YSJZ --- Abbreviation of natural gas compressor package

245 --- 10 times the maximum discharge pressure (Unit: MPa)

330 --- Rounding value of the maximum power (Unit: kW)

The rated power of the unit is 330bkW@1800RPM and the design displacement

capacity of single unit is 5 MMSCFD. This unit adopts three-stage compression

(cylinder 2.75"×2+3"×2+2"×2). The way to control displacement capacity is speed

adjustment, return valve opening, clearance opening length and intake and exhaust

pressure control.

It is necessary to calculate and check before the displacement capacity changes to

ensure safe operation. Do not attempt to operate outside the design conditions. If you

want to change any original state of the unit or change the original working condition to

meet the production needs, please contact Jereh engineer in the following way, and they

will provide you with necessary guidance.

Tel: 44009977567

Strictly abide by this instruction manual, which is the guarantee of safe operation of unit

and the foundation of extending service life.

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 Natural Gas Compressor Package
CHAPTER 1 SAFETY NOTICE

Incorrect operation, lubrication, maintenance or repair will cause casualties. Do not work

until you have understood the manual clearly.

Jereh can't anticipate every situation in which danger may occur. Therefore, the manual

cannot give warnings for all cases. If you want to use tools, fixings, operation procedure or

operation technology that are not recommended by Jereh, you have to make sure that you

and others are safe. Meanwhile, ensure the operation, lubrication, maintenance or repair

that you chose doesn’t damage the product and cause the hidden danger.

Do not change any configuration without Jereh's permission. Approval of Jereh is required

before adjustment and change.

Safety is the first when operating equipment, especially in the presence of pressure,

rotating equipment, high-voltage cables or inflammables. In some cases, attention should

be paid to toxic substances. As a result, individuals are in danger in above situations. All

operators should understand the manual clearly in order to operate safely. Always ensure

observe related procedures and standard and wear labor protection equipment around the

unit.

Requirements for equipment operation and maintenance personnel:

1. Trained and pass the verification;

2. Have relevant operation qualification.

These people must know the safety regulations and procedures well.

The operator must know the following:

1. Don’t operate unless you have a good view;

2. Keep the working environment clean and tidy and remove obstructions, hand tools and other

objects when operating equipment;

3. Ensure all the operation buttons and valve positions are in the correct position before starting

device;

4. Don’t clean and maintain the equipment without pressure relief and combustible gas

replacement;

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5. Obtain permission before welding near the unit, cut off the PLC power supply and remove the

engine computer line;

6. Combustible gas sensor is necessary because there will be combustible gas leakage in the

process of unit operation or shutdown, and combustible gas is colorless and tasteless.

7. Don’t enter places where the oxygen content is lower than 21% or a combustible and toxic

gases are detected;

8. Don’t smoke near the unit;

9. Ensure that the area is ventilated or necessary safety precautions are taken before gas

blowdown or venting;

10. Don’t be close to belt driven fan and coupling driven pump which should be equipped with

protective cover during operation;

11. Keep the passages around the site completely clear;

12. Do not touch high-temperature parts such as compressor exhaust pipes, drums, engine exhaust

lines, etc., to prevent burns;

13. Do not put flammable materials such as cotton yarn and cloth near the exhaust pipe to prevent

burning;

14. All user shall maintain and inspect pressure vessels such as separators at all levels and inlet and

outlet buffer tanks according to the use and management requirements of pressure vessels;

15. During maintenance, power, gas, and water should be cut off or isolation blind plates should

be installed as required and warning signs should be hung on the corresponding parts of the

equipment;

16. Disconnect the power supply and air source and make sure that no one is operating in front of

manual turning;

17. Live maintenance is strictly prohibited.

18. Personnel are not allowed to approach the unit during startup;

19. The unit should be checked and confirmed in strict accordance with the Ariel compressor

operation process and unit start-up inspection confirmation card before starting;

20. Check and fasten all fasteners after the unit is turned on and running normally.

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21. Do not change the original state of any filter of the unit without authorization, which is also

applicable to other configurations. Approval of Jereh is required before necessary adjustment;

22. If the starting motor is driven by natural gas, the air in the system must be completely replaced

before starting, and manual operation of the solenoid valve is prohibited.

There are many specific safety signs on this product. Please refer to the original manual of the

compressor and engine for these signs. Please be familiar with all safety signs.

Please ensure that all safety signs are legible.

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 Natural Gas Compressor Package
CHAPTER 2 MAIN TECHNICAL DATA

2.1 MAIN TECHNICAL DATA

The following data are from your bidding document. Jereh configures the product according

to the following parameters. For gas components, it is recommended to take samples every

month for analysis to determine whether they meet the parameters in the bidding document.

If there is any difference, it may cause poor lubrication, displacement difference and other

faults. Refer to the following for relevant parameters. These data are helpful for your better

application of the product;

Table 2-1 Field Parameters

Division of electrical
Class 1,Division 2,Group D
hazardous areas
Electrical explosion-proof
ExDIIBT4;IP55
level and protection level
Public system conditions Auxiliary power supply：415 V 50 HZ 3 Ph

Control power 24VDC and UPS power supply

Fuel gas pressure 5.9~6.9barG

Instrument air pressure 6.9~8.2barG

Table 2-2 Components of Process Gas

Component CASE 1（mol %）

Methane 84.87

Ehane 4.15

Propane 2.76

Isobutane 1.59

N-Butane 1.55

I-Pentane 0.33

N-Pentane 0.16

N-Hexane 0.05

CO2 4.54

H2O 0.01

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Table 2-3 Process Gas Parameters

Name Standard unit

Inlet Pressure 58 kg/cm²g

Inlet Temperature 20~40 °C

Outlet Pressure 250 kg/cm²g

Outlet Temperature ≤50 °C

Displacement 5 MMSCFD

Table 2-4 Engine Parameters

Name Standard unit

Rated Power 330 kW

Rated Speed 1800 RPM

Cylinder Diameter Φ 152 mm

Stroke 165 mm

Number of Cylinders 6V pcs

Displacement 18 L

Fuel Gas Consumption 87 N𝑚𝑚3 /h

Table 2-5 Compressor Parameters

model ARIEL JGA/4 unit

Speed (Maximum) 1800 RPM

Compression Cylinder 2.75"×2+3"×2+2"×2

Compression Series 3 level

Number of Cylinders 6 pcs

Stroke 76.2 mm

Piston Rod Diameter 28.575 mm

Maximum Allowable Total Load of
89 kN
Piston Rod
Maximum Allowable Tension of
45 kN
Piston Rod
Maximum Allowable Compress of
49 kN
Piston Rod
Cylinder Cooling Mode Natural cooling

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Table 2-6 Main Systems Configuration

System Configuration

Equipped with main oil pump and cylinder

Lubrication System lubricator, oil tank, oil cooler, pre-lube electric
pump.
Control Panel and Control System PLC Control Panel

Air Cooler Driven by Engine

Table 2-7 Lube Oil Brand and Consumption

Note: For new units, run in for 200 hours first, and then the lubricator should be adjusted

to the normal working time shown in the data plate of the forced oil lubricator.
Initial Oil
Filling Consumption Exchange
No Brand
Position Volume Interval
.
L L/d h
Compressor Normal:
1 45 Mobil
Crankcase 4000
subject to Pegasus
Lubrication
2 62 oil
Pipes Small 805
analysis
volume,
Normal:
negligible Mobil
1500
Engine
3 100 subject to Pegasus
Crankcase
oil
805
analysis
Oil Makeup
Tank Mobil
Normal: Refill as
4 (Compressor 80 Pegasus
And Engine 1.1L/d needed 805
crankcase)
Mobil
Oil Makeup
Tank Super
Normal: Refill as
5 (Compressor 80 Cylinder
8L/d needed
Cylinder And
Oil 600W,
Packing)
ISO VG680

Note：

1. An oil analysis program is the most effective way to determine frame oil change intervals.

Consistent oil analysis can identify when to change oil on the basis of need rather than a

scheduled interval. Depending on service, oil analysis can significantly extend oil change

intervals.

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The consumption of this package is theoretical initial consumption. Due to the different

components on site, there may be changes. Please refer to the actual oil consumption on

site.

In order to ensure that the cylinder is fully lubricated, on the basis of the normal hours

indicated on the identification plate, it is recommended to confirm after each adjustment of

the oil amount according to the following procedure. The economical oil injection amount

helps reduce losses.

Cylinder lubrication test paper test:

1. Remove the cylinder clearance head, and move the piston of the target cylinder at the

inner dead position. ,

2. Apply light pressure and wipe the inner wall of the cylinder with two layers of cigarette

paper. Starting from the top, wipe down along the circumference of the inner wall of the

cylinder at an angle of 20°. The layer of paper attached to the inner wall surface of the

cylinder should be colored (soaked with oil), but the second layer of paper should not be

saturated.

3. Repeat this test on both sides of the inner wall of the cylinder, starting from the top at an

angle of approximately 90°, using two layers of clean paper on each side. If the first layer

of paper against the inner wall of the cylinder is not stained, it may indicate insufficient

lubrication; if both layers of paper are stained, it may indicate excessive lubrication. In either

case, Ariel generally recommends changing the amount of lubrication accordingly and

repeating all test paper tests until the test passes.

4. Repeat this test for all cylinders. If the test shows that the lubrication amount of a certain

cylinder has decreased or increased, the cycle time of the forced oil injection pump should

be adjusted to achieve a 5% incremental change (see "Adjustment of Forced Oil

Lubrication"). After running for 24 hours, repeat the oil film test on the relevant cylinder.

Attentions:

1. The test paper test can only indicate the amount of oil film. None of these methods can

explain the quality of viscosity, but can explain the effect of changes in gas quality.

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Lubricating oil diluted with water, hydrocarbons, compounds or other components will

produce a lot of oil film or moisture on the surface, but the dilution effect may result in the

reduce of load capability, so that the complete load of the compressor cannot be satisfied.

2. To avoid personal injury, make sure that the gas pressure left in the drive and

compressor cylinder cannot turn the compressor crankshaft during maintenance.

3. Before any maintenance or parts disassembly, the pressure in the compressor cylinder

should be completely relieved. After maintenance is completed, the entire system should

be purged before operating the equipment to avoid the presence of explosive air/gas

mixtures.

Table 2-8 Unit Power & Consumption

415 V/50 HZ
NO Number Total
Description Power
. Operating Voltage (Each Power
（Kw）
Unit) （Kw）
240VAC/1PH/50HZ,
1 PLC control cabinet 1 1.5kW 1.5kW
UPS
Compressor pre- 415VAC/3PH+N
2 1 0.75kW 0.75kW
lubrication pump /50HZ
Package cooling 415VAC/3PH+N
3 1 0.37kW 0.37kW
pump /50HZ
Sum 2.62W

Alarming Parameter Table：

Table 2-9 Alarming Parameter

Name Units LL L H HH

Inlet Pressure Transmitter Psi 740 782 868 890

1st Discharge Pressure
Transmitter
Psi 1536 1579
2nd Discharge Pressure
Transmitter
Psi 2631 2688
3rd Discharge Pressure
Transmitter
Psi 3655 3726
Engine Lube Oil Pressure
Transmitter
Psi 35 40
Compressor Lube Oil Pressure
Transmitter
Psi 45 50

Inlet Temperature Sensor ℉ 112 119

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1st Discharge Temperature
Sensor 1
℉ 194 202
1st Discharge Temperature
Sensor 2
℉ 194 202
2nd Discharge Temperature
Sensor 1
℉ 218 223
2nd Discharge Temperature
Sensor 2
℉ 218 223
3rd Discharge Temperature
Sensor 1
℉ 184 187
3rd Discharge Temperature
Sensor 2
℉ 184 187
Engine Lube Oil Temperature
Sensor
℉ 200 205
Compressor Lube Temperature
Sensor
℉ 185 190
Compressor Bearing Temperature
Sensor1
℉ 220 230
Compressor Bearing Temperature
Sensor2
℉ 220 230
Compressor Bearing Temperature
Sensor3
℉ 220 230
Compressor Bearing Temperature
Sensor4
℉ 220 230

Engine Vibration Transmitter mm/s 16 18

Compressor Vibration Transmitter mm/s 5.1 6.1

Engine Speed Transmitter RPM 1890 1980

Jacket Water Tank Level Switch √

Auxiliary Water Tank Level Switch √

Oil Tank Level Switch 1 √

Oil Tank Level Switch 2 √

Engine Crankcase Oil Level
Controller
√
Compressor Crankcase Oil Level
Controller
√

Compressor Oil No-flow Switch 1 √

Compressor Oil No-flow Switch 2 √

Air Cooler Vibration Switch 1 √

Air Cooler Vibration Switch 2 √

The above alarming shutdown values are initial values before delivery. Specific setting

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values can be confirmed according to onsite working conditions during commissioning. The

closer to the actual display of the protection value, the better protection will be provided to

the compressor package. But the actual value cannot beyond the value range set in the

table above. Due to the different of environment temperature in winter and summer, the

adjustment of the related parameter of compressor package is necessary. No matter when

the parameter settings needed to be changed, please consult Jereh for approval before

adjust the parameters.

Attention: It is recommended to completely remember or post the parameters of the

alarming and shutdown parameters on the PLC cabinet or data collection room. Regular

data comparison is conductive to the early detection of the compressor package problems.

We suggest you to form a special inspection system or data save system to record all data

of the compressor package every 2 hours or export all data displayed by the control room

computer every day for archiving. The analysis of data is conducive to the prevention,

analysis and avoidance of failure. Without detailed data, it will be difficult to analyze the

root cause. Jereh has extensive experience in data storage and inspection information

management.

2.2 COMPRESSOR PACKAGE WORKING CONDITION

PARAMETERS

Table 2-10 Compressor Package Design Flow and Process Conditions Performance

Parameters
Dischar
Suction ge Rot Sha Sucti
Dischar
Pressur Pressu ate ft on VVCP
No Flow ge
e re Spe Pow Temp Opening
. MMSCFD Temp.
ed er . %
kg/cm²g kg/cm² °C
rpm kW °C
g
180
1 58 250 5 289 30 ≤50 0
0

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CHAPTER 3 PACKAGE CONTROL SYSTEM

Before operating the compressor control system, the operator needs to read and fully

understand the contents of this chapter.

1. Package control system belongs to pivotal equipment, and full-time care should be

conducted to the control system. Full-time management personnel shall have certain

electrical knowledge, electrical safety knowledge and other relevant qualifications, and

shall accept all applicable safety training, regularly maintain and inspect control system.

2. When the compressor starts for the first time or restarts after a long time, all electrical

equipment wiring screws should be retightened and the main power circuit and insulation

resistance of the motor should be tested.

3. Frequent starting and stopping of units and power switches are strictly prohibited.

4. Below contents are electrical safety inspection. If any abnormality is found in the

following inspection, maintenance and replacement shall be carried out immediately.

1) Whether the insulation of electrical equipment is aged, damped or damaged, and
whether the insulation resistance is qualified.
2) Whether the ground and neutral is correct and reliable, and whether the protective
device complies with the safety regulations.
3) Whether the electrical connection parts are in good condition, and whether the
temperature of electrical equipment and electrical circuit is appropriate.
4) Regularly check the insulation resistance of electrical equipment and the grounding
resistance of grounding device.
5) Regularly check whether the electrical connection parts are reliable and corroded.
6) Check the warning lights, horn and emergency shutdown system to ensure they
operate correctly.
5. Inspect internal parts inside the control cabinet (box, table):
1) The inside and outside of the control cabinet (box, table) shall be kept clean and tidy.
No objects, especially conductive objects, shall be placed. No sundries shall be placed on
the top.
2) During use and storage, please make sure that there is no water leakage into the
electric control box.
3) In case of long-term shutdown, lock or seal the control cabinet (box, table),
disconnect the power supply, and do not open the cabinet door when energized.

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6. Operators must be trained and qualified for high pressure operation.
7. For the maintenance and repair of all electrical equipment, please strictly refer to the
equipment user manual for operation.
8. Electrical equipment should be maintained by qualified personnel.
9. The safety valve and safety protection setting value shall not be changed as will, and
the safety valve, transmitter, instrument, etc. shall be regularly adjusted as required.
10. The grounding of electrical and instrument control system shall be reliable without
short circuit.
Failure to follow the above safety principles may result in equipment damage and
personal injury.

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3.1 OVERVIEW
The compressor control system is only used to control the compressor of project (APSL
CNG compressor project).
The compressor control system is mainly composed of Program Logic Controller (PLC),
Human Machine Interface (HMI), Micro Circuit Breaker (MCB), and other electrical
components.
PLC has data collection and processing functions, HMI has real-time data display and
historical data management functions. HMI exchanges data with PLC directly, the
operator can view and set the information of the compressor through HMI, for more
details, please see the HMI screen introduction section.
The compressor control system has multiple protection functions, which can effectively
protect the compressor and extend the service life of the compressor. Operators should
be familiar with all operations of the compressor control system.
The compressor control system can be remotely monitored via Modbus protocol.

3.2TECHNICAL DATA
 Input AC voltage: 3 x 415 V, 1 x 240 V
 Input voltage tolerance: ±10%
 Input frequency: 50 Hz
 Input frequency tolerance: ±1%
 Control circuit DC voltage: 24 V

3.3 ENVIRONMENTAL CONDITIONS

 Operating altitude: 2000 m max
 The compressor control system should be perpendicular to the horizontal ground and
the angle of inclination should not exceed 5 °.
 The location of the compressor control system should be able to prevent interference
from external rain or snow.

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3.4 HMI SCREEN INTRODUCTION
1. Main Screen
After power on, HMI displays the Main Screen, as shown in Figure 1:

Figure 1
Main Screen includes Compressor Accumulative Running Time, Compressor Status
Indication, Language Switch (English/ Chinese), Main Equipment Status Indication, and
Control Buttons, etc.
 Compressor Accumulative Running Time: Displays compressor’s accumulative
running time.
 Compressor Status Indication: Displays process status indication, includes ESD
energized，Test mode，Shutdowns energized，Ready to start，Compressor pre-
lube，Engine starting，No-load running-engine warm，Loading，Load Running，
Unloading，Normal stop-cooldown，Normal stop-post-lube，Shutdown stop- post-
lube，ESD stop-no post-lube.

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2. Parameters Display Screen
Click the "Parameters Display" button in the main screen to enter the compressor
parameter display screen, as shown in Figure 2:

Figure 2
Click the "Page Down" button in the above figure to enter the engine parameters display
screen, as shown in figure 3:

Figure 3

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 Natural Gas Compressor Package
Click the "Page Down" button in the above figure to enter the switch display screen, as
shown in figure 4:

Figure 4

3 Parameters Inquire Screen

Click the "Parameters inquire" button on the main screen to enter the parameters inquire
screen, as shown in figure 5:

Figure 5
Click the "Control Parameters Inquire" button in the above figure to enter the control
parameter inquire screen, where you can inquire the control value corresponding to the
pivotal parameters of the unit operation, as shown in figure 6:

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Figure 6
Click the "Page Down" button in the above figure to enter the alarm parameter inquire
screen, as shown in figure 7:

Figure 7
Click the "Page Down" button in the above figure to enter the shutdown parameter inquire
screen, as shown in figure 8:

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Figure 8

4. Device Operation Screen

Click the "Device Operation" button on the main screen to enter the device operation
screen, as shown in figure 9:

Figure 9
This screen includes control buttons of compressor oil pump, cooler pump.
When the compressor is stopped, operator can start/stop the oil pump/cooler pump in
manual mode or test mode.

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5. Alarms & Shutdowns Screen
Click the "Alarms & Shutdowns" button on the main screen to enter the alarm and
shutdowns screen, as shown in figure 10:

Figure 10
This screen records the alarm and shutdown information of the unit. By selecting the
button on the right side of the screen, you can inquire the alarm and shutdown information
at different times.

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6. Management Screen
Click the "Management" button on the main screen to enter the management screen, as
shown in figure 11:
This screen is only valid for users with advanced permissions. If the current user’s
authority is not high enough, the button is invalid.
The advanced management screen mainly includes the following switching buttons:
control parameters setting, alarm parameters setting, shutdown parameters setting,
bypass setting, device test, password modification, and system configuration. By clicking
different switch buttons to enter the corresponding setting screen, when the unit is
officially put into operation, the operator shall not change the parameter settings inside at
will.
The bypass setting and device test screen are used for unit debugging. When the unit is
debugged, it is not recommended that the user enter these screens to prevent
misoperation.

Figure 11
Click the'Control Parameters Setting' button in the'Management' screen to enter the
control parameters setting screen, where you can set the control values corresponding to
the pivotal parameters of the unit's operation, as shown in figure 12:

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Figure 12
Click the "Page Down" button in the above figure to enter the alarm parameters setting
screen, as shown in figure 13:

Figure 13
Click the "Page Down" button in the above figure to enter the shutdown parameters
setting screen, as shown in figure 14:

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 Natural Gas Compressor Package

Figure 14
Click the "Device Test" button on the management screen to enter the device test screen,
as shown in figure 15:

Figure 15
During on-site commissioning, select the mode button in the upper right corner of the
screen as the test mode, and then you can perform the individual manual test of the above
equipment. Note before exiting this screen, be sure to reset the mode button to normal
mode.
Click the "Bypass Screen" button on the management screen to enter the bypass screen,
as shown in figure 16:

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 Natural Gas Compressor Package

Figure 16
The bypass function is only used during the commissioning of the unit. When the unit is put
into operation, the operator is not allowed to enter this screen to make settings.
Click the "Modify Password" button in the management screen to enter the password
change screen, as shown in figure17:

Figure 17
Click the "System Configuration" button in the management screen to enter the system
setting screen. This function is strictly forbidden to be used by users, and is only used by
debuggers to configure the system.

3.5 OPERATION PROCEDURE

Prerequisites for start:
 Power supply of the compressor control system is normal.
 Distribution circuit of the compressor control system is normal.
 Enclosure of the compressor control system is well sealed.

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 All ESD signals are normal.
 All status of valves are right.
 The pipeline has been inflated with 0.5Mpa (can set) gas through the intake bypass
valve.

Check before starting the engine:

NO. Detailed description
YES NO N/A

A. Cooling System

Whether there is leakage when the unit is not

1
running
The inlet and outlet pipeline valves of auxiliary
2
water and jacket water are open

3 All drain, water inlet and outlet valve are closed

B. Starting Air System

Does the air motor lubricator have sufficient

1
lubricating oil?
Manual bar the engine for more than one turn
2
without additional resistance
The air inlet valve has been opened manually
3
and slowly before starting
After starting, the air inlet valve for the start
motor has been closed, and the gas between the
4
air inlet valve and the pneumatic motor has been
vented
C. Fuel Gas System

The temperature of fuel gas is ºC, meeting

1
the start-up requirement;
Fuel gas pressure PSI, meeting startup
2
requirements

D. Lubricating Oil System

Check whether the crankcase oil level of oil
1 dipstick and oil level controller is in the position
between high and low
Open the valve of oil pipeline allowing the oil
2
enters into the system

3 Drain valve and filled oil nozzle valve closed

E. Control System

1 HMI interface display is normal.

2 The displayed alarm has been eliminated

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3 Local module display is normal

Compressor Inspection Content

A. Instrument Air

The instrument air system pressure is 7~8.4kg/cm²g, and there

1
is no leakage.
B. Electrical Instrument & Control
Safety valves, pressure gauges, thermometers, etc are
1
calibrated？
The local control cabinet and explosion-proof junction box are
2
well connected and have no power supply problem.
Pressure transmitters, temperature sensors, liquid level
3
switches, etc are normal after inspecting.
All electric devices are correctly installed and there is no loose
4
connections
Parameters of all the security alarms and protection devices are
5
correctly set, and feedbacks are correct through test.

6 Speed monitoring and speed limit are set.

Overspeed 1980 RPM .
Automatic control valve can open and close correctly through
7
test.

8 The final version of the package control program is debugged.

9 The remote control signals are calibrated.

Compressor vibration sensors and driving equipment vibration

10
sensors are normal after test.

11 All electric devices are reliably grounded.

The discharge temperature and pressure alarm setting are in

12
accordance with PID.

C. Compressor

1 Manual bar the compressor for at least 3 turns.

D. Lubrication System
Ball valve between the lube oil tank and oil level controller, and
1 the same between oil level controller and crankcase has been
opened.
2 The oil level in the force feed lubricator is above 1/2

3 Manually operate Force feed lube for Cylinder lubricating for 5

strokes or more
Pre-lube pump running time before compressor startup is not
4 less than 30 seconds. The actual running time is
second .

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5 Pre-lube pump startup pressure is not less than 0.21MPag. The

actual pressure is _________ MPag.
E. Air Cooler

1 Mechanical vibration switches are proved correct through test.

Bearings and fan blades rotate without resistance. Motor rotate

2
in the right direction.

3 Bolts on finned tube bundle free end are released.

4 The bearing is filled with grease

5 Belt tightness is checked to be normal.

F. Circulating Water

1 Required coolant has been added.

Brand/Model___________________________
2 The water tank level at the 2/3 position of the tank.

3 The vent pipe is installed.

When the inspection is finished and the start-up conditions are met, first turn the “Power
switch” of the control cabinet panel to the “ON” position, the power indicator of the control
cabinet will turn on, and the initial screen will be entered after the display unit starts
successfully.
1. Start-up operation
Turn the power switch on the control cabinet panel to the "on" position, the power
indicator of the control cabinet turns on, and the HMI (Human Machine Interface) enters
the main screen. When the “unit status” on the main screen is displayed as “Ready to
start”, the start-up operation can be performed. If there is a fault, you need to remove the
fault and click on the ‘Reset’ button, and wait for the “unit status” to be displayed as
“Ready to start” before starting up. Under ESD conditions or before the first start-up, the
operator needs to manually open the intake bypass valve for purge.
Click the 'Start' button on the control cabinet panel, the program enters the pre-lubrication
stage. In the pre-lubrication phase, after the compressor oil pump runs for 120s (can set),
the engine start process is started. When the engine is successfully started, the 'unit
status' will change to 'no-load running', and this stage is the start-up process stage.
After the unit is running with no load, the system detects lube oil pressure. If the lube oil
pressure is greater than the system setting value of 52 psi (can set), the pre-lube oil pump
will stop.

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 Natural Gas Compressor Package
2. Loading Procedure
During no-load operation, when the compressor oil temperature, engine water
temperature, and engine speed all meet the system settings, the unit automatically starts
the loading process. The suction valve and discharge valve are opened, and the recycle
valve is closed. When the unit is loaded, the process status will change to 'load running'.
3. Unloading Procedure
When the discharge pressure of the final stage reaches the stop setting value or press
the 'stop' button on the control cabinet panel, the unloading process will start
automatically. The vent valve is opened, the recycle valve is opened, and the suction
valve and discharge valve are closed. As the unloading procedures finish, the compressor
package runs with no load.
4. Shutdown Procedure
Normal stop during load running: When the final discharge pressure reaches the set stop
value or press the "stop" button on the control cabinet panel, the unit will first perform the
unloading process. After unloading, the unit will enter the shutdown stage, and the
compressor and engine will be automatically lubricated, and the oil pump will stop when
the lubrication timer expire.
Normal stop in the process of no-load running: After pressing the "stop" button on the
control cabinet panel, the unit will enter the normal stop stage. The compressor and
engine will be automatically lubricated after the lubrication timer expire, and the oil pump
will stop running.
Emergency shutdown: In case of any emergency or sudden situation during the operation
of the unit, the unit will stop immediately when the control system receives the remote
ESD command issued by the DCS system. The emergency shutdown will occur without
compressor and engine post-lubrication. After the unit inspection, the remote ESD signal
shall be reset after confirming that there is no more dangerous situation.
Shutdown: During the operation of the unit, if the temperature, pressure, vibration and
other data exceed the protection setpoint, switch signals such as liquid level and oil flow
enter into abnormal state, or press the local emergency stop button on the control cabinet
panel, it will cause the shutdown. The screen will display the shutdown information and
record the shutdown information in the alarms & shutdowns screen for the operator to
quickly inquire the fault point, and at the same time the sound and light alarm on the top
of the control cabinet will start to alarm. The shutdown process is automatically followed
by the lubrication process. During troubleshooting, after the operator presses the mute
button on the control cabinet panel, the audible and visual alarm can be eliminated. After
troubleshooting, press the 'reset' button and the system will automatically reset.

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 Natural Gas Compressor Package
3.6 FAILURE PROTECTION
1. Pressure Protection
The pressure protection includes suction pressure protection, discharge pressure
protection, compressor/engine oil pressure protection, etc. The compressor package
alarms at low suction pressure. The low alarm and low low SD of suction/oil pressure will
only be enabled after the unit running.
2. Temperature Protection
The temperature protection includes suction temperature protection, discharge
temperature protection, compressor/engine oil temperature protection, compressor
bearing temperature protection, etc. The temperature protection works all the time.
3. Vibration Protection
The vibration protection includes compressor vibration and engine vibration protection.
The protection works all the time.
4. Liquid Level Protection
The liquid level protection includes scrubber level, compressor/engine oil level and oil
tank level. The protection works all the time.
5. Fault Handling
When the unit fails, the sound and light alarm will keep in active to remind operator to
check the fault. A prompt HMI display will pop up on the screen to remind fault information
and record the alarm at the same time. When the fault is eliminated, click the reset button
to clear the alarm and make the system ready to restart.
Using the mute button, operator can eliminate the sound and light alarm.

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 Natural Gas Compressor Package

Unit Operation Flow Chart

1. Is the control cabinet power on?

2. Is the oil level normal? (Observe crankcase and oil tank oil level above 1/2)
3. Is the instrument air pressure of the instrument greater than 0.6mpa?
4. Is there any resistance when bar the crankshaft?
5. The lubricating oil pump start to pump oil and manually pump the force feed
Check before lubricator? (No oil flow indicator flashes more than 20 times?)
starting 6. Check whether the process gas path, instrument air, oil path, water valve is
unobstructed? Is there any water pressure?
7. Check whether there is fault alarm in PLC control cabinet and Ex. control box.
8. Check the automatic switch of the touch screen are all in the automatic position?
9. If the unit has just stopped, is there an interval of 30 minutes?

10. Is there pressure in the unit pipeline?(No, purge please)

Unit purge 11. Does the unit stop for longer than 4 hours?(Please purge)
Note: Purge is divided into pipeline purge and cylinder purge, each purge is 120S.
12. Open the intake bypass valve to inflate 1/2 of the intake pressure set value.

Press the
If the suction pressure is suitable, the start sequence continues.
Start button

1. Is the pre-lubricated pump in automatic mode? (Switch to auto mode)

Pre-lube 2. Is the explosion-proof power distribution cabinet energized?
Note: Pre-lubricated for 60s, the main motor start confirmation screen will appear
stage after completion, click "confirm" and package shall start without load.

1. Is the oil cooler on? Please note that the no-load time is not allowed to exceed 2
hours, if the oil and water temperature rises too slow then turn off part of the recycle
valve of the package to increase the load of the compressor.
2. Is there oil pressure? Is the No Flow Timer lamp flashing? Is crankcase oil level
between 1/2 and 2/3? (When the lubricating oil pressure is greater than 0.35mpa,
No-load the pre-lubricating oil pump stops.)
3. Observe whether the operating parameters are abnormal. (See alarm stop value
running table for details)
Note: The suction, discharge and vent valves are closed and the recycle valve is
opened at this stage. The running status shows no load status. When the lube oil
temperature of the compressor reaches 15℃, the lube oil temperature of the engine
reaches 38℃, and the cooling water temperature reaches above 50℃, it will be
automatically loaded under the loading conditions.

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 Natural Gas Compressor Package

Loading Open the discharge valve and suction valve, close the recycle valve, and the unit
enters the load stage.
stage

When the final discharge pressure reaches the stop setpoint, the unit automatically
executes the unloading process. When the vent valve is opened and depressurizes to
Unload 8MPa (can set), the recycle valve is opened, the suction valve and the discharge valve
stage are closed. When the internal pressure of the unit pipeline is less than 0.5MPa, the vent
valve is closed and the unit enters the no-load stage.

Observe whether the operating parameters are abnormal.（If there is any abnormality,
No-load
you can choose to press the emergency stop button）
running

This stage can be divided into two types. One is in the loading stage, when the discharge
pressure of the final stage reaches the stop setpoint or the stop button is pressed, the
Stop stage unit will automatically execute the unloading process and the cooldown process.One is
to press the stop button when the unit is in no-load running status, and the unit will perform
the cooldown process. After the stop is completed, the unit will enter the post-lube stage.

Post-lube
Note: The unit will be stop after at least 60S lubrication.

Note: After the unit stop, the process status of the unit shows that "Ready to start" to
Stop finish prepare for the next start-up.

Note: If any one of the alarm shutdowns is triggered during the operation of the unit, the
Post-lube sound and light alarm on the top of the control cabinet will start to alarm. The shutdown
process is automatically followed by the lubrication process. After troubleshooting, press
the 'reset' button and the system will automatically reset.

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 Natural Gas Compressor Package

CHAPTER 4 MAINTENANCE

Good maintenance can ensure the safe and reliable operation of the natural gas

compressor unit, extend the service life of the unit, and reduce the operation cost of the

unit. Therefore, strict implementation of the maintenance of natural gas compressor unit is

the primary guarantee to improve the utilization rate of equipment.

It is very necessary to make a good record of each maintenance operation and establish

corresponding equipment account record. Records should be reviewed by experienced

technicians to determine if the condition of compressor operation requires maintenance.

The maintenance of natural gas compressor is divided into preventive maintenance and

every shift, weekly, monthly, half a year, one side and three years maintenance.

The maintenance personnel must have Ariel intermediate maintenance certificate, and the

operation quality of the operation engineer without authority cannot be guaranteed, which

affects the quality assurance of the unit. Jereh does not agree with the schedule

maintenance & preventative maintenance of the product by any team or individual without

certificate or authorization, so the failure will not fall into the scope of the quality assurance.

4.1 COMPRESSOR UNIT MAINTENANCE SUMMARY LIST

Daily
on 500 8000
Inspection items 2000h 4000h 6000h
deman h h
d
Engine
Clean or replace the air filter
√ √
according to the indicator
Check the prelubricated
lubricator and add oil if √
necessary
Check crankcase for oil level
√
and leaks
ESP fault history record and
√
check
Replace the filter element of
√
centrifugal oil filter
Clean the magnetic oil plug √ √ √ √ √
Change crankcase lubricating
√ √ √ √ √
oil

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 Natural Gas Compressor Package
Water pump idler lubrication √
Auxiliary water pump
√
lubrication
Spark plug replacement √
Check ignition coil, replace O-
√
ring if necessary
Check the extension of spark
plug and replace the rubber √
sheath and O-ring if necessary
Jacket auxiliary water pump
belt tension inspection and √
adjustment
Crankcase ventilation system
√
inspection
Oil filter element replacement √ √ √ √
Oxygen sensor replacement √
Gas regulating filter cleaning /
√
replacement
Cooling water level check, fill if
√ √ √ √ √ √
necessary
Check of Cooling water PH √
Detection and calibration of
√
engine alarm shutdown device
Valve clearance check and
√ √
adjustment
Cylinder pressure check √
Check knock sensor and clean √
Check or clean the cooling
√
system
Engine alignment check √ √ √ √ √
Check exhaust back pressure √
Check, lubricate and test
√ √
throttle actuator connecting rod
Inspect ESM harness
connections for breakage and √ √
aging
Check ground connection √
IPM-D timing disk and sensor
√
cleaning inspection
Auxiliary water and jacket water
√
system hose inspection
Oil sump cleaning √
Check the air supply side of
√
intercooler
Check or replace air and gas
√
valve of carburetor
Replace carburetor diaphragm √
Replacement of carburetor liner √
Check all belts and replace if
√ √
necessary
Check crankcase relief valve √

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 Natural Gas Compressor Package
Clean or replace the filter
element of crankcase √
ventilation system
Check the cleanliness of
√
ventilation check valve
Check or replace the exhaust
√
door
Replace diaphragm and O-ring
√
of crankcase pressure regulator
Turbocharger cleaning and
√
inspection
Open exhaust manifold side
√
cover to inspect internal scaling
Clean or replace the fuel
√ √
separator filter element
Check engine outlet bellows for
deviation and adjust if √ √
necessary
Clean the starter motor Y filter √ √ √ √
Compressor
Record and monitor the
√
following:
Check operating speed RPM,
gas pressure and temperature
to determine whether the
√
equipment is operating under
the design parameters and
expected conditions.
Note: Determine whether the
high-pressure and low-pressure
shutdown settings are set as
close as possible to the normal
√
operating conditions. The set
value must ensure that the
compressor allowable value is
not exceeded.
Bearing temperature - if the
equipment is equipped with a
√
main bearing temperature
sensor.
Oil pressure for crankcase
lubricating oil - at operating
temperature (maximum oil
temperature at inlet is 190 °F
(88°C)), the oil pressure shown
√
by the pressure gauge behind
the filter should be 50 to 60psig
(3.5-4.2barg).If the pressure is
below 50psig, turn off the
compressor and troubleshoot.
Crankcase inlet oil
√
temperature.
Lubricating oil filter differential
√
pressure-if the differential

34
 Natural Gas Compressor Package
pressure of the filter exceeds
the allowable value, it means
that the oil filter needs to be
replaced. For specific operation
procedures, please refer to the
nameplate of the lubricating oil
filter on the top cover or the
Maintenance and Repair
Manual.
Check the oil level of the
crankcase lubricating oil. The
√
oil level should be basically in
the middle of the sight glass.
Check whether the crankcase
has sufficient oil supply. For
√
dry-type crankcases, check the
oil level of the oil tank.
Check the oil level of the force
feed lubricator. This oil level
√
should be filled up to the
overflow line.
Record and monitor the
temperature of the packing vent √
and check for leaks at the vent.
Check the exhaust port of the
valve unloader actuator for √
leakage.
Check for leakage in the vent of
√
the clearance pocket
Confirm whether the high
outlett temperature shutdown
setting is within 10% of the
normal working exhaust
√
temperature or as close to the
normal exhaust temperature as
possible. Do not exceed the
maximum shutdown set point.
Record and monitor cylinder
√
valve cover temperature
Check the oil distribution block
cycle time. Refer to the
nameplate of the crankcase for
the correct cycle time.
Contaminating gases may √
require shorter cycle times. For
units operating at non-rated
speeds, check the lube oil data
sheet.
Check for gas, oil and coolant
√
leakage.
Check for abnormal noise or
√
vibration
For more recommended
√
inspections (such as the liquid

35
 Natural Gas Compressor Package
level of the separator, the
working state of the drain valve,
the position of the shutter of the
cooler, etc.), please refer to the
documentation of the packager.
Check and record the cylinder
√
clearance and its setting value
Drain and replace the lube oil in
√ √ √ √
the forced feed lubricator
Change crankcase lube oil. √ √ √ √ √
Clean the filter element of the
small oil filter of the forced feed √
lubrication system (if any)
Replace the oil filter. For
specific operation procedures,
please refer to the filter
√ √ √ √ √
nameplate on the top cover of
the crankcase or Maintenance
and Repair Manual.
Change the lube oil. For
extremely dirty environments or
based on lube oil supplier
recommendations or lube oil
√
analysis results, different lube
oil replacement cycles may be
required. Follow the steps
below:
Check the crankcase level and
make sure that the inner bore
of the main bearing is centered.
√
For flatness and soft foot
requirements, please refer to
Ariel document ER-82
Check the lubrication of the
cylinder. For specific
operations, please refer to √
Maintenance and Repair
Manual
Check the torque of the Anchor
√
bolt.
Measure the cold and hot
√ √ √ √ √
alignment of the coupling
Oiling the threads in the stem
of VVCP (Variable clearance √
volume cavity)
Open the forced feed lubricator
and visually check the wear of
√
the pump follower, cam and
gear.
To carry out pressure test on
the distribution block. Please
√
refer to Maintenance and
Repair Manual for details.
Measure, record and monitor: √

36
 Natural Gas Compressor Package
. Main bearing clearance,
connecting rod bearing
√ √ √ √
clearance and crankshaft radial
and axial channeling clearance.
Piston dead end clearance √ √ √ √
. Crosshead and guide
√ √ √ √
clearance
. The piston rod drop √ √ √ √
Piston rod diameter
measurement and appearance √ √ √ √
inspection
Dismantle the cylinder valve
√ √ √ √
and replace the valve assembly
If equipped with a valve
unloader, check for damage or
wear of the actuator stem.
√
Visually inspect stem seals for
damage or wear to make sure
the actuator is free to move
Inspect pneumatic cylinder
clearance pocket for damage or
wear (seat surfaces and √
stem/stem seals). Make sure
the actuator is free to move.
Inspect cylinder inner wall for
damage or wear. In case of any
of the following circumstances,
the cylinder body shall be √ √
replaced or the inner wall shall
be repaired：
The inner wall has surface
√
defects or lacerations
. Wall roundness more than
0.001 inch/wall diameter √
(0.001mm/mm) or tapered
Check the piston ring and
√
support ring:
a. Measure and record piston
ring condition, ring open √
clearance and lateral clearance
b. Measure and record the
radial thickness of the support √
ring
c. When replacing the piston
ring, re-measure and record the
√
side clearance to check the
wear of ring groove
d. If the ring is damaged or
exceeds the wear limit
specified in the Repair and √
repair manual, the ring shall be
replaced
Check the piston rod for √ √ √ √ √

37
 Natural Gas Compressor Package
damage or excessive wear.
The piston rod should be
replaced if any of the following
occurs:
. A piston rod is knocked or
√
scratched
. The actual size is more than
0.005 inches (0.13mm) smaller √
than the standard size.
. Non-roundness greater than
0.001 inch (0.03mm)/inch rod √
diameter.
. Taper over 0.002 inch
√
(0.05mm)/ inch rod diameter
Reassemble piston rod
packing and oil wiper and
replace if necessary. Please √
refer to Maintenance and
Repair Manual for details.
Clean the filter of the crankcase
breather with appropriate √ √ √ √ √
solvents.
Check and adjust the
transmission chain. Please
√
refer to ER - 74 for specific
operating procedures.
If the compressor crankcase is
equipped with an explosion-
√ √ √ √ √
proof valve, then visually
inspect and operate the valve.
Check the fastener torque of
gas nozzle flange, valve stem,
piston rod stuffing,
crossheading and crankcase,
crossheading and crankcase,
crossheading and cylinder, √
forging steel cylinder mounting
flange, mid-body and cylinder,
mid-body and crossheading
and series cylinder and
cylinder.
Check the strainers at the
√ √ √ √ √
entrance and between stages

Clean the Y filter of the pre-

√ √ √ √ √
lubricator

Drain the liquid or impurities in

√ √ √ √ √
the vessel.

Replace external filters √ √ √ √ √

Air cooler

38
 Natural Gas Compressor Package

Check the tightness of the belt

√ √ √ √ √
and adjust if necessary

Replacement belt √

Axis levelling and angle check √ √

Check the alignment of the tire-

√ √ √
coupling or other coupling

Lithium-based grease injection √ √

Torque check of connecting

√ √ √ √ √
bolts such as fan and bearing

Bearing inspection √

Leakage detection and

√ √ √ √ √
elimination

Bug Screen is clean √ √ √ √ √

Motor wiring and sealing

√ √ √
inspection

Inspect the cleanness of the

conduit or bridge, clean if √
necessary.
Electrical and other
Check the inside of the pulse
tube and, if necessary, purge √ √
and drain the internal impurities

Check all sensors and local

√
instruments

Check all safety valves √

Check control cabinet wiring,

and fasten all connection √ √
points,

Check that the safety devices,

√
replace if necessary,

Clean the internal of control

√ √ √ √ √
cabinet

Check any loosening or

leakage of the root of all valve, √ √
tighten and repair if necessary

Check motor insulation and

√
lubrication

Check grounding. √ √

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 Natural Gas Compressor Package

Calibrate time display √ √ √ √ √

Check heater function √ √ √ √ √

Check the oil-water heating

device and flow detection √ √
device

Check torque of anchor bolts √

Check the leakage of pipeline

such as process gas and √ √ √
instrument air

Check the internal wiring and

leakage of the oil-water heating √ √
unit

Drain the oil from the dirty oil

√ √ √ √ √
sum tank

Check whether there is liquid

inside the vent system, drain √ √ √ √ √
the liquid if any.

Manually debug and test the

√
movement of each valve

Eliminate all leakage in the unit √ √ √ √ √

Test the effectiveness of all

√ √ √ √ √
alarm stop devices

Check and adjust mechanical

√ √ √ √ √
vibration switches

Note :

1. The items indicated in the table should be conducted;

2. If there is no configuration on the unit as described above, please ignore;

3. The user should adjust the maintenance content according to the actual production

situation. This maintenance content is the basic maintenance;

4. Maintenance personnel shall hold Jereh's authorization certificate and any failure due

to improper maintenance are not within the warranty scope of the unit.

40
 Natural Gas Compressor Package
CHAPTER 5 MAIN FAILURES AND TROUBLESHOOTING

5.1 PACKAGE FAILURES AND TROUBLESHOOTING

Malfunction Reason Troubleshooting

Provide starting gas at specified

Insufficient starting gas pressure; pressure;
Compressor Loose starting pipe and serious Eliminate leakage and
package fails leakage; looseness;
to start up. Blocked starting pipe strainer; Clean the blocked starting pipes;
Incorrect crankshaft position. Bar the package to adjust
crankshaft position.
Damaged spark plug or improper
Abnormal
clearance; Replace or adjust clearance;
operation or
Fuel gas regulating valve fails; Maintain or replace;
disordered
Worn or dirty permanent magnet Remove dirt and readjust.
controls
motor.
Adjust the oil level to required
Oil level is too high;
Much lube oil level;
Damaged piston rod packing;
consumption Repair or replace;
Scratched piston ring;
in crankcase Replace piston ring;
Blocked air filter.
Clean filter cartridge.
Replace lube oil timely;
Temperature
Lube oil is too dense or used for a Refill lube oil to required level;
of crank
long time; Adjust the clearance to required
bearing or
Lube oil contains water; value;
connecting
Not enough lube oil in crankcase; Check shaft diameter and
rod bearing is
Bearing clearance is too small. bearing shell; replace bearing
too high.
shell if necessary.
Speed drops Stuck piston ring; Maintain or replace;
to shutdown The bearing overheats and burns Inspect lubrication;
(under normal the shell; Remove block or leakage;
ignition Too large loss of fuel pressure; Adjust the load to specified
condition). Too much load. value.
There is air clogging in the
lubricator; Discharge the air from lubricator;
Check valve connected to cylinder Clean the check valve;
Lubricator
is blocked; Repair or replace;
doesn’t pump
Lubricator is blocked or damaged; Check oil pipe or fill lube oil;
oil.
Oil level of lubricator is low; Check lubricator transmission
Lubricator transmission doesn’t device and eliminate the failure.
work.

41
 Natural Gas Compressor Package
5.2 CYLINDER FAILURES AND TROUBLESHOOTING

Malfunction Reason Troubleshooting

1. Shutdown and take out
1. Broken valve plate or other
Sharp shocking the objects;
metal objects drop into cylinder;
sound in 2. Repair or replace
2. There is excessive fluid or
cylinder cylinder.
pocket leaks.
1. Assembling clearance of friction
surface is too small;
1. Disassemble and repair;
2. Uneven clearance caused by
Screaming or 2. Replace piston ring;
over damaged or broken piston
muffled sound 3. Replace bearing shell or
rings;
of cylinder fasten nuts.
3. Clearance of connecting rod
bearing is too large or
connecting rod bolt is loose.
1. Weld the crosshead
Shocking
1. Crosshead guide clearance is outer diameter and
reverberation
too large. process it to required
of cylinder
clearance.
Abnormal
1. Replace valve plate or
sound in 1. Valve plate or spring is broken.
spring.
cylinder valve
Cylinder
1. Repair or replace;
discharge
1. Discharge valve leakage; 2. Find the reason of high
temperature
2. Suction temperature is too high. suction temperature and
exceeds
correct.
required value.
1. Repair or replace;
1. Cylinder valve leaks;
Cylinder 2. Check or replace;
2. Packing leaks;
displacement is 3. Clean dirt and repair
3. Piston rod is scratched;
insufficient. piston rod;
4. Piston ring leaks.
4. Repair or replace.
1. There is dirt in the cylinder and 1. Disassemble and repair
Cylinder the cylinder is scratched; cylinder;
overheats. 2. Too little or no lube oil in the 2. Check oil injection
cylinder. system.
1. Caused by pipe vibration. 1. Eliminate pipe vibration;
2. Packing or piston rod is worn 2. Check and repair;
out; 3. Disassemble and repair
Abnormal 3. Foreign objects drop into cylinder, remove foreign
vibration of cylinder; objects;
cylinder 4. Crosshead guide clearance is 4. Weld the crosshead out
too large; diameter and process it
5. The cooperation of each to required clearance;
component is poor. 5. Check and adjust.

42