Engineering Specs

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n Cooper Energy Services (2/00)

UNCONTROLLED COPYContact Technical Publications Dept.for current version. (937) 327-4279 Compressor Cylinder Technical Data Book

ENGINEERINGSTANDARDS

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ES 2Protection Of Non-Lube CompressorCylinders For Shipment & Extended Storage

1.0 ScopeThis procedure explains the necessary steps required to protect non-lube compressorcylinders from rust and oxidation during shipment and subsequent storage before startup.

2.0 RequirementsAll non-lubricated compressor cylinders shall be prepared according to the followingprocedure before being shipped or placed in extended storage:

a. Ascertain that all cylinder body and cylinder head water jackets have been drained.All liquid must be removed from these jackets and internal surfaces thoroughly dried.

b. Remove all cylinder heads, fixed volume pockets, and/or variable volume pockets.Also, remove all distance piece covers.

c. Remove all valves and valve retainers and suction valve unloaders from the cylinderbodies. Be very careful to identify from which location the valves came in case thevalves are non-interchangeable designs. If they are such, they will only fit in thelocations where installed and should not be mixed in order to prevent difficulty inreinstalling them.

d. Remove the piston rod and packing assembly, including the oil scraper, packings fromeach cylinder body, and distance piece.

e. Through all the exposed openings in the cylinder body and distance pieces, wipe allmoisture from the cylinder bores, gas passages, and distance pieces using a syntheticsponge or lint-free cloth.

f. Spray all cylinder bodies and distance pieces internally with a MIL-C-23411 rustpreventative. The cylinder bore and all gas passages should be covered with thiscorrosion inhibitor.

g. Place a sufficient layer of VPI paper in the cylinder bore and set a number of desiccantbags on top of the VPI paper in the cylinder. Do the same thing in all distance piececompartments.

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UNCONTROLLED COPYContact Technical Publications Dept.for current version. (937) 327-4279


h. Reinstall all cylinder heads, fixed volume pockets, variable volume pockets, distancepiece covers, and all valve caps. Do not reinstall the piston rod packings and valves.

i. Seal the suction and discharge flanges or nozzles of the cylinder body by makinggaskets of VPI paper and waxed paper. Install a steel cover plate over each suction anddischarge opening, making sure to install the paper gaskets between the cover plateand cylinder body (for shipping only).

j. Wrap all of the removed parts with waxed and VPI paper and pack for shipment orstorage. Each box containing these wrapped parts should contain a sufficient quantityof desiccant bags and should then be sealed.

k When the overall compressor unit is shipped or stored, it is recommended that thecylinders in particular be adequately covered with a heavy tarp or canvas cover.

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ES 11Rod Load Limitations OnThe W Series Compressor1.0 Scope

The purpose of this standard is to clearly define the application limits of the variouscompressor piston rods such that Marketing and Engineering will have firm guidelineswhen calculating the compressor performance.

2.0 RequirementsExternal Rod Net Rod

Rod Dia. (“) Load (Lbs.) Load (Lbs.) Comments

2 30,000 35,000 Standard*2-1/4 (MW6) 35,000 40,0002-1/2 (SW6) 42,500 46,5002-1/2 (W7) 45,000 52,5002-1/2 (W7) 55,000 60,000

2 22,500 26,000 Colmonoy coated in packing area2-1/4 (MW6) 26,000 30,000 (Spec 207 or 204)2-1/2 (SW6) 41,250 44,5002-1/2 (W7) 33,570 39,0002-1/2 (W7) 41,250 44,500

2 23,000 27,000 Reduced hardness for H2S service2-1/4 (MW6) 27,000 30,750 (Spec 204 or 207 heat treated per2-1/2 (SW6) 42,500 46,500 Spec H2S)2-1/2 (W7) 34,750 40,2502-1/2 (W7) 42,500 46,500

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2 30,000 35,000 Custom 450 Stainless Steel (Spec 2392-1/4 (MW6) 35,000 40,000 heat treated to 30-34 HRC) or 17-4 PH2-1/2 (SW6) 42,500 46,500 stainless steel (Spec 246-A heat treated2-1/2 (W7) 45,000 52,500 to 28-35 HRC). Both good for H2S and2-1/2 (W7) 55,000 60,000 CO2 Service.

*Note: The standard rod is Material Spec 207 (forging) and 204 (bar) and may include any of ourstandard finishes in the packing area (except Colmonoy) without affecting the rating of the rod.

3.0 ProcedureMarketing is responsible to size applications such that the external rod load is lower thanthe limits listed above. In the event that the external rod load is exceeded but it appears tobe a borderline case, Engineering will, at Marketing’s request, evaluate the internal rod loadsin an attempt to arrive at a suitable application and still not exceed the limits set above.

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ES 13Trimming Superior And AjaxCompressors For Sour GasApplications In Lubricated Service1.0 Purpose

1.1 To define and clarify the compressor design criteria to be used in applying compressorsin sour gas service to prevent the occurrence of sulfide stress corrosion cracking anduntimely failure of compressor components.

1.2 To establish compressor design criteria that follow the guidelines of API 11P and NACEMR0175 for sour gas service.

1.3 To establish Ajax and Superior Packaging design criteria that follow the guidelines ofAPI 11P and NACE MR0175.

1.4 To establish and define different levels of protection depending upon the customer’srequirements.

1.4.1 The standard protection level will be per guidelines established by API 11P anddescribed in Section 4.0.

1.4.2 For more rigid protection requirements the guidelines used will be NACEMR0175, described in Section 5.0. This stricter protection may be neededto comply with stricter regulatory controls or customer requirements.

1.4.3 Since the customer knows the application details of his process much morethoroughly than does Ajax-Superior, the customer may determine that higherlevels of H2S trim are required and opt to buy these. Ajax-Superior will makeevery effort to accommodate these special requirements.

2.0 Application2.1 These guidelines apply only to lubricated compressor units; requirements will be

different on a non-lube compressor and will be decided on an individual basis.

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2.2 Section 4.0 designates the trim requirement when units are designed to the guidelinesof API 11P.

a. Section 4.1 for H2S concentrations up to and including 2% by volume applies toAjax and Superior model compressors, including RAM and JOY.

b. Section 4.2 for H2S concentrations between 2% and 5% (Level 1-11P) applies only toAjax and Superior model compressors, including RAM.

c. Section 4.3 for H2S concentrations greater than 5% (Level 2-11P) applies only toAjax and Superior model compressors, including RAM.

2.3 Section 5.0 designates the trim requirements when units are designed to more nearlymeet the guidelines of NACE MR0175 and applies only to Ajax and Superior modelcompressors, including RAM.

2.4 Section 6.0 designates the trim requirements for Ajax Packaging when it is designed tomeet the guidelines of API 11P.

2.5 Section 7.0 designates the trim requirements for Ajax Packaging when it is designed tomore nearly meet the guidelines of NACE MR0175 and more stringent customerrequirements.

2.6 When CO2 concentrations greater than 5% are present with an H2S concentrationgreater than 2%, the units should be trimmed per the Level 2-11P requirements inSection 4.3 as a minimum. In addition, the requirements in Section 7.0 of CO2 trimstandard (ES14—contact Ajax-Superior Marketing) will be required.

3.0 Responsibilities3.1 Marketing’s responsibilities are:

3.1.1 To acquire reliable gas analysis; and to identify, to both engineering and thecustomer, all sour gas applications as early as possible (hopefully in the pre-quotation stage).

3.1.2 To be familiar with the various requirements set herein.

3.1.3 To price all sour gas units appropriately.

3.1.4 To educate the involved customers and end-users on their responsibilities

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concerning the maintenance and operational procedures to be used forsour gas compressors.

3.2 Engineering’s responsibilities are:

3.2.1 To define and specify properly designed components in accordance with theguidelines set herein.

3.2.2 To review all sour gas applications forwarded by Marketing and assist them asrequired in tailoring individual applications to requirements.

3.2.3 To set the standards for design and proper maintenance and keep them updatedas the “state of the art” advances.

3.2.4 To assure that copies of this standard as well as Engineering Standard ES1002(page 1-70) for Superior products and ESS-L-811 and ESS-L-168 for Ajax productsare properly distributed in instruction manuals for sour gas units.

3.3 Responsibilities of the customer:

3.3.1 To advise Ajax-Superior Sales and Marketing when the recommended trimrequirements in this specification are not considered adequate and to negotiatewhat is required prior to order release.

3.3.2 To maintain the sour gas compressors in accordance with the standards setherein and to adhere to the particular minimum lubrication recommendationsspecified.

3.3.3 To assure that maintenance and operating procedures are well understood andfollowed and that all required safety training and safety procedures for handlingsour gas have been addressed. Those safety procedures must be enforced for allpersons working at or visiting the unit site.

4.0 Standard Trim RequirementsUnless otherwise required by specific customer requirements, sour gas units will be trimmedusing the guidelines of the latest edition of API 11P.

Exceptions to this can occur on an individual basis when either high H2S levels exist or otherconstituents are present which affect the trim.

4.1 Hydrogen sulfide (H2S) concentrations up to and including 2% by volume:

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4.1.1 For any concentration of H2S below .005% (50 ppm) no special requirementsare necessarily relative to the trimming of the equipment.

4.1.2 For any concentration of H2S from .005% (50 ppm) up to and including2% by volume in lubricated service special trim will not be required. Standardmaterial is acceptable and special lubrication practices are recommended.

4.1.3 The frame lubricant used must have a total base number (TBN) of 15 or higherto help prevent the lubricant from turning acid and damaging bearings andbushings. This alkalinity must be maintained during operation in the machineby appropriate timely makeup or complete oil changes. At no time should thelubricant TBN be less than approximately 30% of the original TBN number.

4.1.4 The frame lubricant must meet or exceed the requirements of MIL-L-2104B,Supplement No. 1.

4.1.5 A complete oil analysis program on the frame lubricant is required to determineproper oil change intervals as well as to monitor the condition of the lubricantand the unit.

4.1.6 Compressor cylinder lubricants must adhere to the requirements of Ajax-Superior Engineering Standard ES1002 (page 1-70) for Superior models and ESS-L-811 and ESS-L-168 for Ajax models. Viscosities are to be on the high side of thepressure conditions normally required and a 3 to 8% compounding with acidlesstallow (similar to steam cylinder oils) is also required.

4.1.7 The compressor cylinder lubricant rate is to be double the normal rate forequivalent non-sour gas applications.

4.1.8 Brass, bronze, copper, and other copper alloys shall not be used on hardware forgas wetted parts. On external components, and other components that are notnormally gas wetted, yellow metals are to be avoided where practical or asspecified by agreement with the customer. This requirement shall befollowed for units and packages.

Sections 6.0 and 7.0 define yellow metal removal requirements for Ajax Packaging.

4.1.9 The compressor distance pieces are to be properly vented in accordance withlocal safety standards to provide maximum safety to personnel.

4.1.10 Soft iron or aluminum gaskets are to be used between the valve and valve seat.

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4.1.11 The O-ring material used for standard Superior equipment is Viton (Spec. 473)and this is also acceptable for H2S service. For lower temperature operations(<275°F.) Neoprene (Spec. 479) can be specified as an option.

For Ajax compressor cylinders, the standard O-ring material is Neoprene.

4.1.12 For Ajax Packaging requirements in this level, see Sections 6.0 and 7.0 of thisstandard.

4.1.13 For RAM compressors, an auxiliary distance piece or an acceptable purgedpacking design is required to keep cylinder oil from contaminating the frame oil.

For Ajax and Superior models, the standard crosshead guide/distance piece isacceptable.

4.2 Level 1-11P Trim (2-5% H2S)

4.2.1 Concentrations of H2S from greater than 2% up to and including 5% by volume:

4.2.2 All of the special requirements already discussed apply, plus the additionalrequirements listed in Section 4.2.

4.2.3 A suitable corrosion inhibitor should be added to the cylinder lubricating oilas defined by the user’s oil manufacturer.

4.2.4 Cylinders are to be equipped with a suction flushing system (injection ofcylinder lubricating oil into the suction nozzle of each cylinder). This is inaddition to the regular cylinder lubrication. This helps to resist the naturalsolvent action of the sour gas and insures a thorough distribution of oil for betterlubrication. It also helps to better form a barrier to corrosion by coating all thevalve surfaces with an oil film.

Superior RAM cylinders and Ajax cylinders are excluded from this requirementas standard practice.

4.2.5 Distance Piece: For RAM compressors, an auxiliary distance piece is required.

4.2.6 For Superior compressors, oil slingers are to be used where adequate space isavailable on each compressor rod in the distance piece compartment to assurethat none of the H2S contaminated cylinder or packing lubricant works its wayback into the crankcase and contaminates the frame lubricating system. Anauxiliary distance piece may be required for this application.

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For RAM units, oil slingers are not required, but can be added as an option ifspace permits.

For Ajax compressors, oil slingers are not required, but can be added as an option.If oil slingers are requested by the customer, then it may require a distance pieceto provide room for the slinger.

Cylinders mounted on Joy frames are excluded from this requirement.

4.2.7 Packing and Piston Ring: Packing and piston ring material shall either be non-metallic or contain no copper bearing metals.

4.2.8 Compressor Valve: Compressor valves will be standard construction and hardness.

4.2.9 Carbon Steel Parts: All carbon steel, alloy steel, or 12CR steel parts which aregas wetted (come in contact with the process gas stream) are to have a maximumhardness of 22 HRC. This is to include all internal fasteners and V.V. pocketscrews, but excludes compressor valve assembly fasteners.

4.2.10 Piston Rod: The piston rods are to be either AISI 4140 alloy steel with a hardnessof 15-22 HRC (Heat Treat Spec H2S) or Custom 450 stainless steel with a hardnessof 30-34 HRC (Heat Treat Spec Z) or 17-4 PH (Spec 246-A) stainless steel with ahardness of 28-33 HRC (Heat Treat Spec ZA). The reduced hardness 4140 materialwill have lower mechanical properties and for some Superior compressors willrequire deration of the rod load capacity of the machine as detailed in Ajax-Superior Engineering Standard ES11 (contact Superior Marketing). Using theCustom 450 or 17-4 PH material will not require deration.

For Ajax cylinders deration is not necessary unless specified by Engineering.

Piston Rod Coating: Piston rods must be coated in the packing area. For Superiorrods tungsten carbide coating is used. For Ajax rods Colmonoy coating ortungsten carbide coatings are used.

4.2.11 Forged Steel Cylinders: Forged steel cylinder bodies made of AISI 1045, 4140, orlow alloy steel are to have a maximum hardness of 235 HB. Engineering willevaluate these applications on an individual basis as some cylinder pressureratings may have to be reduced because of the mechanical properties restrictions.

4.2.12 Piping and Vessels: All process piping, pulsation drums, scrubbers and coolerswill comply with NACE MR0175 and shall have a minimum 1/16" corrosion

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allowance. This requirement is the packager’s responsibility.

Sections 6.0 and 7.0 define Ajax Packaging requirements in this level.

4.2.13 Instrumentation: All instrumentation that comes in contact with the processstream (liquid level controls, shutdowns, bourdon tubes, process valving, reliefvalves, etc.) shall be suitable for corrosion gas service (i.e., plated fittings areacceptable). This requirement is the packager’s responsibility.


4.3 Level 2-11P Trim (>5% H2S)

4.3.1 Concentrations of H2S greater than 5% by volume.

4.3.2 All of the special requirements already discussed in Level 1-11P apply plus theadditional requirements listed in Section 4.3.

4.3.3 Compressor Valves: Valve seats, guards, and valve bolts made of carbon steel orAISI 4140 alloy steel shall have a maximum hardness of 22HRC (Heat Treat SpecH2S). This may reduce the pressure differential capability of specific valvedesigns and thus the pressure differential capability of the cylinders.Engineering will evaluate these on an individual basis and select appropriatealternative valve designs to meet the application requirements.

For Superior compressor valves free-machining carbon or alloy steel materialshall not be used for this level H2S.

For Ajax compressor valves, free machining material shall be used unless H2Slevels warrant special engineering selections.

This reduced hardness requirement also includes steel valve cages (retainers)when they are used.

Compressor valve components may also be made of AISI 416 stainless steel witha maximum hardness of 22HRC.

4.3.4 Compressor Valve Plates: Valve plates wherever possible are to be plastic tobetter prevent seat wear against the softer valve seats. For discharge temperaturesto 280°F., thermoplastic plates (Spec 484A) can be used; for higher dischargetemperatures, PEEK (Spec 490) material can be used as the non-metallic plate.

When metallic plates are required Inconel X-750 (Spec 241) will be used.

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4.3.5 Compressor Valve Springs: The standard 17-7PH valve spring material will be used.

4.3.6 Distance Piece: For Ajax and Superior model compressors, two-compartmentconfiguration is required with pressure packing located between the distancepiece and the compressor frame. This means an auxiliary distance piece must beadded to the standard crosshead guide/distance piece. The outer compartmentmust be purged with inert gas to a pressure of 3-5" H2O (see Section 4.3.10). Theinner compartment can either be separately vented or purged with inert gas to apressure of 3-5" H2O.

The packing case is to be tubed to an external point on the distance piece forthese models.

For RAM compressors, purging is required for the auxiliary distance piece.

4.3.7 Compressor Fasteners: All compressor cylinder and distance piece critical bolting,capscrews, studs, and nuts which come in contact with the process gas stream shallconform to ASTM A193-B7M (bolts and studs) and ASTM A194-2HM (nuts).

4.3.8 Piping and Vessels: Unless otherwise specified by the purchaser, all process piping,pulsation drums, scrubbers, and cooler headers will be 100% radiographed and postheat-treated and shall have a minimum 1/8" corrosion allowance. Threadedconnections over 3/4" are not allowed. 100% ASME inspection criteria are to beused. This requirement is the packager’s responsibility.

Sections 6.0 and 7.0 define Ajax Packaging requirements in this level. Also, forAjax Packaging, threaded connections up to and including one inch will bespecified; all connections above this shall be flanged.

4.3.9 Instrumentation: All instrumentation that comes in contact with the processstream (liquid level controls, shutdowns, bourdon tubes, process valving, reliefvalves, etc.) shall meet the full requirements of NACE MR0125 except thatstainless steel tubing fittings are required. This requirement is the packager’sresponsibility.


4.3.10 Purge Systems: The distance piece shall be purged with inert gas. The packager isresponsible for purging per these requirements. If other venting or purgingsystems are desired, the details are to be negotiated between the purchaser andthe packager (i.e. vacuum systems, or sweet natural gas purge). The final detailedsystem should provide for the safety of persons around the equipment and

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should prevent contamination of the frame oil with sour gas. Packing cases willnot be purged unless required by the customer.

4.3.11 Cooler Tubes: The gas cooler tubes shall be furnished in 304 or 316 stainlesssteel. This requirement is the packager’s responsibility.


5.0 Enhanced H2S Trim Requirements5.1 These sections cover H2S trim requirements based on guidelines established by NACE

MR0175. These sections specify more rigid H2S trim levels than required for standardAPI 11P trim.

5.2 When a customer requires H2S trim in excess of API 11P for requirements meetingNACE, the Ajax and Superior equipment will be trimmed using the guidelines knownas Class IV and described in the remaining sections.

5.3 This enhanced level of trim can be used for any concentration of H2S as required bythe customer. Trimming to this level may be required for even very lowconcentrations of H2S (500 ppm) if regulations controlling the equipment requirestrict adherence to NACE MR0175.

5.4 Class IV H2S Trim

5.4.1 A suitable corrosion inhibitor should be added to the cylinder lubricating oil asdefined by the user’s oil manufacturer.

5.4.2 All the special requirements specified and recommended in Section 4.1 of thisstandard should be followed.

5.4.3 The cylinders are to be equipped with a suction flushing system (injection ofcylinder lubricating oil into the suction nozzle of each cylinder).

5.4.4 Two-compartment distance pieces are required. The outer compartment must bepurged with inert gas to a pressure of 3-5" H2O (See Section 5.4.16). The innercompartment can either be separately vented as described previously or purgedwith inert gas to a pressure of 3-5" H2O.

5.4.5 For Superior model compressors, oil slingers are to be used where adequate spaceis available on each compressor rod in the distance piece compartment to insure

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that none of the H2S contaminated cylinder or packing lubricant works its wayback into the crankcase and contaminates the frame lubricating system.

For Ajax model compressors, oil slingers are not required but can be added as anoption.

5.4.6 Compressor valve springs are to be Inconel.

5.4.7 Packing garter springs are to be Inconel.

5.4.8 Piston Rod: The piston rods are to be either AISI 4140 alloy steel with a hardnessof 15-22 HRC (Heat Treat Spec H2S) or Custom 450 stainless steel with a hardnessof 30-34 HRC (Heat Treat Spec Z), or 17-4PH (Spec 246-A) stainless steel with ahardness of 28-33 HRC (Heat Treat Spec ZA). The reduced hardness 4140 materialwill have lower mechanical properties and for some Superior compressors willrequire deration of the rod load capacity of the machine as detailed in Ajax-Superior Engineering Standard ES11. Using the Custom 450 or 17-4PH materialwill not require deration.

For Ajax cylinders deration is also not necessary unless specified by Engineering.

Tungsten carbide coating is required in the packing travel area of the Superiorpiston rods. For Ajax rods, Colmonoy coating or tungsten carbide coatings are used.

5.4.9 Compressor Valves: The valve seats, guards, and valve bolts are to be made ofcarbon steel or AISI 4140 alloy steel with a hardness of 22 HRC maximum (HeatTreat Spec H2S). This may reduce the pressure differential capability of thecylinders. Engineering will evaluate these on an individual basis and selectappropriate alternative valve designs to meet the application requirements.

For Superior and for Ajax guards and seats in this classification, free machiningcarbon or alloy steel shall not be used.

Compressor valve components may also be made of AISI 416 stainless steel witha maximum hardness of 22 HRC.

This reduced hardness requirement also includes steel valve cages (retainers)when they are used.

5.4.10 Forged Steel Cylinders: Forged steel cylinder bodies are to be made of AISI 1045,4140, or low alloy steel with a maximum hardness of 235 HB. Engineering willevaluate these applications on an individual basis as some cylinder pressureratings may have to be reduced.

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5.4.11 Carbon Steel Parts: All steel gas wetted parts are to have a maximum hardness of22 HRC. This is to include all internal fasteners and V.V. pocket screws, and alsoincludes compressor valve assembly fasteners.

5.4.12 Compressor Valve Plates: Valve plates, wherever possible, are to be plastic tobetter prevent seat wear against the softer valve seats. For Superior compressorswith discharge temperatures to 280°F, thermoplastic plates (Spec. 484A) can beused; for higher discharge temperatures, PEEK (Spec. 490) material shall be usedas the non-metal plate.

For all RAM and Ajax cylinders, Peek material shall be used at all temperatures.

When metal plates are required, Inconel X-750 (Spec. 241) shall be used.

5.4.13 Compressor Fasteners: All compressor cylinder and distance piece critical bolting,capscrews, studs, or nuts which come in contact with the process gas stream shallconform to ASTM A193-B7M (bolts and studs) and ASTM A194-2HM (nuts).

5.4.14 Piping and Vessels: Unless otherwise specified by the purchaser, all processpiping, pulsation drums, scrubbers and cooler headers will be 100% radiographedand post heat-treated and shall have a minimum 1/8" corrosion allowance.Threaded connections over 3/4" are not allowed. 100% ASME inspection criteriaare to be used. This requirement is the packager’s responsibility.

Section 7.4 defines the Ajax Packaging requirements in this level. Also, for AjaxPackaging, threaded connections up to and including one inch will be specified;all connections above this shall be flanged.

5.4.15 Instrumentation: All instrumentation that comes in contact with the processstream (liquid level controls, shutdowns, bourdon tubes, process valving, reliefvalves, etc.) shall meet the full requirements of NACE MR0175 except wherestainless steel tubing fittings are required. This requirement is the packager’sresponsibility.

Section 7.4 defines the Ajax Packaging requirements in this level.

5.4.16 Purge Systems: The distance piece shall be purged with inert gas. The packager isresponsible for purging per these requirements. If other venting or purgingsystems are desired, the details are to be negotiated between the purchaser andthe packager (i.e., vacuum systems, or sweet natural gas purge). The final detailedsystem should provide for the safety of persons around the equipment andshould prevent contamination of the frame oil with sour gas. Packing cases will

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not be purged unless required by the customer.

5.4.17 Cooler Tubes: Gas cooler tubes shall be furnished in 304 or 316 stainless steel.This requirement is the packager’s responsibility.

6.0 Ajax Packaging Requirements For H2S Service(API 11P Guidelines)6.1 This section covers H2S trim requirements for the Packaging portion of the Ajax model

frame and compressor units. These requirements are based on the guidelines of API 11P.

6.2 For trace H2S (trace is defined as 0.005 mole % H2S or 50 ppm) up to and including 2%by volume:

6.2.1 All gaskets in the process gas wetted piping shall be stainless flexitallic (spiralwound AISI 316 stainless steel).

6.2.2 The distance piece(s) shall be vented to the skid edge.

6.2.3 Distance piece(s) shall have only steel access door covers.

6.2.4 Use H2S trim scrubber controls, including stainless steel float and body, forscrubber level switch, level controller, and automatic dump valve; stainless steelfor expanded metal in scrubbers; 304L mesh; and stainless steel ball valve forscrubber manual drain.

6.2.5 Remove yellow metals from the instrument gas Meco regulator.

6.2.6 Use H2S trim manual blowdown valve including stainless steel valve body and ball.

6.2.7 Provide tinnized wiring in the panel (this is standard release for panel wiring).

6.2.8 Provide Altronic PHL or Murphy environmentally sealed pressure gauges withstainless steel movement and bourdon tube.

6.3 For H2S concentrations from greater than 2% up to and including 5% by volume:

6.3.1 Include all of the special requirements already discussed in Section 6.2.

6.3.2 Corrosion allowance for the process gas piping, pulsation bottles, scrubbers, andcooler gas headers shall be 1/8".

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6.3.3 Provide H2S trim for instrument panel.

6.3.4 Provide H2S trimmed process gas relief valves.

6.3.5 Provide two (2) compartment lubricators with additional day tank and levelswitch.

6.4 For H2S concentrations greater than 5% by volume:

6.4.1 Include all special requirements already discussed in Sections 6.2 and 6.3.

6.4.2 Piping and vessels: Unless otherwise specified by the purchaser, the followingare required:

a. 100% radiography of process gas pressure vessel butt and seam welds.

b. 100% radiography of butt welds in gas piping.

c. All vessels and gas piping shall be stress relieved.

d. All cooler gas section headers shall be stress relieved.

e. Magnetic particle test all flanged connections in pressure vessels perANSI B31.3.

f. Magnetic particle test threaded connections (couplings, etc.) in pressurevessels and process gas piping per ANSI B31.3.

6.4.3 Use 316 stainless steel in place of plated steel fittings for panel instrument andlubrication tubing.

6.4.4 Use 304 or 316 stainless steel for gas cooler tubes and use shoulder plug design.

6.4.5 Use 316 stainless steel in place of carbon steel for panel pulsation dampeners.

6.4.6 Compressor packing vent to be tubed to the edge of the skid.

6.4.7 Provide NACE trimmed instrumentation and process valves for parts coming incontact with the process stream.

6.5 Fuel Gas Packaging:

6.5.1 It is not the intent of this standard to specify allowable levels of H2S in the fuelgas. However, if H2S is present in the fuel gas or starting gas above a trace amount(50 ppm), then special piping and packaging will be necessary to properly handlethe gas. These special requirements for Ajax Packaging are listed in this section.

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6.5.2 Provide H2S trimmed fuel gas relief valve.

6.5.3 Use carbon steel for the fuel gas block valve body and ball.

6.5.4 Use carbon steel for the starting gas block valve body and ball.

7.0 Enhanced Ajax Packaging Requirements ForH2S Service (Special Customer Requirements)

7.1 This section covers H2S trim requirements for the Packaging portion of the Ajax modelframes and compressors when special customer requirements or stricter adherence toNACE MR0175 are necessary.

7.2 H2S concentration of trace or above (trace is defined as 0.005 mole % H2S or 50 ppm):

7.2.1 Piping and Vessels: Unless otherwise specified by the purchaser, the following arerequired whenever there is a trace or above concentration of H2S. Thisrequirement exceeds the requirement of API 11-P.

a. 100% radiography of process gas pressure vessel butt and seam welds.

b. 100% radiography of butt welds in gas piping.

c. 100% radiography of cooler gas header welds.

d. All vessels and gas piping shall be stress relieved.

e. All cooler gas section headers shall be stress relieved.

7.2.2 All gaskets in the process gas wetted piping shall be stainless flexitallic (spiralwound AISI 316 stainless).

7.2.3 Scrubbers used for H2S service should have 304L mesh which is normallystandard.

7.2.4 Use stainless steel ball valve for scrubber manual drain which is normallystandard.

7.2.5 All process gas wetted instrumentation to be suitable for H2S service with allyellow metal removed.

7.2.6 Remove yellow metals from the level controllers and dump valves.

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7.2.7 Remove yellow metals from the instrument gas Meco regulator.

7.2.8 Provide Altronic PHL or Murphy environmentally sealed pressure gauges withstainless steel movement and bourdon tube.

7.2.9 Provide tinnized wiring in the panel (this is standard release for panel wiring).

7.2.10 Use carbon steel in place of bronze valves in the jacket water system.

7.2.11 Provide two-compartment lubricator with additional day tank and level switch.

7.3 H2S concentration > 0.5%:

7.3.1 Include all the special trim as specified in Section 7.2.

7.3.2 Corrosion allowance for the process gas piping, pulsation bottles, scrubbers, andcooler headers, shall be 1/8".

7.3.3 Magnetic particle test of flanged connections in pressure vessels is to beperformed per ANSI B31.3.

7.3.4 Magnetic particle test of threaded connections (couplings, etc.) in pressure vesselsand process gas piping is to be performed per ANSI B31.3.

7.3.5 Use 304 stainless steel or SA 179 seamless carbon steel tubes for cooler gassections.

7.3.6 Use stainless steel in place of carbon steel for expanded metal in scrubbers.

7.3.7 Use stainless steel float for scrubber level switch.

7.3.8 Use stainless steel body for scrubber level switch, level controller, and usestainless steel automatic dump valve.

7.3.9 Use stainless steel in place of carbon steel for the blowdown valve body and ball.

7.3.10 Provide NACE trimmed process gas relief valves.

7.3.11 Use 316 stainless steel in place of carbon steel for panel pulsation dampeners.

7.3.12 Remove all yellow metals from all components including external and non-gaswetted components (i.e., drains, valves, cooling systems, etc.)

22



ES 13

7.4 H2S concentration > 5%:

7.4.1 Include all the special trim as specified in Sections 7.2 and 7.3.

7.4.2 Pressure vessel design criteria will include full couplings.

7.4.3 Pressure vessel design criteria will include reinforcement pads on all flangedconnections.

7.4.4 Use 316 stainless steel in place of plated steel fittings for panel instrument andlubrication tubing.

7.4.5 Corrosion test connections (couplings) are to be fabricated in the cold sidedischarge piping.

7.4.6 Use 304 or 316 stainless steel for gas cooler tubes and use shoulder plug design.

7.5 Fuel Gas Packaging:

7.5.1 It is not the intent of this standard to specify allowable levels of H2S in the fuelgas. However, if H2S is present in the fuel gas or starting gas above a trace amount(50 ppm), then special piping and packaging will be necessary to properly handlethe gas. These special requirements for Ajax Packaging are listed in this section.

7.5.2 Use carbon steel in place of ductile iron for Fisher fuel gas regulator.

7.5.3 Provide NACE trimmed fuel gas relief valve.

7.5.4 Use stainless steel for the fuel gas block valve body and ball.

7.5.5 Use stainless steel for the starting gas block valve body and ball.

23



ES 14

ES 14Trimming Compressors for CarbonDioxide/Natural Gas Applications inLubricated Service1.0 Scope

1.1 This specification is to be used as a guide in trimming CES Superior manufacturedcompressors for the compression of gas having various percentages of carbondioxide (CO2).

1.2 These guidelines apply only to lubricated compressor units; requirements will bedifferent on a non-lube compressor and will be decided on an individual basis.

1.3 This specification follows the guidelines established in the latest edition of APISpecification 11P. Where this specification deviates from 11P it will be noted. Some ofthe wording and graph data is taken directly from this API publication.

Special trimming and materials other than those specified in this specification willbe negotiated on an individual basis in order to meet a customer’s specificrequirements.

1.4 Figure 1 in this specification shows the pressure and CO2 concentration parameterswhere special trimming is required.

2.0 Purpose2.1 Carbon dioxide is soluble to some degree in water and will form a weak carbonic

acid solution. The solubility of CO2 in water increases with increasing pressure anddecreases with increasing temperature. Water droplets are normally present in gasstreams handled by Ajax-Superior equipment, and even when separation anddehydration equipment is used it is subject to system upsets. Therefore, this

24



specification is written to limit the susceptibility of this equipment to potentialcarbonic acid corrosion. (See Section 5.2 below).

2.2 Carbonic acid is a fairly weak acid; therefore, general corrosion is normally not aproblem on compressor materials except as concentrations increase. The realproblem is in the areas that see higher gas velocities (i.e. valves around piston rodseals, etc.) where erosion of the protective film occurs and accelerates the corrosion.

3.0 Responsibilities3.1 Marketing’s responsibility:

3.1.1 To acquire reliable gas analysis and to identify, to both Engineering and thecustomer, gas concentrations requiring special trim as early as possible(hopefully in the pre-quotation stage).

3.1.2 To be familiar with the various requirements set herein.

3.1.3 To price all units requiring the special trim appropriately.

3.1.4 To educate the involved customers and end-users on their responsibilityconcerning the maintenance and operational procedures to be used for CO2

compression.

3.2 Engineering’s responsibility:

3.2.1 To define and specify properly-designed components in accordance with theguidelines set herein.

3.2.2 To review all CO2 applications forwarded by Marketing and assist them, asrequired, in tailoring individual applications to requirements.

3.2.3 To set the standards for design and proper maintenanace, and to keep themupdated as the “state of the art” advances.

3.2.4 To assure that copies of this standard, as well as Engineering Standard ES 1002,are properly distributed in instruction manuals for CO2 units.

3.3 Responsibility of the customer:

ES 14

25



ES 14

3.3.1 To maintain the CO2 compressors in accordance with the standards setherein.

4.0 Lubrication of Units4.1 We recommend that, because of the dilution effect of CO2, an inhibited oil with a

viscosity one grade heavier than standard be used. These recommendations arefound in Engineering Standard ES1002.

5.0 Gas Concentration Levels Requiring Special Trim5.1 For lubricated compression units operating below 400 psig suction pressure or with

pressure/CO2 concentration parameters to the left of the curve in Figure 1, no specialtrim is required. All metal gaskets should be soft iron or aluminum and o-ringsshould be nitrile, neoprene, or viton, depending on operating temperatures.

5.2 Corrosion will not be a problem in dry CO2; therefoe, if the customer can guaranteethat his dehydration equipment will absolutely prevent moisture dropoutanywhere in the equipment downstream of the dehydration process, then specialtrim will not be required. This guarantee of bone-dry gas should be in writing andfiled in the sales packet.

5.3 For non-lubricated compression jobs, special trim will be required for any CO2

concentration above 2%.

5.4 In the actual application of this standard, lubricated units having CO2 levels fallingto the left of the curve in Figure 1 should be judged on an individual basis. If the gas isknown to be extremely dirty, or if customer maintenance is known from pastexperience to be poor, or if the unit is designed to operate with more than normalstops and starts or complex unloading, then special trim may be necessary at lowerCO2 concentrations and pressures.

6.0 Trimming for Carbon Dioxide6.1 Valve Body and Bolts: valve seats and guards and center bolt shall be AISI 416

stainless steel at standard hardness levels (Superior Specification 251 Heat Treat WA).This section meets exactly the API 11P requirements.

26



6.2 Valve Springs: springs shall be the Superior standard 17-7PH stainless steel.

6.3 Valve Plates: plates shall be either plastic or Superior’s standard AISI 410 (SuperiorSpecification 243). This meets 11P requirements.

6.4 Piston Rods: the standard shall be AISI 4140 rods at the standard hardness and withtungsten carbide coating. An alternative to this is AISI 416 stainless steel inductionhardened in the packing travel area. The 11P specification calls for a maximumhardness of 22 HRC; we do not feel this is necessary if H2S is not present.

6.5 Valve cap and seat gaskets are to be aluminum or soft iron. The 11P specificationstates gaskets are to be soft iron, but under typical CO2 conditions aluminumgaskets, where required, are not sensitive to the environment.

6.6 Unloader Parts: it is recommended that unloader valves be Armoloy-plated on thestems in the bushing and seal travel area. This is not required by 11P but we havefound it beneficial in supplying a reliable product. Stainless steel valves can also beused instead of plating.

6.7 All other compressor cylinder components can be standard material.

7.0 Lubricated Sour Gas Compressors WithCarbon Dioxide7.1 For carbon dioxide concentrations less than 5%, Engineering Standard ES 13 should be

used for the trimming of units handling sour (hydrogen sulfide) gas and CO2.

7.2 Sour gas units having greater than 2% H2S and greater than 5% CO2 should betrimmed per ES 13 Level 2-11P or Class IV with the following additional inclusions(the attached curve should not be followed):

7.2.1 Valve Body and Bolts: where H2S levels are such that reduced hardness valvesare required, valve seats and guards and center bolt shall be made from AISI416 stainless steel and reduced in hardness to 22 HRC maximum (SuperiorSpecification 251 Heat Treat WD).

7.2.2 Valve Plates: plates shall be either plastic or Inconel X-750 (SuperiorSpecification 241) for all levels of H2S above 2%.

ES 14

27



7.2.3 Unloader Parts: unloader valves should be reduced in hardness to 22 HRCmaximum (ES 13) and then Armoloy plated on the stems in the bushing orseal travel area.

Unloader valves can also be stainless steel with a hardness of 22HRCmaximum.

Figure I – Trimming Curve for CO2 Concentrations(Lubricated Units with < 2% H2S)

ES 14

5 10 20 30 40 50 60 70 80 90 100

Percent CO

0

300

600

900

1200Suction Pressure

Special trim required

Special trim not required

2

28



ES 19Compressor Frame and CylinderAssembly Criteria

1.0 ScopeThis standard lists the assembly criteria for the MW, SW, W7, WH, MH, RAM and JOY framesand cylinders, along with the RAM, JOY, Superior (traditional and WH), Ajax, and pipelinecylinders.

2.0 PurposeThis standard defines the assembly criteria that establish a machine to be an acceptableproduct to be shipped to the customer.

3.0 ProceduresMachines are to be assembled and tested using the following:

3.1 Torque Table (pages 3 and 4).

3.2 Clearance Table (page 8).

3.3 Pressure testing of components.

3.3.1 Hydrotests are performed on all cylinder bodies, heads, bonnets, and valve coversper Engineering Standard ES 5011. Test procedures are determined fromindividual part drawings.

3.3.2 Helium tests are performed per ES 5011 when required by the sales release or forgases with molecular weights below 12.

3.4 Valve leak testing is done per ES 4023.

3.5 Assembly inspections are performed per General Operating Procedure 10.1003;included in this standard are the following:

3.5.1 Frame bar over test per ES 5029.

3.5.2 Recording of torques and clearances per Form SI-418, SI-400, SI-461, SI-402, and SI-468 found in Procedure 10.1003.

Page 1 of 9

29



3.5.3 Recording reciprocating part weights per Form SI-417 found in Procedure 10.1003.See Section 3.6 of this procedure (ES 19) for balancing details.

3.5.4 Completion of inspection checklists per Form SI-415 and SI-419 found inProcedure 10.1003.

3.5.5 Air testing of all assembled cylinder bodies to make sure all seals are not leakingper Testing Standard 35.0903.

3.5.6 Pneumatically operated valve or head unloaders are bench-tested to make surethey operate properly per ES 4024.

3.6 Frame/Cylinder Balancing

3.6.1 Unless specified differently on the sales release, opposing throws are to bebalanced to within three pounds.

3.6.2 Opposing connecting rods are to be balanced to within one pound.

3.6.3 Actual weights of moving components are to be recorded on Form SI 417. Partsare to be weighed to the nearest one-tenth of a pound.

3.6.4 Parts to be weighed are the connecting rod, piston/rod, crosshead, and balanceweights.

3.6.5 Piston/Rod weight is to include (stamp total weight on end of piston):

• Piston• Rod• Any fasteners holding the piston to the rod• Ring carrier, where applicable• Piston rings and riders

For RAM only cylinders, the weight also includes the nut on the crosshead endof the rod.

3.6.6 Crosshead weight is to include (stamp total weight on crosshead):

• Crosshead• Crosshead shoes• Crosshead shoe fasteners

Page 2 of 9

30



3.6.7 Connecting rod weight is to include (stamp total weight on conn rod so it can beseen from top of frame):

• Connecting rod

(The connecting rod weight does not include the bearing shells or thecrosshead pin).

3.6.8 Balancing Weights:

Balancing weights are chosen to give the required total weight. On RAM units,the balancing is done with bolt-on weights.

3.7 Special Testing: occasionally, special tests or inspections are required by customers andshall be specified in the Sales Release. Special tests or inspections required byEngineering are documented on Form 60.04-17, Compressor Frame and Cylinder SpecialTest/Inspection Requirements (page 9).

3.8 Unless otherwise stated on the Sales Release, all units are to be protected in accordancewith ES 5 for North American shipments. Exported equipment is to be protected perES 7.

Recommended Torques (Foot/Pounds) - Compressors

W7 SW MW WH MH RAM

Connecting 1-1/8"-12 UNF nut 1"-14 UNS nut 1"-14 UNS nut 1"-8 UNJ bolt 1"-8 UNJ bolt 1"-14 UNS boltRod 430-460 320-330 250-260 500 430-450 460

Main Bearing 1-1/8"-12 UNF nut 3/4"-10 UNC nut 3/4"-10 UNC nut 3/4"-10 UNC nut 3/4"-10 UNC nut 1"-8 UNC boltCap 430-460 180-200 180-200 185-200 185-200 350

Base Spacer 1-1/4"-12 UNF 1-1/8"-12 UNF 1-1/8"-12 UNF 1-1/8"-7 bolt 1-1/8"-7 bolt 7/8"-9 UNC boltBolt/Nut 640-700 380-410 380-410 380-400 380-400 300

Crosshead Pin 3/4"-16 UNF UNF 3/4"-16 UNF N/A N/A N/ANut 105-115 105-115 105-115

Soc. Head Cap- 5/8"-11 UNC Allen Screw Allen Screw 5/8"-11 5/8"-11 3/4-10screws Allen Soc. HeadScrews-Rod 60-70 Grade 5 60-65 60-65 60-70 60-70 120-140Packing

Crosshead 1-1/2"-20 UNF- Flat Head Flat Head 3/8"-16 UNC 1/2"-20 UNF 1/2"-20 UNFShoe Flat Head Capscrew

35-45 25-30 25-30 18-20 30-35 20-25

Balance Weight N/A N/A N/A N/A N/A 5/8"-11 UNCCapscrew 62

Page 3 of 9

31



W7 SW MW WH MH RAM

Balance Nut 2-1/2"-10 UN 2-1/2"-10 UNS 2-1/4"-8 UN 2-1/2"-10 UNS 2-1/2"-10 UNS 2"-8 UNor Crosshead 2650-3250 2650-3250 1500-2000 2650-3250 1900-2300 1100Jam Nut

Piston-to- 2"-8 UNF 2"-12 UN 2"-12 UN 7/8"-9 UNRC 7/8"-9 UNRC 1-1/2"-12 UNPiston Rod 1180-1265 1760-2150 1760-2150 Capscrew Capscrew 1100Nut (for thru rod) 200-220 200-220

For Multi-bolt, 2"-8 UN 2"-8 UN see misc. fasteners. 1500-1600 1500-1600

(for Thru Rod) (for Thru Rod)

Crankshaft N/A N/A N/A N/A N/A 5/16"-18 UNCDrive Gear 15Capscrew

Cyl/Crosshead 7/8"-9 UNC 7/8"-9 UNC 7/8"-9 UNC 7/8"-9 UNC 7/8"-9 UNC 7/8"-9 UNCGuide Capscrew 200 200 200 200-220 200-220 200

Valve Caps See Note 1 See Note 1 See Note 1 See Table for See Table for See Misc.Valve Caps Valve Caps Nuts

RAM Cylinder N/A N/A N/A N/A N/A See TableHalf Bolting For RAM

Half Bolting

WH6 Cylinder N/A N/A See Table for See Table for N/AHalf Bolting WH6 Half WH6 Half

Bolting Bolting

Valve Size Center Bolt Hoerbiger Spiralock

2.375" 3-53.25" 3-5

4.00" Slotted Seat 13-15 5/16"-24 22-26Center Bolt 4.00" Drilled Seat 29-32 3/8"-24 41-45Torque 5.25" 13-15 7/16"-20 58-62All Models 5.75" 18-20

7.00" 18-208.00" 18-209.125" 18-20

Coupling Hub 3"-12UNLockout for 25-50 ft.-lbsTapered Shafts

Set Screw Size 5/8"-18 UNF Torque perMisc. Fasteners

Page 4 of 9

32



RAM Cylinder Half BoltingCylinder Size (in) Class Fastener Size Torque

15.50 417CC 7/8" - 8 300 ft-lbs16.00 418CC 7/8" - 8 300 ft-lbs17.50 419CC 1" - 8 375 ft-lbs18.00 420CC 1" - 8 375 ft-lbs19.50 421CC 1" - 8 375 ft-lbs20.00 422CC 1" - 8 375 ft-lbs

Torques based on lubricated threads and S.A.E. grade fasteners or better

WH Cylinder Half BoltingCylinder Size (in) Class Fastener Size Torque

117"/18" RD-#645/646 1-1/8" - 7 590-61019"/20" SD-#648/649 1" - 8 see Misc. Fastener table22-1/2, 23-1/2, 25-1/2, 26-1/2" TD-#650/651/652/653 1" - 8 see Misc. Fastener table

Model Bolt Size Torque

500 3/4" - 16 260 ft-lbsThomas 550 7/8" - 14 350 ft-lbsFlex 600 1" - 14 335 ft-lbs*Coupling 700 1-1/8" - 12 425 ft-lbs*(coupling to hub 750 1-1/4" - 12 560 ft-lbs*bolting.) 800 1-3/8" - 12 740 ft-lbs*

850 1-1/2" - 12 950 ft-lbs*

* These nuts are cadmium plated.

RAM Coupling Special Torque Values Adapter to Hub Bolting 1" - 8 bolt 600 ft-lbs torque

Page 5 of 9

33



Miscellaneous Fastener Torques

Size Torque (ft-lbs)1/4" 4 - 6

Miscellaneous Fastener Size 3/8" 12 - 18

(all models unless detailed 1/2" 35 - 45

otherwise under particular 5/8" 60 - 70

applications) 3/4" 120 -140

7/8" 200 - 220

1" 260 -290

1-1/8" 370 -410

1-1/4" 520 -570

1-3/8" 700 - 770

1-3/4" Jackscrew 930 - 1030

(2500# Cylinder) 850 - 900

WH/MH Valve Cap Special Torque Values

Cylinder Number Cylinder Diameter Valve Cap Nut Torque (ft-lbs)615 6.00" 370

616 6-1/4" 370

617 6-3/4" 370

618 5-3/4" 300

619 6-1/4" 300

620 6-3/4" 300

621 7-1/4" 300

Notes:

1. On the W7, SW, and MW cylinders, torque valve cap nuts on 3-3/4" and smaller diameter cylindersor cylinders with working pressure of 4,000 psi or greater to 300 ft-lbs (all others use miscellaneousfastener table).

2. On the W7, SW, and MW, each crosshead pin to be checked two (2) hours after first being placed inservice, re-torquing bolt nut to 105 - 115 ft/lb. This procedure to again be followed at the end of one (1)week's service, at which time each pin should be in a stable and permanent position.

3. Torque figures are for threads lubricated with lubriplate or petroleum-based oil. Do not use anycompounds containing molybdenum disulfide as a thread lubricant.

Page 6 of 9

34



Joy Compressor - Recommended Torques (ft-lbs) - Model (WBF)

DescriptionConnecting Rod Nut 1-1/8" - 12 NF 380-400 ft/lbs

Main Bearing Cap Nuts 3/4" - 10 UNC 200 ft/lbs

Piston Rod Packing Nut 5/8" -11 UNC 75 ft/lbs

Crosshead Nut 2" - 12 UN 900 ft/lbs

Piston Nut 1-3/4" - 12 UN 700 ft/lbs

5/8" - 11 UNC Hex Hd. Grade 2 75

3/4" - 1- UNC Hex Hd. Grade 2 100

3/4" - 10 NC Stud 160

Valve Caps 7/8" - 9 NC Stud Grade B7 250

1" - 8 NC Stud Grade B7 360

1-1/8" - 7 NC Stud Grade B7 500

1-3/8" - 8 NC Stud Grade B7 700

5/8" - 11 UNC Hex Hd. Grade 2 75

5/8" - 11 UNC Soc. Hd. (1960 Series) 135

3/4" - 10 UNC Soc. Hd. (1960 Series) 250

7/8" - 9 UNC Soc. Hd. (1960 series) 330

1" - 8 UNC Soc. Hd. (1960 Series) 550

Head Bolts for Gas Compressors 3/4" - 10 UNC Ferry Capscrew 250

3/4" - 10 NC Stud Grade B7 200



3/4" - 10 UNC Soc. Hd. (1936 Series) 120

7/8" - 9 UNC Soc. Hd. (1936 Series) 190

3/4" - 10 NC Stud Grade 2 120

Other Fastener Application 7/8" - 9 NC Stud Grade 2 110

Distance Piece to Frames 1" - 8 NC Stud Grade 2 160

Clearance Pockets, Caps, etc. 3/4" - 10 NC Stud Grade B7 200



Use W7, SW, etc., table of Miscellaneous Size Fasteners for torque value of any item not listed here.

#10 - 32 UNF 36 (in-lb)

1/4" - 28 UNF 86 (in-lb)

5/16" - 24 UNF 14 (in-lb)

Valve Center Bolt 3/8" - 24 UNF 25 (in-lb)

7/16" - 20 UNF 40 (in-lb)

1/2" - 20 UNF 65 (in-lb)

9/16" - 18 UNF 90 (in-lb)

5/8" - 18 UNF 130 (in-lb)

Page 7 of 9

35



Running Clearances

ssalCrosserpmoCyoJ

noitpircseD 7W WS/WM 6HM 6HW MAR DHX27 DHX47 DHX67

tsurhTtfahsknarC 710./210. 220./110. 220./110. 220./110. 410./600. 550./040. 820./110. 240./620.

gniraeBniaM /400.4900.

/400.4800.

/400.4800.

/400.4800. 800./400. 600./300. 600./300. 600./300.

doRgnitcennoCtsurhT +130./610. 720./410.

+130./610. 920./710. 720./410. 230./810. 220./810. 220./810. 220./810.

doRgnitcennoCgniraeB

/400.4900.

/400.4800.

/400.4900.

/400.4800. 800./400. /300.

8600./300.8600.

/300.8600.

otniPdaehssorCgnihsuB 600./300. 600./300. 400./300. /300.

5600./300.5400. 600./500. 600./500. 600./500.

ediuGotdaehssorC 510./010. 510./010. 020./110. 020./800. 410./800. 210./700. 210./700. 210./700.

otniPdaehssorCdaehssorC * * /5100.

300./5100.5300.

/5100.5300.

/3000.0100.

/300.0100.

/300.0100.

gnihsuBniPdaehssorCtiFecnerefretnI

/5200.400.

/5200.400. 800./400. 800./400. /5300.

0600. 700./400. 700./400. 700./400.

butS-raeGevirDtiFecnerefretnItfahS

/5300.500.

/5300.500.

/5000.0200.

/5000.0200.

/5000.0200. A/N A/N A/N

evirDpmuPliOebuLhsalkcaBraeG 410./010. 700./500. 010./600. 010./600. 010./600. A/N A/N A/N

rotoRpmuPliOebuLpiT.xaMraeG

ecnaraelCA/N A/N A/N A/N A/N 400. 400. 400.

raeGpmuPliOebuLyalPdnE

27W700./400.

26WS/M700./400.

67/47800./500.

86/66/46800./500. 700./300. 700./300. retaL 010./400. 010./500. 010./500.

EHdnEnotsiPECecnaraelC

***080.***040.

***080.***040.

***080.***040.

***080.***040.

***080.***040.

***070.***060.

***070.***060.

***070.***060.

ecnarelotwolnomlifliorofnoisnemidtnirpmorfdewolla100.+

.tiflatem-ot-latemasihcussadnanipderepatsesU*

010.ebotsiecnaraelcdnedaeheht,revewoh;srednilycllaniseulavesehteveihcaotelbissopebtonyamtI**.ecnaraelcdneknarcehtnahtretaerg

3/1dedivideboterasecnaraelceht,revewoh;srednilycllaniseulavesehteveihcaotelbissopebtonyamtI***.dnedaehehtno3/2dnadneknarcehtno

Page 8 of 9

36



Compressor Frame and CylinderSpecial Test/Inspection Requirements

Register Number

Compressor Frame

Cylinder Class/Type

Customer

Date

Special Test and/or Inspection

Issued by Date(Engineering Representative)

Checked by Date(Engineering Representative)

Tests/Inspections successfully accomplished

Approved by(Test Supervisor)

Form No. 60.04-17

Page 9 of 9

37



ES 20Guard And Spring Reference List For RAM,WH, MH, & W7 Assemblies

1.0 ScopeThis list has been put together to allow for the identification of parts required to convertone valve assembly to another.

2.0 BackgroundFor any given size or type of valve listed, only two possible parts can change: the guard and/or the spring. In a lot of cases, only the spring changes. Guard assembly part numbers arelisted, but they differ from the guard in that they include one or two locating pins, PartNumber 757-135-001. Some guard assemblies use pins 757-135-004; these are marked by **.

3.0 ResponsibilitiesAfter using this chart to change over a valve assembly, the party making the change has tore-identify the assembly (stamp-over or cover the original assembly part number with Xsand re-mark the valve with the new assembly part number).

RAM Valve Assembly Guard and Spring Reference List Valve Assembly Guard Spring Spring Guard Assembly* Size Type Part No. Part No. Part No. Qty. Part No.

4" (S) 9OCFT 600-394 757-830-179 757-833-051 18 758-134-0864" (S) 9OCFT 600-389 757-830-179 757-833-050 18 758-134-0864" (S) 9OCFT 600-392 757-830-179 757-833-041 18 758-134-0864" (D) 9OCFT 600-395 757-830-180 757-833-050 18 758-134-0874" (D) 9OCFT 600-393 757-830-180 757-833-041 18 758-134-0874" (D) 9OCFT 600-390 757-830-180 757-833-003 18 758-134-087

4-7/8" (S) 116CGT 600-352 757-830-149 757-833-045 12 758-134-0514-7/8" (S) 116CGT 600-354 757-830-149 757-833-012 12 758-134-0514-7/8" (S) 116CGT 600-356 757-830-149 757-833-003 12 758-134-0514-7/8" (D) 116CGT 600-353 757-830-150 757-833-045 24 758-134-0524-7/8" (D) 116CGT 600-355 757-830-150 757-833-012 24 758-134-0524-7/8" (D) 116CGT 600-357 757-830-150 757-833-003 24 758-134-062

5-1/4" (S) 127CGT 600-287 757-830-109 757-833-008 13 758-134-0115-1/4" (S) 127CGT 600-289 757-830-110 757-833-044 13 758-134-0135-1/4" (S) 127CGT 600-291 757-830-110 757-833-045 13 758-134-0135-1/4" (S) 127CGT 600-408 757-830-110 757-833-012 13 758-134-0135-1/4" (D) 127CGT 600-288 757-830-111 757-833-008 26 758-134-0125-1/4" (D) 127CGT 600-290 757-830-112 757-833-044 26 758-134-0145-1/4" (D) 127CGT 600-292 757-830-112 757-833-045 26 758-134-0145-1/4" (D) 127CGT 600-409 757-830-112 757-833-012 26 758-134-014

S = Suction ValveD = Discharge Valve* Includes Locating Pin 757-135-001; quantity varies.

38



RAM Valve Assembly Guard and Spring Reference List Valve Assembly Guard Spring Spring Guard Assembly* Size Type Part No. Part No. Part No. Qty. Part No.

5-3/4" (S) 137CHT 600-181 757-830-100 757-833-017 14 758-134-0015-3/4" (S) 137CHT 600-285 757-830-105 757-833-008 28 758-134-0075-3/4" (S) 137CHT 600-295 757-830-114 757-833-044 28 758-134-1725-3/4" (S) 137CHT 600-297 757-830-114 757-833-045 28 758-134-1725-3/4" (S) 137CHT 600-410 757-830-114 757-833-012 28 768-134-1725-3/4" (D) 137CHT 600-182 757-830-098 757-833-017 28 758-134-0025-3/4" (D) 137CHT 600-286 757-830-106 757-833-044 28 758-134-0085-3/4" (D) 137CHT 600-296 757-830-106 757-833-045 28 758-134-0085-3/4" (D) 137CHT 600-298 757-830-106 757-833-012 28 758-134-0085-3/4" (D) 137CHT 600-411 757-830-106 757-833-003 28 758-134-008

6-1/2" (S) 158CJT 600-348 757-830-146 757-833-008 17 758-134-0496-1/2" (S) 158CJT 600-350 757-830-183 757-833-044 17 758-134-0956-1/2" (S) 158CJT 600-402 757-830-183 757-833-045 17 758-134-0956-1/2" (D) 158CJT 600-349 757-830-147 757-833-008 34 758-134-0506-1/2" (D) 158CJT 600-351 757-830-148 757-833-044 34 758-134-0966-1/2" (D) 158CJT 600-403 757-830-148 757-833-045 34 758-134-096

7" (S) 169CJT 600-183 757-830-097 757-833-008 18 758-134-0037" (S) 169CJT 600-299 757-830-115 757-833-044 18 758-134-0167" (S) 169CJT 600-406 757-830-115 757-833-045 18 758-134-0167" (D) 169CJT 600-184 757-830-099 757-833-008 18 758-134-0047" (D) 169CJT 600-300 757-830-116 757-833-044 36 758-134-1177" (D) 169CJT 600-407 757-830-116 757-833-045 36 758-134-117

8" (S) 190CKT 600-301 757-830-119 757-833-044 21 758-134-0208" (S) 190CKT 600-404 757-830-119 757-833-045 21 758-134-0208" (S) 190CKT 600-302 757-830-120 757-833-044 42 758-134-0218" (S) 190CKT 600-405 757-830-120 757-833-045 42 758-134-021

S = Suction ValveD = Discharge Valve* Includes Locating Pin 757-135-001; quantity varies.

Page 2 of 5

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WH Valve Assembly Guard and Spring Reference List Valve Assembly Guard Spring Spring Guard Assembly* Size Type Part No. Part No. Part No. Qty. Part No.

4-3/8" (D) 102CFT 625-015-001 757-830-200 757-833-044 20 758-134-1074-3/8" (D) 102CFT 625-015-002 757-830-200 757-833-045 20 758-134-1074-3/8" (D) 102CFT 625-015-003 757-830-200 757-833-012 20 758-134-1024-3/8" (S) 102CFT 625-016-001 757-830-198 757-833-008 20 758-134-1054-3/8" (S) 102CFT 625-016-002 757-830-199 757-833-044 20 758-134-1064-3/8" (S) 102CFT 625-016-003 757-830-099 757-833-045 20 758-134-106

5-1/4" (S) 116CGT 625-044-001 757-830-207 757-833-044 12 758-134-1145-1/4" (S) 116CGT 625-044-002 757-830-207 757-833-045 12 758-134-1145-1/4" (S) 116CGT 625-044-003 757-830-207 757-833-012 12 758-134-1145-1/4" (S) 116CGT 625-044-004 757-830-207 757-833-003 12 758-134-1145-1/4" (D) 116CGT 625-045-001 757-830-208 757-833-044 24 758-134-1155-1/4" (D) 116CGT 625-045-002 757-830-208 757-833-045 24 758-134-1155-1/4" (D) 116CGT 625-045-003 757-830-208 757-833-012 24 758-134-1155-1/4" (D) 116CGT 625-045-004 757-830-208 757-833-003 24 758-134-115

5-3/8" (S) 127CGT 625-046-001 757-830-209 757-833-008 13 758-134-1165-3/8" (S) 127CGT 625-046-002 757-830-209 757-833-017 13 758-134-1165-3/8" (S) 127CGT 625-046-003 757-830-211 757-833-012 13 758-134-1185-3/8" (S) 127CGT 625-046-004 757-830-211 757-833-003 13 758-134-1185-3/8" (S) 127CGT 625-046-005 757-830-213 757-833-012 26 758-134-1205-3/8" (D) 127CGT 625-047-001 757-830-210 757-833-008 26 758-134-1175-3/8" (D) 127CGT 625-047-002 757-830-210 757-833-017 26 758-134-1175-3/8" (D) 127CGT 625-047-003 757-830-212 757-833-045 26 758-134-1195-3/8" (D) 127CGT 625-047-004 757-830-212 757-833-012 26 758-134-1195-3/8" (D) 127CGT 625-047-005 757-830-212 757-833-003 26 758-134-119

5-7/8" (S) 137CHT 625-064-001 757-830-214 757-833-008 14 758-134-1215-7/8" (S) 137CHT 625-064-002 757-830-214 757-833-017 14 758-134-1215-7/8" (S) 137CHT 625-064-003 757-830-216 757-833-012 14 758-134-1235-7/8" (S) 137CHT 625-064-004 757-830-216 757-833-003 14 758-134-1235-7/8" (D) 137CHT 625-065-001 757-830-215 757-833-028 28 758-134-1225-7/8" (D) 137CHT 625-065-002 757-830-217 757-833-044 28 758-134-1245-7/8" (D) 137CHT 625-065-003 757-830-217 757-833-045 28 758-134-1245-7/8" (D) 137CHT 625-065-004 757-830-217 757-833-012 28 758-134-124

S = Suction ValveD = Discharge Valve* Guard assembly includes guard and plate guide pins.

Page 3 of 5

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WH Valve Assembly, Guard and Spring Reference List (cont.) Valve Assembly Guard Spring Spring Guard Assembly* Size Type Part No. Part No. Part No. Qty. Part No.

6-1/8" (S) 148CHT 625-066-001 757-830-218 757-833-044 16 758-134-1256-1/8" (S) 148CHT 625-066-002 757-830-218 757-833-045 16 758-134-1256-1/8" (S) 148CHT 625-066-003 757-830-218 757-833-012 16 758-134-1256-1/8" (D) 148CHT 625-067-001 757-830-219 757-833-008 32 758-134-1266-1/8" (D) 148CHT 625-067-002 757-830-220 757-833-044 32 758-134-1276-1/8" (D) 148CHT 625-067-003 757-830-220 757-833-045 32 758-134-127

7" (S) 169CJT 625-134-001 757-830-248 757-833-008 18 758-134-155**7" (S) 169CJT 625-134-002 757-830-249 757-833-044 18 758-134-156**7" (S) 169CJT 625-134-003 757-830-249 757-833-045 18 758-134-156**7" (D) 169CJT 625-135-001 757-830-250 757-833-044 18 758-134-157**7" (D) 169CJT 625-135-002 757-830-250 757-833-045 18 758-134-157**7" (D) 169CJT 625-135-004 757-830-250 757-833-012 18 758-134-157**

8" (S) 190CKT 625-136-001 757-830-251 757-833-008 21 758-134-158**8" (S) 190CKT 625-136-002 757-830-252 757-833-044 21 758-134-159**8" (S) 190CKT 625-136-003 757-830-252 757-833-045 21 758-134-159**8" (D) 190CKT 625-137-001 757-830-253 757-833-044 21 758-134-160**8" (D) 190CKT 625-137-002 757-830-253 757-833-045 21 758-134-160**8" (D) 190CKT 625-137-003 757-830-253 757-833-012 21 758-134-160**

9-1/8" (S) 221CMT 625-138-001 757-830-254 757-833-008 24 758-134-1619-1/8" (S) 221CMT 625-138-002 757-830-255 757-833-044 24 758-134-1629-1/8" (D) 221CMT 625-139-001 757-830-256 757-833-044 24 758-134-1639-1/8" (D) 221CMT 625-139-002 757-830-256 757-833-045 24 758-134-163

4-1/8" (S) 90CFT 625-146-001 757-830-257 757-833-044 18 758-134-1644-1/8" (S) 90CFT 625-146-002 757-830-257 757-833-045 18 758-134-1644-1/8" (S) 90CFT 625-146-003 757-830-257 757-833-012 18 758-134-1644-1/8" (D) 90CFT 625-147-001 757-830-258 757-833-012 18 758-134-1654-1/8" (D) 90CFT 625-147-002 757-830-258 757-833-003 18 758-134-165

4-5/8" (S) 102CFT 625-148-001 757-830-259 757-833-044 20 758-134-1664-5/8" (S) 102CFT 625-148-002 757-830-259 757-833-045 20 758-134-1664-5/8" (S) 102CFT 625-148-003 757-830-259 757-833-012 20 758-134-1664-5/8" (D) 102CFT 625-149-001 757-830-260 757-833-012 20 758-134-1674-5/8" (D) 102CFT 625-149-002 757-830-260 757-833-003 20 758-134-167


Page 4 of 5

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WH Valve Assembly, Guard and Spring Reference List (cont.) Valve Assembly Guard Spring Spring Guard Assembly* Size Type Part No. Part No. Part No. Qty. Part No.

5-5/16" (S) 116CGT 625-150-001 757-830-261 757-833-044 24 758-134-1685-5/16" (S) 116CGT 625-150-002 757-830-261 757-833-045 24 758-134-1685-5/16" (S) 116CGT 625-150-003 757-830-261 757-833-012 24 758-134-1685-5/16" (D) 116CGT 625-151-001 757-830-262 757-833-012 24 758-134-1695-5/16" (D) 116CGT 625-151-002 757-830-262 757-833-003 24 758-134-169

5-3/4" (S) 127CGT 625-152-001 757-830-263 757-833-044 26 758-134-1705-3/4" (S) 127CGT 625-152-002 757-830-263 757-833-045 26 758-134-1705-3/4" (S) 127CGT 625-152-003 757-830-263 757-833-012 26 758-134-1705-3/4" (D) 127CGT 625-153-001 757-830-264 757-833-012 26 758-134-1715-3/4" (D) 127CGT 625-153-002 757-830-264 757-833-003 26 758-134-171


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42



ES 23Superior Compressor Cylinder AndCylinder Class Designations

1.0 ScopeThis standard describes the formats used for designating the compressor cylinder numbersand cylinder class names.

2.0 PurposeThe purpose of this standard is to explain the appropriate designations which are used toidentify existing cylinders or cylinder classes, or which may be combined to identify a newcylinder or cylinder class.

3.0 Compressor Cylinder DesignationsStandard format: Bore diameter + (1 to 4 digits) + (2 characters)

Examples: 10.25" 140CD (an MW6 cylinder)10.25" 629CH (a WH6 cylinder)10.50" 411CC (a RAM cylinder)

Bore diameter: Piston/bore diameter, in inches, of the cylinder

Digits: Number which defines a specific cylinder pattern and bore size. Thesenumbers are assigned in ascending order with bore size, or subsequently,in order in which new cylinders are designed.W6 cylinders number range = 1 to 199, 1701 to 1999

Cylinders with N-I, N-R valves are numbered as 5000 + the last threedigits of the standard number.

WH6 cylinders number range = 601 to 699RAM cylinders number range = 401 to 499

First character: Letter which designates cylinder material and linerA = Cast iron body no linerB = Cast iron body with liner

ES 23

43



C = Ductile iron no linerD = Ductile iron with linerE = Cast steel with linerF = Forged steel with linerG = Forged steel (Old W6BS Class) with linerH = Forged steel no liner

Second character: Letter which designates the external rod load ratingA 25,000 lb (W6 and LW6 frame) 2" piston rodB 27,500 lb (W6 frames) 2" piston rodC 30,000 lb (W6 and RAM frame) 2" piston rodD 35,000 lb (MW6 frames) 2-1/4" piston rodE 45,000 lb (W7 frames) 2-1/2" piston rodH 50,000 lb (WH6 frames) 2-1/2" piston rodM 38,000 lb (MH6 frames) 2-1/4" piston rodS 42,500 lb (SW6 frames) 2-1/2" piston rodX 55,000 lb (W7 frames) 2-1/2" piston rod

4.0 Compressor Cylinder Class Designations4.1 W6 Cylinder class format: (W6) + (one or more characters)

Example: W6JD =“W” for White Motor W series frame“6” for the original 6" stroke designLast characters – a combination of some or all of the following:Initial character(s) – One or more letters which designate the order, bybore size, of the original classes, or subsequently, the order by whichsuccessive new classes are/were designed.Next character – Letter A, designating that a cast class is lineredNext character – Letter D, designating a ductile iron body

or – Letter S, designating that the body is steeland/or – Letter F, designating a forged steel body

Historically, selection of the last characters did not always precisely follow thepreceding rules, but generally did so. Exceptions include the W6AS, W6BSR, andW6BS which are all forged steel cylinder classes, and the W6ED class, some cylindersof which are linered.

ES 23

44



4.2 WH6 cylinder class format: (WH6) + (one or more characters)

Example: WH6QD =“WH” for WH cylinder revitalization designs“6” for the base 6" stroke designLast character(s) – A combination of some or all of the following:Initial Character(s) – One or more letters which designate the order, bybore size, of the original classes, or subsequently, the order in whichsuccessive new classes are/were designed.

Next character – Letter D, designating a ductile iron bodyor – Letters S and/or F, designating forged steel body

4.3 RAM cylinder class format: (C15) + (a single character)

Example: C15A =“C15” – Reference to the RAM’s preliminary compressor productdesignation

Last character(s) – Letter which designates the order, by bore size, of theoriginal classes, or subsequently, the order in which successive new classesare/were designed.

ES 23

45



ES 27Compressor Performance Guarantee1.0 Scope

This standard covers the acceptable compressor performance guarantee for all Superiorcompressors manufactured.

2.0 RequirementsThe following information is required to guarantee an operating condition:

• Suction pressure

• Discharge pressure

• RPM

• Gas analysis

• Site Conditions (ambient pressure and temperature)

• Suction temperature

• All pressure drops due to interstage & after-cooling, pulsation bottle, and any other external equipment.

3.0 Cooler Pressure DropsThe following pressure drops should be utilized for estimating drops through gas piping,intercoolers and aftercoolers for gases with a specific gravity less than 1.0 (29 MW).

Pressure - PSIG Pressure Drop

Up to 100 5% but not less than 5 PSIG

100 - 500 4% but not less than 8 PSIG

500 - 1500 3% but not less than 20 PSIG

1500 + 2 % but not more than 40 PSIG

For gases with a specific gravity greater than 1.0 (29 MW) add an additional 1% to the abovenumbers.

4.0 Suction Pressure DropsA pressure drop of 1% should be utilized for estimating the suction pressure drop throughthe gas piping and suction bottles. However, if the actual value is known, it should be used.

Page 1 of 3

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5.0 Performance GuaranteeCooper Energy Services will guarantee a single design point as calculated by the currentversion of the CASCADE performance calculation program for each compressor manufac-tured. All other performance calculations are expected, but are not guaranteed. However, it ispossible to guarantee multiple operating points provided the operating conditions areestablished prior to final design. The guaranteed design point is based on gas conditions atthe cylinder flange. In order to guarantee a design point at the packaged skid edge, allpressure drops need to be known and the performance will need to be calculated utilizingthese pressure drops, as outlined in sections 3.0 and 4.0. A current process gas analysis isneeded to validate all guarantees. Compressor guarantees are usually based on pre-pulsation/analog studies. If changes are made due to a pulsation/analog study, all compressor perform-ance calculations will need to be corrected as necessary.

5.1 Single Design Point Guarantee

5.1.1 All double acting conditions at all pressure ratios.

The capacity and brake power per flow are guaranteed to a tolerance of +/- 3%for the following operating conditions:

• Specific Gravity less than 1.0 (29 MW.)

• Including Gas Transmission projects where the compression ratio is less than 1.8.


• Specific Gravity greater than 1.0 (29 MW.)

• Suction Pressure less than 10 PSIG.

• Specific Gravity greater than 1.0 (29 MW) and suction pressure less than 10 PSIG.

5.1.2 All single acting conditions at all pressure ratios.





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5.2 Multiple Design Point Guarantee at all pressure ratios.

For multiple point guarantees, the single design point guarantee, refer to 5.1, willhold for the design point and the other points can be guaranteed as follows:

5.2.1 All double acting conditions







• Specific gravity greater than 1.0 (29 MW) and suction pressure less than 10 psig.

5.2.2 All single acting conditions at all pressure ratios.








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ES 1002

1.1

1.2

2.1

2.2

ES 1002Lubrication Recommendations ForSuperior Reciprocating CompressorFrames And Cylinders1.0 Basic Requirements

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 responsibleconcerns will provide the best assurance for achieving effective lubrication. Use ofsuch products should always be accomplished according to the manufacturer'srecommendations.

Compressor design, operating conditions, and the gases being handled all have asignificant effect on how well a lubricant performs in the given application. Thisstandard has been prepared to assist users in selecting the proper lubricant for eachapplication.

2.0 Compressor FramesAny lubricant that performs satisfactorily in a Superior engine will generally performwell in a compressor frame. Compressor frame lubricating oils should normally be thesame as used in the engines and should be selected in accordance with SuperiorStandard ES 1001 (contact Superior Marketing).

In addition to the requirements of paragraph 2.1, the frame lubricant must be capableof operating with the type of gas being handled by the compressor cylinders. For mostsweetnatural gases and allied gas services, a lubricating oil with the minimumqualities specified in ES 1001 will be suitable. In applications where the compressorcylinders are handling corrosive gases such as H2S or CO2, a lubricant with a higherTBN or method for adequate retention of the original TBN is recommended forservice in the frame.

3.0 Compressor Cylinders3.1 Minimum Qualities of a Compressor Cylinder Lubricant

49



ES 1002

Because of the variety of gases and operating conditions encountered by Superiorcompressor cylinders, the lubricant must be selected with the proper characteristics tobe suitable for the application involved. In all applications, the oil used for compressorcylinders should have the following qualities:

a. Good wetting ability;

b. High film strength;

c. Good chemical stability;

d. Clean & well refined;

e. Oxidation & corrosion inhibitors not required, but may be beneficial;

f. Pour point must be equal to gas suction temperature minus 15 - 20° F;

g. Good resistance to carbon deposits and sludging formation; if any carbon isformed, it should be the soft, loose, and flaky type;

h. Minimum flash point of 400° F.

3.2 Break-In

For the first 500 hours of operation, an initial break-in oil should be used. The break-inoil should be a good straight mineral oil compounded with 3% - 8% acidless tallow (orother suitable fatty additives) and have a viscosity of 125 - 150 SSU at 210° F, orconsistent with the oil selected for the specific service, whichever is higher. Usually agood grade of steam cylinder oil (containing 5% to 8% acidless tallow) mixed in equalproportions with the oil selected for extended service will be a good break-in oil. Forcold weather environments, where heating of the oil can not be practically achieved,an SAE 30 or SAE 40 weight oil with 3% compounding with "winter strained lard oil"may be substituted.

3.3 Viscosity Requirements

The viscosity of the oil should be selected on the basis of cylinder size (diameter) andthe operating pressure conditions of the cylinder. For multi-stage applications, theviscosity required for the highest pressure cylinder can also be used in lower pressurecylinders. The viscosities listed in Table 1 are the suggested minimum requirements.These values will be adequate for most oils. However, oils of the same viscosity maynot necessarily have identical lubricating qualities. Periodic examination of thecylinder bores during the first few weeks of operation is recommended to assure thatlubrication is adequate.

50



Service Recommendations

a. Wet Air

b. High Pressure (psig)

c. High Discharge Temp- eratures (350° - 375° F)

d. Natural Gases, Methane, Ethane

e. Natural Gases saturated with water and/or wet with higher-ended hydro- carbons.

f. Butane, Propane, Ethylene, Carbon Dioxide

g. Hydrogen, Nitrogen, Helium, Carbon Monoxide, Exhaust Gas, Ammonia Synthesis

h. Ammonia

i. Hydrogen Sulphide

Requires compounding with 3% - 5% acidless tallow orother suitable fatty oils. Increase supply over normal.

Use minimum viscosity listed in Table 1 plus 3% - 5%compounding with tallow if the gas is “wet.”

Consult Superior, Springfield office.

Use viscosity table and 3% - 5% compounding withtallow if the gas is “wet” and/or water saturated.

Requires compounding with 3% - 5% acidless tallow orother suitable fatty oils. Increase supply over normal.

These gases are diluents of oil. Use next higher viscosityover Table 1 recommendations. Increase supplyquantities over normal. Lubricant must be dry.

These are inert gases relative to lubricating oils. UseViscosity Table.

Use a mixed base or napthenic straight mineral oil.

Use dry, compounded, straight mineral oil. 3% - 5%compounding with acidless tallow and addition ofcorrosion and oxidation inhibitors is required. Viscosityselection per Table 1.

ES 1002

3.4 Application Recommendations

Many applications require special attention in addition to that given to most naturalgas and similar services. The process in which a gas is being utilized will often influencethe lubricating oil selected. The following recommendations will providebasic guidelinesin selecting the proper lubricant for these special applications. Final selection should bemade only after consultation with Superior and the desired oil supplier.

51



ES 1002

3.5 Lubrication Rate

a. Experience has shown that the quantity of oil required to properly lubricatecompressor cylinders is dependent upon bore diameter, stroke, and speed.For the Superior 6" stroke compressors operating at 900 RPM, 1/5 pint perday for each inch of cylinder bore diameter has normally proven to be anadequate quantity.

b. The piston rod and packing is considered as a separate cylinder but withdouble the lubrication rate required. Packings, then, require 2/5 pint per dayfor each inch of rod diameter.

c. Sight feed lubricators are often used on compressors and can be used to checkthe lubrication rate. A quantity of 1/5 pint per day per inch of cylinder bore isequivalent to one drop per minute per inch of bore for a very heavy oil andranges up to two drops per minute per inch of bore for very light oils.

d. Example: The power lubrication rates for a W62 compressor with (1) 10"cylinder and (1) 20" cylinder operating at 900 RPM are:

2.25" packing = 2.25 x 2/5 pint/day = 0.9 pint/day (4-8 drops/min)2.25" packing = 2.25 x 2/5 pint/day = 0.9 pint/day (4-8 drops/min)10" cylinder = 10" x 1/5 pint/day = 2 pints/day (10-20 drops/min)20" cylinder = 20" x 1/5 pint/day = 4 pints/day (20-40 drops/min)Total Lubrication Rate = 7.8 pints/day (38-76 drops/min)

e. The lubrication rate for break-in should be double that for normal operation.

f. The lubrication rates determined according to paragraph (a) above will beadequate for most compressor applications. The gas being compressed, itscleanliness and tendencies to act as an oil diluent, and the type of oil beingused all influence the lubrication rate required. Many applications mayrequire more or less than the calculated feed rates. To assure that adequatelubrication is being achieved, a periodic visual inspection of the cylinder boreand piston rod are recommended. Initial setting and adjustments to the feedrate should also be accomplished on a 24-hour basis since the drop size varieswith the viscosity of the oil.

g. Over-lubrication can be just as harmful as under-lubrication. Excesslubrication can cause valve deposits, valve breakages, and contamination ofthe gas stream and other down-stream equipment.

52



ES 1002

Table 1

Viscosity Requirements for SuperiorReciprocating Compressor Cylinders

Minimum Viscosity (SSU @ 210° F)

Pressure Cylinder Diameters

(psig)0 - 10" 10" - 15" 15" - 20" above 20"

0 - 500 60 - 70 60 -75 65 - 75 65 - 80

500 - 1,000 70 - 80 70 -85 75 - 85 75 - 90

1,000 - 2,000 80 - 100 85 - 100 � �

2,000 - 4,000 100 - 150 � � �

4,000 & up 150 - 200 � � �

4.0 Synthetic LubricantsSynthetic lubricants have gained popularity in recent years primarily because of theirhigher flash points. This makes them highly desirable from a safety and fire reductionstandpoint. However, synthetics impose problems which are usually not associated withnatural mineral oils. They dissolve paints, are corrosive to common bearing materials such aslead and tin, and they have low viscosity indexes. For these reasons, when synthetics areconsidered for use in compressor cylinders or frames, Superior’s Springfield office should beconsulted.

5.0 Multi-Grade LubricantsRecently, multi-grade oils have gained popularity because of their ability to provide thesame protection as heavier single-grade oils without putting undue stresses on thecompressor cylinder lubrication system. However, all multi-grade oils do not provide thesame protection. For this reason, if a multi-grade oil is being considered for use as a cylinderlubricant, Superior’s Springfield office should be consulted.

53



6.1

6.2

6.4

6.6

6.5

6.3

ES 1002

6.0 Additional Recommendations

For wet and saturated gas conditions, 0-1,000 psig, use a minimum viscosity of 85 SSU@ 210° F with 3% - 8% compounding with acidless tallow, or two grades heavier thannormally used for the pressure conditions involved.

For heavy hydrocarbon and sour gases, use the next higher viscosity over that shownin the table with a minimum of 85 SSU @ 210° F.

For refrigeration service, use the highest possible viscosity that should be used, whilestill retaining the pour point 15° F below gas suction temperature.

For chemically active gases, consult the Springfield office.

Whenever there is any question as to viscosity selection, always use the heavier oil.

For oil viscosities over 100 SSU @ 210° F, measures should be taken to maintainlubricator pump inlet oil temperatures at or above 120° F.

54



ES 3002Welded Clearance Volume Bottles forCompressors: Material andFabrication Requirements1.0 Scope

This standard covers bottle component material specifications and welding procedurerequirements for all compressor clearance volume bottles.

2.0 Requirements(Ref: Tube Turn #311 Catalog & CA 3994)

2.1 All bottle component material shall be as follows and shall be called for on all bottledrawings. (Ref. Sheet 1342)

a. All straight pipe sections ASTM-A53, Type S Grade B 35,000b. All reducers and caps ASTM-A234 Grade B 35,000c. Adaptor 3" - 600# WNF ASTM-A105 — 35,000d. Adaptor 6" - 150# WNF ASTM-A105 — 35,000e. Adaptor 1 1/2" - 300# WNF ASTM-A105 — 35,000f. Adaptor B904-891 & B904-901 ASTM-A181 Grade 11 35,000g. Adaptor B907-351 & B936-661 ASTM-A515 Grade 70 35,000

2.2 The allowable pressure data shall be includedon all drawings as shown in the example to theright for corrosion allowance. The data shouldbe entered in the appropriate spaces.

2.3 All drawings shall include the following note:

“A.S.M.E. Code Construction (No Stamping)”

The above note will have the “No Stamping” words deleted only when a customer hasrequested complete ASME certification.

Yield StrengthMinimum PSI

MAXIMUM ALLOWABLEWORKING PRESSURE CORR. ALLOWANCE 0" .062" .125"

This bottle for use on a cylinderof lower MAWP than the abovepressures.

ES 3002

55



ES 3002

2.4 All bottles shall be designed to have a maximum stress of 11,000 psi or less withreference to the static yield strength of the material of 35,000 psi.

Stresses shall be calculated by ASME formulae as follows:

S1 = P(R1 + 0.6t

1) For Circumferential Stress

Et1

S2 = P(R2 - 0.4t

2) For Longitudinal Stress

2Et2

S = pounds/square inch, stress

t = wall thickness, inches

P = pounds/square inch, pressure

R = inside radius of bottles, inches

E = joint efficiency

Ref: See Section VIII of ASME Unfired Pressure Vessel Code

2.5 When lethal and/or corrosive gases are involved, determine the appropriate safetyfactor and corrosion allowance thickness to be used. Determine maximum allowableworking pressure for the specific application.

56



ES 3003

ES 3003Outboard Cylinder VibrationSuppression Device:Installation Instructions For Head OrCover Mounting1.0 Scope

Outboard cylinder vibration suppression devices are only to be attached to heads or coverswhen bosses on cylinder bodies are not available. It is Ajax-Superior’s intent to provide suchbosses on all cylinders. This is the preferred area of attachment and must be used if available.

2.0 PurposeTo advise customers and Cooper Energy Services Group field service personnel ofinstallation procedures for outboard cylinder vibration suppression devices.

3.0 Compressor ModelsAll Superior W-7, MW-6, and SW-6 compressors with subject devices furnished.

4.0 Design PhilosophyThe outboard cylinder vibration suppression devices generically referred to as:

Outboard Cylinder Supports Cylinder Support Plates

Cylinder Head Supports A-Frame Supports and/or A-Frame Devices

are furnished by the packager when requested by customers and/or recommended byanalog and/or mechanical analysis of vessels and piping.

The purpose of the device is to “mechanically tune” the vibration frequency of thecompressor manifold system higher (i.e. cylinders, pulsation dampeners and close sections ofprocess piping). The goal is to insure that the natural mechanical frequency of the manifoldsystem is at least 10% away from a first and second natural compressor order. Installation ofthe device will normally raise the natural frequency of the manifold system. In order toconfirm that the goal has been achieved, a bump test must be performed.

57



The outboard cylinder vibration suppression devices are designed such that when thecompressor cylinders have reached normal operating temperatures, adjustment must bemade to minimize strain so that there is no vertical, horizontal, or axial loading on the studsattaching the device to the cylinder. The adjustments must be made using means otherthan loosening the attaching stud nuts. Additionally, the design is such that a section of thedevice can be removed to allow convenient removal of the cylinder head for maintenance.Every time the device is disturbed or the minimum load point changes, it must be reset.

WARNING: Failure to adhere to the requirements of this standard maycause excessive loading on compressor components or bolting. The effects ofsuch excessive loading may cause catastrophic failure of gas-containingcomponents, leading to extensive property damage, personal injury ordeath from rupture and/or fire.

5.0 ReferencesAppendix A - Recommended Torques for Model C

Appendix B - Drawing SK-7370Model C Outboard CylinderVibration Suppression Device for Cast Nodular Iron Cylinders

Appendix C - Drawing SK-7369Model FS Outboard CylinderVibration Suppression Device for Forged Steel Cylinders

6.0 ProcedureOutboard cylinder vibration suppression devices are furnished in two differentconfigurations. Model C is for installation on cast nodular iron cylinders; Model FS is forinstallation on forged steel cylinders. Model C attaches to the cylinder at the lower cylinderhead studs, while Model FS attaches to the cylinder at the lower two bolts of the gas passagecover.

6.1 Field Preparation

6.1.1 Anchor Bolt Installation

Prior to installation of anchor bolts in the concrete, they should be completelycoated with a release agent to prevent adhesion to the concrete or grout.

ES 3003

58



ES 3003

6.1.2 Cast Cylinders

Loosen all cylinder head nuts securing the head to the cylinder. Remove twonuts from the cylinder head studs that match the outboard cylinder vibrationsuppression device (OCVSD) bracket. Remove these two standard studs andinstall longer studs required to attach the OCVSD bracket. Re-torque all headnuts uniformly in a crisscross pattern according to torque table in Appendix Cfor first nuts.

6.1.3 Forged Bodies

Loosen all gas passage cover cap-screws securing the cover to the cylinder.Remove the bottom two cap-screws from the cylinder gas passage cover. Installlonger studs required to attach the OCVSD bracket. Re-torque the four nuts in acrisscross pattern evenly and uniformly according to the torque table inAppendix C for first nuts.

6.1.4 Anchor Bolts - Prior to Grouting

Re-coat the anchor bolts extending out of the concrete floor with anti-seize or arelease agent to prevent concrete or grout adhesion to the bolts.

6.1.5 OCVSD (Outboard Cylinder Vibration Suppression Device)

Disassemble the OCVSD upper mounting bracket and shims from the OCVSDlower mounting bracket.

6.2 Field Assembly and Installation

6.2.1 Install the lower mounting bracket onto the structural support beam furnishedby the site contractor. The structural support beam should be installed overanchor bolts extending out of the concrete floor such that there is a 1" spacebeneath the bottom flange of the structural support beam for grouting. Threadthe nuts finger tight onto the anchor bolts.

6.2.2 Install the upper mounting bracket over the cylinder head studs (on Model C) orgas passage studs (on Model FS). Assemble the upper mounting bracket to theOCVSD lower mounting bracket with .045" (three .010" and three .005" shims) ofthe shim pack between the shimming plates. Make sure all bolt holes arecentered. If they are not, make adjustments at the structural support beam tocenter the studs in the upper mounting bracket holes.

59



ES 3003

6.2.3 Secure the OCVSD upper attaching bracket to the cylinder as follows:

a. Models C & FS

Torque all nuts to produce even seating of the bracket and uniform loading onthe nuts according to the torque table in Appendix C for second nuts.

6.3 Pre-Grout Installation Check

6.3.1 Loosen the nuts on the anchor bolts at the structural support beam. Remove anyspacers which may have been used to insure 1" space for grout.

6.3.2 Check the shimming plates in the upper and lower mounting brackets and thestructural support beam to insure that they remained level during installation.

6.3.3 Check to insure that adequate space remains below the structural support beam(1" ±1/4” across the length and width of the lower flange) for grouting.

6.4 Grouting

Grout the structural support beam in place according to grout manufacturer’sinstructions.

6.5 Post-Grout Assembly and Pre-Startup Check

6.5.1 Loosen the nuts between the upper mounting bracket and the lower mountingbracket at the shimming plates.

6.5.2 Torque the nuts on anchor bolts protruding through the structural support beamin accordance with anchor bolt manufacturer’s recommendations.NOTE: Pre-stress on anchor bolts exceeding 20,000 psi is not recommended (seeAppendix C for torque values).

6.5.3 Check for space between the upper and lower mounting brackets’ shimming plates.

a. If space is not present, adjust shim pack to achieve zero air gap with no upwardpressure.

b. If space is present, insert shims between the upper and lower mountingbrackets at the shimming plates to fill the space without causing upwardpressure on the upper mounting bracket.

60



6.5.4 Torque bolts and nuts connecting the upper and lower mounting brackets at theshimming plates to 100-115 ft-lb.

6.6 Hot-Run Check and Adjustment

6.6.1 The compressor should be run at least 8 hours with the frame and cylinders atnormal operating temperatures, after which the unit should be shut down.

6.6.2 Loosen the nuts connecting the upper and lower mounting brackets at theshimming plates.

6.6.3 Repeat Steps 3 and 4 under “Post-Grout Assembly” Section.

6.6.4 Check all other nuts for correct torque.

ES 3003

ThreadDiameter

First NutFoot-Pounds

Second NutFoot-Pounds

3/4" 105 to 115 60

7/8" 170 to 190 100

1" 260 to 290 150

1 1/8" 370 to 410 215

1 1/4" 520 to 570 300

1 3/8" 700 to 770 395

1 1/2" 930 to 1030 530

61



7.0 Appendix A - Recommended Torques ForCylinder Attachment BoltsAll torque values listed are for lubricated threads and nut seating surface.

7.1 J-Bolts Anchor

NOTE: Torque per anchor bolt manufacturer’s recommendations,but do not exceed 20,000 psi pre-stress.

The following chart provides torque recommended for anchor bolt pre-stress value.

All torque values listed are for lubricated threads and nut seating surface.

NOTE: Coat anchor bolts with anti-seize or other release agent toprevent concrete or grout adhesion during installation.

ES 3003

ThreadDiameter Foot-Pounds

3/4 10" 60

7/8 9" 100

1 8" 150

62



Mod

el C

Out

boar

d C

ylin

der

Vib

rati

on S

uppr

essi

on D

evic

eFo

r C

ast

Nod

ular

Iron

Cyl

inde

rs

TB

A

TB

AT

o a

llow

for

clear

readin

g o

f T

I

.25 s

him

allo

wa

nce

1.0

0 g

rout

allo

wa

nce

7

5

4T

yp. (3

)pla

ces

6

1

8

2 3

Upper

mountin

gbra

cket (t

yp.)

Shim

min

gpla

tes

(typ

.)

Low

er

mountin

gbra

cket (t

yp.)

(3)

3/4

N. C

. bolts

C/W

1 n

ut each

by

cust

om

er

Str

uct

ura

l support

beam

by

cust

om

er

A

Anch

ors

by

cust

om

er.

Note

: a

nch

or

bolts

to b

eco

ate

d w

ith a

rele

ase

agent

to p

reve

nt co

ncr

ete

or

gro

ut

adhesi

on.

Pla

te a

ttach

ed to b

olt

to a

nch

or

into

concr

ete

Top o

f co

ncr

ete

5.0

0

1.0

0

Typ

.

Typ

.

Typ

.

3/8

3/8

3/8

3/8

3/83/8

2.0

0

1.8

75

LE

GE

ND

TB

A

-

To

Be

Ad

vise

dC

TS

-

C

ut

To

Su

itN

TS

-

N

ot

To

Sca

le

T

I

-

Te

mp

era

ture

In

dic

ato

r

6.0

0

8.0 Appendix B - Drawing SK-7370

63



Drawing SK-7370Model C Outboard Cylinder Vibration Suppression Device

For Cast Nodular Iron Cylinders

Bill of MaterialItem Quantity Description Material

1 1 1" PL. x 7.75 x 14.88 LG. -CTS- ASTM A-362 1 1" x 35.50 x TBA LG. -CTS- ASTM A-363 1 1" PL. x 6.00 x 35.50 LG. ASTM A-364 3 3/4 f Hex head bolt x 3.25 LG. C/W 1 nut ea. GR-A5 1 6.00 f STD. SMLS pipe x 2.00 LG. ASTM A-106-B6 1 1" PL. x 5.00 x 16.50 LG. ASTM A-367 1 1" PL. x 5.00 x 16.50 LG. ASTM A-368 1 Shim pack (3 ea. 0.005, 0.010, & 0.030) CS

Note: BOM qty's are for one support only.

7.75

14.88

TBA

1.50Typ.

TBA

Number & size of bolthole to be determinedupon receipt of cylinder

ITEM #1 DETAIL

6.00

1.257.25 10.50 10.50

35.50

ITEM #3 DETAIL

.875 φ thru3-places


2.25

6.00

6.00

16.50

5.00

1.25

ITEM #6 DETAIL


ITEM #7 DETAIL

2.25

6.00

6.00

16.50

1.25

5.00

ITEM #8 DETAIL

.62Typ.3 slots

2.25

5.00

1.25

6.00

16.50

6.00

Cylinder Head

Cylinder Head Nut (First)

Bracket Nut(Second)

1

6

2

7

Assy. Detail NTS

64



Lege

ndTB

A -

To B

e A

dvis

edTI

- Te

mpe

ratu

re In

dica

tor

Mod

el F

S O

utbo

ard

Cyl

inde

r V

ibra

tion

Sup

pres

sion

Dev

ice

For

Forg

ed S

teel

Cyl

inde

rs

9.0 Appendix C - Drawing SK-7369

Lo

we

r m

ou

ntin

gb

rack

et

(typ

)2

1U

pp

er

mo

un

ting

bra

cke

t (t

yp)

8S

him

min

g

pla

tes

(typ

)6

4T

yp.

(3)

pla

ces

7

53(3

) 3

/4 N

.C.

bo

ltsC

/W 1

nu

t e

ach

by

cust

om

er

Str

uct

ura

l su

pp

ort

be

am

by

cust

om

er

An

cho

rs b

y cu

sto

me

r

No

te:

an

cho

r b

olts

to

be

coa

ted

with

a r

ele

ase

ag

en

tto

pre

ven

t co

ncr

ete

or

gro

ut

ad

he

sio

n

Pla

te a

tta

che

d t

o b

olt

to a

nch

or

into

co

ncr

ete

AT

op

of

con

cre

te

1.0

0 g

rou

ta

llow

an

ce

.25

sh

ima

llow

an

ce

To

allo

w f

or

cle

ar

rea

din

g o

f T

IT

BA

TB

A

5.0

0

1.0

0 3/8 3/8 3/8

3/8

3/8

3/8

Typ

.

Typ

.

Typ

.2

.00

6.0

0

1.8

75

No

te:

1.

Fo

r u

se w

ith f

or g

ed

ste

el c

ylin

de

rs

65



Bill of MaterialItem Quantity Description Material

1 1 1" PL. x 8.12 x 14.88 LG. -CTS- ASTM A-362 1 1" PL.x 35.50 x TBA LG. -CTS- ASTM A-363 1 1" PL. x 6.00 x 35.50 LG. ASTM A-364 3 3/4 f Hex head bolt x 3.25 LG. C/W 1 nut ea. GR-A5 1 6.00 f STD. SMLS pipe x 2.00 LG. ASTM A-106-B6 1 1" PL. x 5.00 x 16.50 LG. ASTM A-367 1 1" PL. x 5.00 x 16.50 LG. ASTM A-368 1 Shim pack (3 ea. 0.005, 0.010, & 0.030) CS

Drawing SK-7369Model C Outboard Cylinder Vibration Suppression Device

For Forged Steel Cylinders

Note: BOM qty's are for one support only.

8.12

14.88

TBA (Typ.)

4.38

ITEM #1 DETAIL

8.75

6.50 6.00

1.25 7.25 10.50 10.50

35.50

ITEM #3 DETAIL



2.25

6.00

6.00

16.50

5.00

1.25

ITEM #6 DETAIL

1.125 φ thru2 places


ITEM #7 DETAIL

2.25

6.00

6.00

16.50

1.25

5.00

ITEM #8 DETAIL

.62Typ.3 slots

2.25

5.00

1.25

6.00

16.50

6.00

Cylinder Head

Cylinder Head Nut

Bracket Nut(Second)

1

6

2

7

Assy. Detail NTS

Passage Nut(First)

66



ES 3004Ajax-Superior Packager Manual1.0 Scope

This specification provides guidelines and requirements for packaging and interfacing withAjax-Superior engines and compressors. It is not intended to encompass all necessary aspectsof properly designed and constructed engine and compressor packages.

2.0 Requirements2.1 Packagers of Ajax-Superior equipment are expected to follow good, generally accepted

industry practices and applicable codes, as well as local, state and federal regulationsfor the design and construction of the packaged product. In addition, and for fullwarranty consideration, the packager is expected to follow application and safetyguidelines as proposed herein, and to pass on to the customer appropriate warningsand safety procedures associated with the equipment.

2.2 A label with operator warning statements will be issued for mounting on theequipment control panel where start-up of the unit is controlled. The label is to bemounted on the front face of the panel as close to operator eye level as practical.

2.3 When specified by the customer or dictated by location, the safety guidelines ofOSHA, NFPA, API or other governing codes are to be followed. It is intended that fornon-refinery applications API-11P is the governing specification. Certain piping onAjax-Superior engine and compressor fuel, oil, and water systems do not meet ANSIB.31.3 but are allowable exceptions due to their proprietary design.

2.4 Cleanliness of piping is very important. The requirements of ES 3001 (page 1-77) andES 3001A (page 1-79), or a mutually agreed upon alternative procedure approved byAjax-Superior, should be followed by packagers.

2.5 Other technical information relating to specific engine or compressor models can befound in the Engineering Technical Data Books and in Ajax-Superior EngineeringStandards provided to packagers. When in doubt, consult the Ajax-SuperiorEngineering Department for recommendations.

ES 3004

67



ES 3004

2.6 Specific guidelines are provided for the following categories of equipment, systems,and applications:

3.0 Compressors3.1 Unit ratings for speed, torque, rod load, cylinder pressure, rod load reversal, etc. are not

to exceed the values specified in the Engineering Data Books, Engineering Standards,or equipment nameplates.

3.2 While it is current industry standard to quote capacity and performance fromcompressor cylinder inlet flange to compressor cylinder discharge flange, it is thepackager’s responsibility to ensure that the design and construction of the packageaccommodates the system pressure drops. The interstage pressure drops (consistentwith the pressure drops represented in the customer proposal and/or contract) andsuction and discharge pressure drops must not overload the equipment or exceedpressure and temperature limits that would cause premature wear or dangerousoperating conditions. If such pressure drops do not impose equipment problems butdo adversely affect the compressor capacity or power required, it is the packager’sresponsibility to advise the customer accordingly.

3.3 All vent connections for crankcase, crosshead guides, distance pieces, unloaders, etc.must be piped to edge of skid, marked for customer connection, or clearly noted onthe equipment outline drawing. Manifolding of vents must meet API-11P standards

eeSegaP .oNmetI noitacilppA

76-6 0.3 srosserpmoC

96-6 0.4 senignEroirepuS

07-6 0.5 senignExajA

17-6 0.6 snwodtuhSytefaSderiuqeR

27-6 0.7 smetsySgnipiPsaG

37-6 0.8 smetsySgnilooC

57-6 0.9 airetirCngiseDdikS

57-6 0.01 airetirCgnilpuoC

67-6 0.11 dnaenignEdednemmoceRsnoitpOrosserpmoC

67-6 0.21 evirDlacinahceMenignE)evirdrosserpmoc-non(

68



ES 3004

and comply with Ajax-Superior Engineering Standards ES 3 (page 1-37) and ES 6001(page 1-123). Location and size of customer vent connections must be clearly shown onthe outline drawing.

3.4 Cylinders and/or pulsation dampeners must be provided with adequate supports fromthe skid or foundation to avoid excessive bending movement of the compressor crankcase.

3.5 Piston ring, packing and rod coating materials must be compatible with the gas to becompressed. See the application guidelines for sour gas or CO2 trim options in ES 13(page 1-50). Also, see API-11P recommendations for corrosive gases. In the event stockcompressor cylinders are used, it is the packager’s responsibility to see that necessarycomponent changes are made. Material recommendations will be made by Ajax-Superior on request.

3.6 The end user of equipment is to be provided with compressor operating curves wherevariable operating conditions are expected. Ajax-Superior will provide assistance on request.

3.7 Packing cooling systems are required for all cylinders rated above 2000 psi and must bedesigned for adequate cooling under the most severe operating conditions specified.The packing cooling system typically must be sized for 400-500 Btu/min/packing andbe a separate system from the jacket cooling system to prevent gas leaks from enteringthe engine or compressor cylinder jackets or intercooler circuit. The coolant pumpand system must be capable of circulating 2 1/2 to 3 gpm per packing with a 30 to 40psi pressure drop through the packings. The maximum coolant inlet temperature shallnot be more than 120° F and the temperature rise across the packing is not to exceed20° F. Coolant is to be treated to prevent corrosion or formation of deposits whichcould block the small passages in the packings; appropriate recommendations are to beprovided in the packager’s instruction manual. An appropriate pump lubricant shall bespecified to the customer if required.

3.8 Compressor cylinder lubrication systems must be designed and built for eachapplication. Lubrication rates and type of lubricant must be provided to the customer.Refer to ES 1001 (contact Superior Marketing) and ES 1002 (page 1-70) for propercylinder lubricant for Superior products or ESS-L-168 and ESS-L-811 for proper cylinderlubricant for Ajax products.

3.9 Compressor cylinders, by serial number, must be mounted on the prescribed throwlocations. The packager may make the initial cylinder location selection and forwardthe information to Springfield Engineering. However, once balance information isdeveloped, it is imperative that the packager install the appropriate serial numbercylinder on the throw location assigned, and that appropriate balance weights beinstalled on all throws.

69



ES 3004

4.0 Superior Engines4.1 Engine exhaust systems should be designed with heavy-duty steel or stainless steel pipe,

Schedule 10 or heavier pipe, with flanged connections and bolted joints to preventdamage in the event of combustion of fuel in the exhaust system. A flex connectorshould be provided at or near the engine so as not to impose excessive flange loading onthe engine or turbocharger exhaust outlet connection. Consideration must be given toboth static weight loads and loading from thermal growth.

4.2 Exhaust systems must be designed to not exceed 10 inches water column of backpressure at 110% engine load at the engine outlet connection to allow for full site ratingof engine. A connection for measuring exhaust back pressure must be included in theexhaust piping just downstream of the engine. Exhaust silencers and heat recovery boilersmust include an adequate fouling factor to allow for reasonable maintenance intervals.(This is particularly important for diesel and dual-fuel applications.) Location of theexhaust gas exit must be such that it does not adversely affect the cooling system and/oris not drawn into, or does not heat up, the air inlet system.

4.3 Exhaust system designs having significant piping inside a building must includeprovision for relieving excessive exhaust gas pressure in the event of an engine backfireor combustion of fuel gas in the exhaust piping. Relief devices need to be located atelbows in order to be effective.

4.4 The fuel gas analysis must be determined for each site, and appropriate enginederation applied. If the fuel is other than pipeline quality gas, consideration should begiven for possible changes in fuel gas composition and the need for future derating.

4.5 For all Superior turbocharged engines, the customer must be provided with theappropriate air/fuel ratio curve or constants for the engine panel. These will besupplied by Ajax-Superior once site information is received. If the engine is moved to anew location and/or fuel quality changes, it may be necessary to develop new controlparameters. Such needs should be referred to the Ajax-Superior EngineeringDepartment for review.

4.6 Normal engine shutdown for spark gas engines is to be accomplished byinterrupting the fuel supply with the ignition still on. This is to prevent combustiblegas from remaining in the exhaust system. The ignition can then be grounded, eithermanually or with an automatic time delay, after 10-20 seconds.

4.7 In general, the driven equipment must have some provision for unloading during thestarting cycle. If bypass piping or unloading provision is not included as part of the

70



ES 3004

package, then it must be included in the station piping. See ES 3007 (page 1-108) forbypass recommendation.

4.8 Turbocharged engines are required to have pre-post lube pumps to ensure adequate oilsupply to the turbocharger on engine startup and shutdown.

4.9 Auxiliary driven equipment such as coolers, special water pumps, etc., must be selectedby the packager with consideration for the horsepower required, side loading wherebelt drive is used, plus any special sheave or coupling where power takeoff is required.All such auxiliary equipment interfaces must be compatible with engine hardwareand systems.

4.10 Engine warm-up and cool-down cycles should be incorporated in the control logicwhenever possible. On start-up, oil and jacket water temperature should reach 120° Fbefore fully loading engine. For normal shutdown, the engine should be allowed torun a minimum governed speed and load for approximately 10 minutes before stopping.

5.0 Ajax Engines5.1 Engine exhaust systems should be designed with heavy-duty steel pipe, preferably

Schedule 40, with flanged connections and bolted joints to prevent damage in theevent of combustion of fuel in the exhaust system. A flex connector or other provisionfor system expansion should be included so as not to impose excessive flange loadingon the engine exhaust outlet connection. Consideration must be given to both staticweight loads and loading from thermal growth.

5.2 Exhaust systems must be designed not to exceed 7" water column back pressure at110% rated load. Location of the exhaust exit must be such that it does not adverselyaffect the cooling system and/or is not drawn into, or does not heat up, the air inletsystem. Satisfactory engine performance is highly dependent on properly tunedexhaust length. Interconnecting exhaust pipe lengths are to be in accordance withAjax-Superior recommendations as shown in SK-8826.

5.3 Exhaust system designs having significant piping inside a building must includeprovision for relieving excessive exhaust gas pressure in the event of an engine backfireor combustion of fuel gas in the exhaust piping. Relief devices or sensors need to belocated at elbows in order to be effective.

71



5.4 The fuel gas analysis must be determined for each site and appropriate engine derationapplied. If the fuel is other than pipeline quality gas, consideration should be given forpossible changes in fuel gas composition and the need for future derating.

5.5 Normal engine shutdown is to be accomplished by interrupting the fuel supply withthe ignition still on.

5.6 The driven equipment must have some provision for unloading during the startingcycle. If bypass piping or unloading provision is not included as part of the package,then it must be included in the station piping.

5.7 Auxiliary driven equipment such as coolers, special water pumps, etc., must be selectedby the packager with consideration for horsepower required, side loading where beltdrive is used, plus any special sheave or coupling where power takeoff is required. Allsuch auxiliary equipment interfaces must be compatible with engine hardware and systems.

6.0 Required Safety Shutdowns6.1 The following shutdowns are minimum requirements on Ajax-Superior products,

either for protection of the equipment itself, or to meet the safety practices outlinedin industry codes (OSHA, NFPA, ANSI, etc.).

6.1.1 Superior Compressors:

Low lube oil pressureCylinder lubrication no-flowVibrationLow suction pressureHigh discharge pressure, each stageHigh discharge temperature, each cylinderHigh jacket water temperature (if not included in engine circuit)

* High suction temperature, each stage

6.1.2 Superior Engines:

OverspeedVibrationHigh jacket water temperatureLow lube oil pressure

** High lube oil temperature (uncooled)High turbine inlet temperature (turbocharged engines)

ES 3004

72



6.1.3 Ajax Engine/Compressors:

OverspeedLow oil level

**High lube oil temp (uncooled)High jacket water temperatureCylinder lubrication no-flow (std. on 600 & 800, recommended on others)Low suction pressureHigh discharge pressure, each stageHigh discharge temperature, each cylinder

NOTE: Vibration shutdown is a recommended option on Ajax units.

NOTE: Gauges, transducers and other instruments must be mounted in locations andin ways that ensure that they are not damaged from heat or vibration which occurs innormal equipment operation.

* Required on compressor applications where there is extensive running in theunloaded condition or with uncooled recycle loops (such as fuel gas boosters).

** Required when NFPA 37 applies.

6.2 Where applicable, NFPA 37 requires remote shutdown capability for shutting off thefuel supply and shutting down lubricating oil pumps not directly driven by theengine. Appropriate control panel location may be sufficient to meet this requirement.

7.0 Gas Piping Systems7.1 Pulsation dampener design must meet customer specifications and, where applicable,

must comply with analog results. In addition, design must be such that pulsations atthe compressor cylinder suction and discharge flanges do not adversely affect valvelife, capacity and/or horsepower required. Pulsation dampeners are to be equippedwith 1/2” NPT or larger taps in the cylinder neck for indicator testing. If dampeners arechambered, there should be an additional tap for each chamber. See ES 3005 (page1-105) for additional guidelines for Superior compressor piping systems.

7.2 Pulsation dampener and associated piping must be such that it does not impose undueloading on the cylinder flange and/or compressor crankcase. Consideration must begiven for torque generated by piping size and weight as well as thermal growth and gaspressure forces. If the package design includes items outside standard designs (such aslarger than normal pulsation dampeners, high gas pulsations, long straight piping

ES 3004

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from dampener flange, etc.), then contact Ajax-Superior Engineering for specific flangeload calculations.

7.3 Adequately sized scrubbers are required upstream of compressor cylinders to preventliquid and solid materials from entering the compressor valves and cylinders.Filtration beyond normal scrubbers and start-up screens may be needed to prevent theentry of fine abrasives. For sites where abrasive particles are present, a filter-separatorshould be considered to remove contaminants which could cause premature wear.Equipment damage or wear from abrasive solids or liquids will notbe covered by Ajax-Superior warranty.

7.4 The general layout and piping arrangement should be such that it does not interferewith reasonable access to and maintenance of compressor components. This includescontrol tubing and bulkhead locations. Additionally, warning and caution labels and/or tags furnished by Ajax-Superior or its suppliers must be left on the equipment andthe package designed such that the views of these items are not obstructed.

7.5 Provision is to be included in the piping and/or control system to unload thecompressor for start-up (and cool down for engine drives). This can be done by usingvalve unloaders and/or a gas bypass system. If the bypass is not part of the package, itmust be included in the station piping. See ES 3007 (page 1-108) for bypass recommendations.

7.6 When a gas bypass is used in the system it should be such that the recirculated gas iscooled to prevent it from reaching harmful temperature levels. This is required forcompressors driven by turbocharged engines that require a warm-up period beforethey can be loaded. It is recommended, but not mandatory, for compressors driven bynaturally aspirated engines. In either case, if the startup requires more than 10 minutesrunning time before loading the compressor, consult Ajax-Superior EngineeringDepartment for proper shutdown protection.

7.7 Relief valves must be provided at the discharge of each stage of compression and be setwithin the tolerance limits specified in API-11P. Relief valves must be located upstreamof each respective cooler section.

8.0 Cooling Systems8.1 It is the packager’s responsibility to adequately size radiators, coolers, piping, and other

components of the cooling system to meet the requirements of the engine and drivenequipment. Consideration should be given to the full range of ambient conditions, air

ES 3004

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flow relative to physical obstacles, closeness to exhaust systems, etc. Cooling systemsmay be required for any or all of the following:

Engine jacket waterEngine lube oilEngine intercoolersCompressor cylinder jacketsCompressor lube oilCompressor rod packings

8.2 Superior engine cooling systems should be pressurized to 7 to 10 psi and includeconsideration for maximum engine horsepower (including 110% DEMA overload) andsite elevation.

8.3 Compressor jacket cooling systems may be of the thermo-syphon type for lowtemperature service. However, if the gas discharge temperature exceeds 210° F or thedifferential temperature from suction to discharge exceeds 150° F, a forced coolantsystem is required. If compressor cylinder ends are operated for extended periodsunloaded, the forced system is required.

8.4 General recommendations for the system coolant are given in the Instruction Manual.Additional information can be found in Engineering Service Bulletin #194.

8.5 In the design of the coolant piping, care should be taken to avoid, where possible, therouting of piping directly over the exhaust components of the engine, as antifreezeand glycol solutions may be flammable.

8.6 Components such as piping valves, pumps, etc., must be sized to maintain the requiredflow rates through the system. Pump net positive suction head must be adequate toensure proper system performance at all operating speeds.

8.7 Adequately sized surge tanks are required with free flowing vents from all high pointsto the tank. A balance line from the surge tank to the pump suction is also required onSuperior engines. Additional information can be found in Engineering Service Bulletin #52.

8.8 Where motor driven water pumps are used, there should be control panel indicationto show that the pump is running. This can be either indication of signal being sent tomotor or jacket water pressure indication.

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9.0 Skid Design Criteria9.1 Skid design must be of sufficient strength and stiffness to maintain alignment between

the driver and driven equipment and to withstand the unbalanced forces and couplesimposed on it. Allowance must be included for thermal growth of each of the components.

9.2 Skid, piping and support design must be such that harmonic excitation is avoided bydesigning components that do not have natural frequencies near the unit naturalfrequency or harmonics of the rotating and reciprocating components. Vibrationanalysis (bump testing) should be used to confirm that new designs will not havevibration problems.

9.3 Skid design must include proper guards for flywheel, pumps, pulleys, drive shafts, etc.to protect operators from moving components. Guard designs are to comply withOSHA 1910.219.

9.4 Provision for shims must be included under the driver and/or driven equipment toallow for field alignment. Fixed location of properly aligned compressors by groutingis acceptable.

9.5 Where fixed ladders and platforms are used, they must comply with OSHA Standard1910.27 and applicable local codes. Placement of components on skid must not voidcompliance of ladders and platforms furnished by Ajax-Superior.

10.0 Coupling Criteria 10.1 When new designs of driver and driven equipment are sold which use a Superior

engine or motor driven compressor, a torsional analysis must be performed and acoupling selection approved by Ajax-Superior Engineering.

10.2 When the torsional analysis dictates a single bearing design, the generator or electricmotor is to be supplied with a forged flanged shaft and a self-aligning, free floatingbearing. This is to prevent thrust loading and/or misalignment with the Superiorequipment due to thermal growth of engine, motor, coupling, or generatorcomponents. See ES 15 (page 1-66) for bearing types and additional information.

10.3 Where electric generators or motor drives are used, the package design and assemblyprocedures must be such that the units do not impose any thrust loading on theSuperior equipment due to magnetic centering forces.

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10.4 Where rubber/elastomer coupling components are used, the coupling guards are to bedesigned to allow for adequate cooling air flow (such as expanded metal material).This is necessary to keep coupling temperatures within a range that will not adverselyaffect the component life.

11.0 Recommended Engine And Compressor Options11.1 Differential pressure gauges, where applicable, should be provided for lube oil, fuel, and

air filters to indicate the need for replacement or cleaning.

11.2 Turbocharged engines should have high quality, durable gauges for the on-engine gasmanifold and air manifold pressure readings.

11.3 All automatic start engines and compressors should have pre-lube and/or post-lubepumps with 2- to 3-minute timers. Startup should not take place until a positivepressure is sensed or observed at the lube oil header. Pre-lube pumps are especiallyimportant for electric motor driven compressors. Low oil pressure lockout for startupshould not exceed 30 seconds.

11.4 All engines should have exhaust pyrometers and/or high exhaust temperatureshutdowns.

11.5 Additional safety shutdowns recommended for engines include:

Low jacket water pressureLow intercooler water pressureExhaust scanning pyrometer, sensing high cylinder temperature and high

cylinder differential temperatureHigh air manifold temperature (on turbocharged engines)High lube oil temperature

11.6 Additional safety shutdowns for compressors include:

Compressor cylinder high differential pressure (for cylinders with net rod load inexcess of 85% of rating or where specified by Ajax-Superior Engineering).

12.0 Engine Mechanical Drive Applications12.1 All mechanical drive applications are to include instrumentation for measuring

exhaust back pressure. A system alarm is recommended.

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12.2 Exhaust scanning pyrometers are required and are to be part of the engine shutdownsystem.

12.3 Engine exhaust piping is to be heavy-duty steel or stainless steel, Schedule 10 orheavier pipe, with flanged connections and bolted joints to prevent damage in theevent of combustion of fuel in the exhaust system. A flex connector should beprovided at or near the engine so as not to impose excessive flange loading on theengine or turbocharger exhaust outlet connection.

12.4 Exhaust system designs having significant piping inside a building must includeprovision for relieving excessive exhaust gas pressure in the event of an engine backfireor combustion of fuel gas in the exhaust piping. Relief devices need to be located atelbows in order to be effective.

12.5 Each engine must have its own exhaust system; no manifolding of multiple exhaustswill be approved by Ajax-Superior Engineering.

12.6 Engines operated with elevated jacket water temperatures (above 195° F) must havemotor driven water pumps with appropriate controls for running the pumps for acool-down cycle (not less than 20 minutes) after engine shutdown. A jacket waterpressure sensor and shutdown are also required.

12.7 Diesel and Dual Fuel engines must have an overhead day tank with gravity feed of thefuel to the fuel supply pump. A separate fuel drip return tank and pump will berequired to return the excess injector fuel to the day tank.

12.8 For normal shutdown, control logic provision must be included to first reduce theload in a controlled manner to prevent engine overspeed. This is particularlyimportant for generator drive units where opening the breaker under load will causean instant overspeed condition.

12.9 On Dual Fuel engines the shutdown logic should be to switch to full diesel operationunder load, then remove the load in a controlled manner, and then shut the engine down.This will allow a cleaning of the injectors and provide for an easier startup when needed.

12.10 Starting air receivers, when required, must be designed and constructed in accordancewith ASME Boiler and Pressure Vessel Code Section VIII.

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ES 3006Compressor Cooling System Design

1.0 Scope1.1 The scope of this Engineering Standard is to present the requirements and tools to

design a satisfactory cooling system.

2.0 Requirements2.1 Cylinders

2.1.1 No cooling is required when the gas discharge temperature is below 140°F andthe gas inlet temperature is greater than 60°F.

2.1.2 Either forced liquid cooling or thermal siphon or stand pipe cooling is requiredwhen the gas discharge temperature is between 140°F and 250°F and the gastemperature rise is less than 170°F.

2.1.3 Forced liquid cooling is required when the gas discharge temperature is greaterthan 250°F or the gas temperature rise is greater than 170°F.

2.2 Frame Lube Oil Coolers

2.2.1 All Superior medium and high speed compressor frames require coolant between140” and 160°F for the oil coolers.

2.3 Piston Rod Packing Cooling

2.3.1 Lubricated packing must have cooling when cylinder discharge pressures areabove 2000 psig.

2.3.2 All non-lube packings require cooling.

2.4 Coolers

2.4.1 Heat rejection from the cylinders and compressor frame oil cooler and packingwill vary with operating and ambient conditions. Add l0%, not including foulingfactor, to the heat transfer requirements to select the coolers and chillers.

Page 1 of 15

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Page 2 of 15

3.0 Procedure3.1 General

3.1.1 This cooling design procedure will apply to a wide range of compressor coolingsystems, including the following:

System Figure

1. Motor or Turbine Drive 12. Generic Engine Drive 23. Matched Engine/Compressor Set 3

All of the systems considered in this Engineering Standard are for ambient aircooling and a thermostatic coolant control to 180° F. The ambient air can varyfrom very cold to extremely hot. In very cold climates, the thermostat allowsrecirculation of coolant through the bypass to warm the fluid coming from theair cooler. The compressor will warm up faster and will start up with warmer oil.When the ambient temperature is very hot, the compressor oil temperaturebecomes hot also. All the systems include a compressor lube oil shut down at 190°F.

3.1.1.1 The Motor or Turbine Drive compressor cooling system will have acoolant temperature shutdown in addition to all of the above systemfeatures.

3.1.1.2 The Generic Engine Drive compressor cooling system is configuredfor engines that lack sufficient jacket coolant capacity in head or flow tosupply cooling for the compressor. Diesel and gas engines developed fromdiesels are likely to have pumps too small to handle requirements of thecompressor. If there is no pump information available, please use thissystem. In this case, a coolant pump and source of power will be requiredto cool the compressor. The existence of the compressor will add to theengine jacket heat load and coolant flow. An air cooler will need to beselected for the additional requirements.

3.1.1.3 The Matched Engine/Compressor Set compressor cooling systemsare used with engines which have jacket coolant pumps sized toaccommodate the cooling requirements of the compressor

80



Page 3 of 15

81



Page 4 of 15

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Page 5 of 15

3.2 System Design

3.2.1 Motor Drive Compressor Cooling System

3.2.1.1 The system is designed for the hottest day of the year when the maximumcoolant temperature is 180° F. The air cooler is selected to remove all of theheat from the compressor frame. The sketch in Figure 4 shows the coolantflow circuit of a motor-driven compressor frame with three (3) cylinders.

Selection of an air cooler requires that the heat loads and the coolant flowfirst be found. These can be determined using the following equations,along with information about the number and kind of cylinders, theframe on which they will be fitted, and the performance required fromthe cylinders.

83



Page 6 of 15

3.2.1.2 The heat load for each cylinder on a frame can be determined with thefollowing relationship:

Equation 1. q = H x ( (Td + Ts) / 2 - Tc - Tr / 2)

where: q = Cylinder Heat Load BTU/HRH = Cylinder heat transfer coefficient (see Table 3) BTU/HR - deg FTd = Gas Discharge Temperature deg. FTs = Gas Suction Temperature deg. FTc = Coolant Inlet Temperature deg. FTr = Coolant Temperature Rise deg. F

The heat load for each is the calculated for a design of 160° F coolant inlettemperature and 10° F temperature rise through the cylinder. The coolantflow through the cylinder is found with Equation 2.

3.2.1.3 The coolant flow through any cylinder or lubricating oil cooler can becalculated for any temperature rise of the heat transfer fluid with thefollowing formula:

Equation 2. G = 0.1247 x q/Tr/Cp/Dc

where: G = Coolant Flow gallons / minuteCp = Coolant Specific Heat (See Table 1) BTU / lb deg. FDC = Coolant Density (See Table 1) lb / cubic ft.

The most common coolant used in the system is a mixture of 50%Ethylene glycol and 50% treated water. Table 1 shows densities andspecific heats for various coolant temperatures.

Table 1

Coolant Temperature “Tc” Density “DC” Specific Heat “Cp”

80° 66.2 .797100° 65.7 .813120° 65.3 .828140° 64.8 .842160° 64.4 .854

84



3.2.1.4 The frame model, which can be found in Table 2, will determine the sizeof oil cooler. The heat load and design flow is picked from the table. Nowthe total heat load and flow is determined and the air cooler can beselected. Next, calculate the resistance of the system to determine theactual coolant flow and select the coolant pump.

3.2.1.5 In Figure 4, the flow resistances are defined as follows:

Roc = oil cooler values are listed in Table 2.

Rc = cylinder values are listed in Table 3.

Rcp = piping to or from compressor frame (Customer supplied)

Rts = thermostat housing at 180° F coolant (Customer supplied)

Rac = air cooler including piping (Customer supplied)

The sketch is a circuit analogous to an electrical circuit. It can be solved ina similar manner. For our circuit, the current law is a variation on Darcy’ sequation for friction loss.

Equation 3. Pd=RxG2

where: Pd = Pressure Drop in psi

R = Flow Resistance psi/gpm2

G = Flow gpm

There are flow resistances in series and in parallel. We need a total systemresistance to calculate the pressure rise across the pump. The oil cooler andcylinders of the compressor frame are piped in parallel flow paths whilethe air cooler, thermostat housing, and the compressor piping are in series.The solution for the total resistance follows:

Equation 4.

where: Rt = the total system resistance.

Page 7 of 15

85



Page 8 of 15

The total flow of the system is the sum of the oil cooler and cylindercoolant flow and is defined as:

Equation 5. Gt = Goc + Gc1 + Gc2 + Gc3

3.2.1.6 The pressure rise across the pump is found using Equation 3. Now thepump can be selected.

3.2.1.7 With the total flow of the system and the resistances of the oil coolerandthe cylinders we can find out how the flow divides. Then we can calculatethe temperature rise across the cylinders and the oil cooler flow.

For the oil cooler:

Equation 6. Goca = (Rcf/Roc).5 x Gt

where: Goac = actual oil cooler flow.Rcf = the total parallel flow resistance of the oil cooler and the cylinders.

The actual flow can be compared with allowable coolant flow range listedin Table 2. If the flow is outside the range, adjustments to the system willbe required.

3.2.1.8 The flow through each cylinder can be calculated in the same way. In theoriginal assumptions, the temperature rise was 10°F. the actual temperaturerise can be calculated with the following equation:

Equation 7. Tra = 10 x Gc/Gca

where: Tra = Actual temperature rise across the cylinderGca = Actual cylinder flow.

If the actual temperature rise is between 10” and 20”F., no change isneeded to the cylinder flow.

3.2.2 Generic Engine Drive Compressor Cooling System

3.2.2.1 The solution to the cooling system is the same except the engine jacketcooling system shares the same air cooler and is sized accordingly.

3.2.3 Matched Engine/Compressor Set Cooling System

3.2.3.1 The compressor cooling system is connected parallel with the engineblock and the exhaust manifold. The combined flow goes through the

86



engine thermostat at 180° and through the customer's air cooler. A propersystem design depends on the compressor oil cooler flow, cylinder coolanttemperature rise, engine temperature rise, and the engine jacket coolantpump capabilities. Figure 5 is a flow circuit schematic for the coolingsystem. The heat into the system from the compressor is calculated withEquation 1. The engine heat load is obtained from the Superior TechnicalData Book for the engine in question, or the engine performance predic-tion program. The coolant flow through the system is estimated with thedesign flow through the engine (obtained from the Water Pump Char-acteristics), the compressor oil cooler and the compressor cylinder flowfor 10° F temperature rise. The customer's air cooler is then selected for thesystem. The air cooler flow resistance is added to the flow system. The totalsystem resistance is determined and head loss versus the flow in the systemare plotted on the Water Pump Characteristics Curve, the pump dischargepressure and total flow through the system for the application rpm. Theflow obtained in this manner is what the pump and the system resistancewill allow. This will usually differ from the original estimate. We need onlyto confirm the change is of no consequence.

where: Reb = Engine block flow resistance (see Table 4).

Rep = Piping to engine thermostat housing (customer supplied).

Rets = Engine thermostat housing (See Table 4).

Gt = System coolant flow

Geb = Flow through engine block

Gtcf = Flow through the compressor frame

Page 9 of 15

87



Page 10 of 15

3.2.3.2 The parallel resistance to flow for the engine and compressor follows:

Equation 8.Re/c = { l }

2

1 1(2Rcp + Rcf) .5 + (Reb) .5

3.2.3.3 The actual flow through the engine is given with the following equation:

Equation 9. Geba = (Re/c/Reb) .5 x Gt

3.2.3.4 The actual temperature rise for the engine block is obtained with thefollowing relation:

Equation 10. Treb = Geb/Geba x 10

If the temperature rise is between 10° F and 2O° F, the flow through theengine block is adequate.

3.2.3.5 The coolant flow to the compressor is found with Equation 11:

Equation 11. Gtcf = (re/c/(2Rcp + Rcf)) .5 x Gt

The compressor coolant flows to the cylinders and oil cooler are obtainedin the same manner as in the motor drive cooling system. They areevaluated in the same way.

3.2.4 Compressor Coolant Piping Recommendations

3.2.4.1 Cylinders - 3/4" piping to and from coolant headers

3.2.4.2 Oil Coolers - piping to and from coolant headers (see Table 2)

3.2.4.3 Headers - piping to and from cooler or engine

Frame Header Pipe Size

MW & SW62, RAM52 1"

W72, MH & WH62 1-1/2"

MH & WH64, MW & SW64, RAM54 1-1/2"

MH & WH66, MW & SW66, W76 2"

W74 2"

MW&SW68 2"

88



3.2.5 Packing Cooling System Design

3.2.5.1 The system consists of a pump, cooler, and packings connected in parallel.The system coolant flow is 2.5 gpm for each packing. The coolanttemperature to the packing is a maximum of 90° F. The heat rejection tothe coolant is 3000 BTU/hr per packing. The coolant supply pressure to thepacking should be 55 psig. The packing flow resistance is 8.8 psi/gpm2. Atypical system is shown in Figure 6.

3.2.5.2 The system for a nonlube packing will be the same except for the coolanttemperature. The coolant entering the packing must be 70° F for a suitablepacking life.

Page 11 of 15

89



Page 12 of 15

3.3 Component Data Heat Loads and Flow Resistance

3.3.1 Lube Oil Cooler

3.3.1.1 The oil cooler heat load and flow resistance for each frame model is listedin Table 2.

emarF /UTBrh MPR traPrelooC

#

*wolF-siseR

ecnat

elbawollAwolF

egnaR)mpg(

ngiseDwolF

)mpg(

epiP**eziS

26HW&HM 000,24 0021 100-261-026 70100.0 05-03 04 "2/1-1

46HW&HM 000,15 0021 200-261-026 70100.0 05-03 04 "2/1-1

66HW&HM 000,69 0021 300-261-026 72200.0 07-05 06 "2/1-1

26WS&WM 001,32 009 241-919 09700.0 51-8 21 "4/3

46WS&WM 002,64 009 441-919 70100.0 05-03 04 "2/1-1

66WS&WM 001,86 009 141-919 71100.0 05-03 04 "2/1-1

86WS&WM 001,29 009 141-919 71100.0 08-06 07 "2/1-1

27W 005,73 009 441-919 70100.0 05-03 04 "2/1-1

47W 000,57 009 441-919 70100.0 07-05 06 "2/1-1

67W 005,211 009 961-919 72200.0 07-05 06 "2/1-1

25MAR 000,61 0021 241-919 09700.0 51-8 21 "4/3

45MAR 000,23 0021 441-919 70100.0 05-03 04 "2/1-1

.sevlavllab)2(owtdnaepipfoteef01sedulcniecnatsiserehT*.relooCotredaeHmorF**

Table 2: Oil Cooler Heat Load and Flow Resistance

90



3.3.2 Cylinders

Page 13 of 15

rebmuN6W 6HWrebmuN

rednilyCretemaiD

egnaRssalC

refsnarTtaeH"H"tneiciffeoC

Fged-rh/UTB

wolFtnalooC*"R"ecnatsiseR

mpg/isp 2

4-1 31.3-57.2 SA 008 410.0

31-01 83.3-00.3 SB 008 410.0

9-5 88.3-52.3 RSB 008 410.0

361-751 016-606 57.4-88.3 FCB 008 410.0

416-116 57.5-00.5 FDB 008 410.0

19-5802-41 57.4-00.4 FSC 008 410.0

89-2903-42 57.4-00.4 C 008 410.0

38,32-12 57.5-00.5 FSD 008 410.0

311,43-13 57.5-00.5 D 008 410.0

386,716-516 57.6-00.6 FSE 008 410.0

411,67 57.5 DAE 008 020.0

93-73 00.7-05.6 E 008 020.0

44-04 00.7-00.6 DE 008 020.0

611-511 57.7-05.7 DE 008 020.0

651-551 00.7-05.6 DE 008 020.0

911,81105-54 05.8-52.7 DF 048 020.0

421-321 05.9-00.9 DF 048 020.0

286-766286,726 05.9-05.8 ADF/DF 048 020.0

221-021,75-15 3.01-57.8 DG 069 020.0

041-341 3.01-00.9 DG 069 020.0

926 52.01 DG 069 020.0

601-201 00.21-00.9 HG 0001 110.0

48,26-5 0.31-5.01 DH 0021 110.0

931-831721-521 5.21-0.11 DH 0021 110.0

Table 3: Cylinder Heat Transfer Coefficients and Flow Resistances

91



Page 14 of 15

Table 3, Continued

rebmuN6W 6HWrebmuN

rednilyCretemaiD

egnaRssalC

refsnarTtaeH"H"tneiciffeoC

Fged-rh/UTB

wolFtnalooC*"R"ecnatsiseR

mpg/isp 2

276-176046-736 0.31-0.11 ADH/DH 0021 110.0

331,66-36 3.51-5.31 DJ 0021 110.0

631-731,211 8.51-0.51 DJ 0021 110.0

111-901 5.41-5.31 DJ 0021 110.0

446-146476-376 8.510.41 ADJ/DJ 0021 110.0

86,801 5.81-0.81 DK 0051 110.0

431-531 5.81-5.71 DK 0051 110.0

08-87 0.91-0.81 ALK 0051 110.0

921,28,07 0.22-0.02 DLK 0051 110.0

77,27,17 0.32-0.22 DL 0051 110.0

031,57-37 0.62-5.42 DM 0051 110.0

231,141 5.62-5.22 DM 0051 110.0

366-266126-816 52.7-57.5 /DN

**ADN 0021 020.0

166-956666-466626-526

00.8-00.6 /DP**ADP 066 020.0

076-866076-036 00.21-00.9 /DQ

**ADQ 0801 110.0

576646-546 0.81-0.71 /DR

ADR 0231 110.0

946-846 5.02-5.91 DS 0051 110.0

156-056 5.32-5.22 DT 0612 110.0

356-256 5.62-5.32 DT 0291 110.0

.sevlavllab)2(owtdnaepipfoteef)01(netsedulcniecnatsiserehT*.stnemeriuqerecivresroferehniamertub,delooc-nonotdetrevnocneebevah.slycesehT**

92



3.3.3 Superior Engines

Table 4: Flow Resistance

enignE kcolBenignE tatsomrehTenignE

BTGS8 640000.0 900000.0

BTGS21 430000.0 900000.0

TGS61 410000.0 900000.0

Page 15 of 15

93



ES 4009Determination of CompressorCylinder Dead Center Position1.0 Scope

This procedure describes the correct way to locate the head end dead center position for anycompressor cylinder. It should be used to mark the flywheel wherever cylinders areindicated with a balance pressure indicator or an analyzer. Analyzers use a pulse from amagnetic pickup to signal out dead center. The pulse is generated from a pin or a hole,which should be located in the largest diameter available on the flywheel.

2.0 Procedure2.1 Remove a crosshead cover on either #l or #2 throw cylinders. These cylinders are

chosen for convenience, since they are closest to the flywheel.

2.2 Manually bar over the unit until the selected (#l or #2) cylinder is approximately deadcenter.

2.3 Install a dial indicator on the crosshead guide in such a manner that the stylus of theindicator rests squarely on one of the ends of the crosshead. On some units, it may beeasier to install the indicator on the crosshead rather than the crosshead guide. In thisarrangement, adjust the stylus so that it rests squarely on a vertical surface ofthe crosshead guide.

2.4 Bar the unit over first in the actualdirection of rotation until the piston isat the approximate head end (HE) deadcenter point (the dial indicator willstop moving at this point). With thecylinder resting on the approximateHE dead center, set the dial indicatorto a zero reading.

2.5 Back the crosshead away from HEDCby barring over the unit in the direc-tion opposite normal rotation untilthe indicator reading exceeds +0.030".

Page 1 of 3

94



Then bar over the unit in the normal rotation until the indicator reads +0.015".

2.6 With the dial indicator reading +0.015, scribe a line on the flywheel (either the engineflywheel or the compressor flywheel, whichever is easier) in line with the pointer. (See“Line 1” in previous sketch in Paragraph 2.5.)

2.7 Continue to bar over the unit in the normalrotational direction until the crossheadtravels through HEDC and the indicator reads+0.030" again. (The indicator reading willdecrease to zero and then increase to +0.030).

Then bar over the unit in the direction oppositenormal rotation until the indicator reads +0.015".

2.8 With the dial indicator reading +0.015, scribe a second line on the flywheel oppositethe pointer. (See “Line 2” in previous sketch in Paragraph 2.7.)

2.9 Now measure the distance between thetwo scribed lines and then scribe a thirdline on the flywheel exactly equidistantbetween the first two lines. This thirdline is the head end dead center (HEDC)point and should be labeled “#l HEDC”or “#2 HEDC”, depending on thecylinder that was checked.

2.10 To check the accuracy of the HEDC line, theprocess should be repeated using 2.10through 2.14. Bar the unit over in the directionopposite normal rotation to align thethird line (see 2.9), HEDC mark, with thepointer. Set the indicator to a zero reading.

2.11 Bar the unit over in the direction oppositenormal rotation, continuing past Line 1 untilthe indictor reads +0.030".

2.12 Bar the unit over in the normal rotation toalign Line 1 with the pointer. Record reading “a.”

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2.13 Continue barring the unit over in the normal rotation past Line 2 until the indicatoragain reads +0.030.

2.14 Bar the unit over in the direction opposite normal rotation to align Line 2 with pointer.Record dial indicator reading “b.” Reading “b” should match reading “a” from Step 2.12within 0.002".

2.15 If “a” and “b” differ by more than 0.002", repeat Steps 2.4 through 2.14 until this level ofaccuracy has been achieved.

2.16 A pin or hole for a magnetic pickup should be installed on the “middle” scribed line.The magnetic pickup must be rigidly mounted and located such that there is a gap of0.030 to 0.040 inches between the pickup tip and the pin or hole.

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ES 4010Balanced Pressure Indicator Testing:Requirements, Procedure &CalculationsA. Scope

This standard outlines the requirements, procedures and calculations necessary to performand properly report a balanced pressure indicator test on a compressor. Its use wi II provideconsistent and accurate results, and conform to current industry-accepted practices. Allindicator tests and reports issued should conform to this standard.

B . Requirements and Procedure1. Assemble the required test equipment shown on Table I, Page 11.

2. Prior to test, all pressure gages should be calibrated using the dead weight tester and allthermometers should be checked for accuracy in an oil or water bath.

3 . When required, measure the clearance volume of the cylinders in question inaccordance with ES 4008.

4. Check all significant hardware (piston rings, packing and valves) and assure that it is ingood working order. Replace parts as required. Set the proper head end and crank endend-clearances.

5. Locate the head end dead center of Throw #2 and properly mark the flywheel inaccordance with ES 4009 .

6. Remove the crankshaft extension cover (C-910-812) from the auxiliary end and installthe crankshaft extension seal (Y-900-461, 465) in its place. This exposes the crankshaft sothat the Balanced Pressure Indicator (BPI) can be coupled to the compressor.

7. Couple the BPI to the crankshaft extension using the Woods coupling assembly. Levelthe indicator and align it to the coupling to prevent binding and vibration and allowfor smooth operation of fhe instrument.

8. Adjust the single lobe cam on the breaker point assembly such that the points just“break” when the #2 cylinder is located on HEDC. (This point setting is also described aswhere the follower is just starting on the down slope of the cam lobe. )

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9. Install all other test gear. All pressure and temperature measurements must be taken atthe cylinder nozzles (flanges) and at the valve caps when connection taps are available.

10. Start the unit, and when the normal operating speed is achieved, readjust the breakerpoint setting. By use of the timing light, adjust the points so that the #2 HEDC mark onthe flywheel is exactly in line with the pointer.

11. Check out all instrumentation to ascertain that it is functioning properly.

12. Allow the unit to reach operating temperatures and then load the compressor. Adjustthe suction and discharge conditions as close to design conditions as possible. Allow theunit to continue running until the operating conditions stabilize.

13. Dismantle and clean the diaphragm pressure pick-ups. Reassemble using newdiaphragms when required. Using a water-filled manometer and the Simpson meter,calibrate the pick-ups so that they operate or “switch” at a pressure differential of 5-10"of water or less. Where measured pressures are 30 psig or less, calibrate the pick-ups to3 - 5" of water. Use the adjustable “spark plug”-type pick-up for these low pressures.

14. Install the pick-ups in the first cylinder and begin indicating. Use the “spark plug” pick-up only in the first stage suction and only where pressures are less than 30 psig.

15. Indicate the first stage cylinder(s) of a multistage unit first and progressively work to thehigher stages, indicating the final stage cylinder(s) last. The pressure pick-ups willnormally function accurately without having to be recalibrated when the cylinders areindicated in this sequence. Any pick-up must be recalibrated when it is moved from ahigher stage to any one of the previous stages.

16. For each set of test conditions, indicate the complete unit (all cylinders) twice. This is toassure that good data is achieved. The proper sequence is to indicate the unit startingwith the first stage and proceeding to the last stage as described in Paragraph 15. Whenthis “first pass” is completed, then indicate the second time using the same sequence.

17. For each cylinder indicated, the following data must be taken:

a. Plot a pressure-time (P-T) card for each end. A separate sheet should be usedfor each end so the cards can be accurately replotted. However, when time does notpermit this, both ends may be superimposed on the same card, providing the cardsare legible.

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Page 3 of 11

b. Each P-T card should be properly labeled and contain a suction line, a dischargeline, the cylinder end line(s), a minimum of 4 reference pressure Ii nes, and the #2HEDC line. Always check the “timing” before plotting each P-T card and againbefore plotting the $2 HEDC line on the card, The ea center line is of paramountimportance d d to the card accuracy and it must be plotted correctly. One degreevariation can mean several per cent error in results.

c. Pressure, temperature, speed, and engine load data must be recorded with eachindicator card and recorded on the ES 4010 data sheet, a sample of which is shownat the end of this standard. ‘ Pressures are to be recorded at the cylinder flanges (orpreferably at the valve caps when connections are available) using the dead weighttester. For pressures 5 5 PSIG, a mercury or water filled manometer should be used inlieu of the dead weight tester* Temperatures are to be recorded at the samelocations as the pressure data using the mercury-in glass or the Fisher ScientificPrecision Thermometers inserted directly into the gas stream. Record the speedwith the Hasler revolution counter.

18. When the last indicator card has been plotted,-do not remove it from the indicator.Stop the unit and then bar over the unit in the normal rotation until the #2 HEDCmark is aligned with the flywheel pointer. At this position, the stylus on the indicatirshould be in line with the dead center line plotted on the card. If not, the timing hasslipped. The data should be voided from this test run and the test repeated.

19. Using the replotter, replot each P-T card into a pressure-volume (P-V) diagram. Eachcylinder end should be plotted on a separate sheet. The total area of the P-V diagramcan be determined by using a planimeter at the same time the card is being replotted,If the cards are planimetered, separately, repeat until the readings agree within 0.5%.

20. Each P-V diagram should contain all of the features as shown on the sample diagramfound on Page 8. CAUTION: When replotting, be certain to properly “phase ” thesuction and discharge lines with the P-V diagram itself. This is extremely importantwhen analyzing valve losses. Proper setting of dead center is imperative in this process.

21. Once the P-V diagram has been replotted, the BHP, capacity, and valve losses (whenrequired) can be calculated using the following method:

a . Scale Factor of P-V diagram:

SF = Pr1 - Pr2

d

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Page 4 of 11

where SF = scale factor of P-V diagram (psi/in.)

Pr1 = a reference pressure on P-V diagram (psi)

Pr2 = another reference pressure on P-V diagram (psi)

d = distance between Pr1 and Pr2 (in.)

b. Indicated Mean Effective Pressure of applicable cylinder end:

IMEP = (SF) (A) L

where IMEP = indicated mean effective pressure (psi)

SF = scale factor of P-V diagram (psi/in.)

A = area of P-V diagram (in.2)

L = length of P-V diagram (in.)

c. Indicated horsepower required by applicable cylinder end:

IHP = (IMEP) (Ap) (N) (S/12)

33000

where IHP = indicated horsepower

IMEP = indicated mean effective pressure (psi)

AP = effective piston area (in.2)

N = rotational speed (RPM)

S = stroke (in.)

d. Brake Horsepower used by applicable cylinder end:

IHPBHP =

EM

where BHP = brake horsepower

IHP = indicated horsepower

EM = mechanical efficiency (0.95)

100



e. Terminal Inlet Pressure (Toe Pressure) in applicable cylinder end:

Pt = Pr + (h) (SF) + Pb

where Pt = terminal inlet pressure (PSIA)

Pr = reference pressure (PSIG)

h = distance from P-V diagram toe to Pr (in.)

SF = scale factor of P-V diagram (PSI/in.)

Pb = atmospheric or barometric pressure (PSIA)

f. Volumetric Efficiency (Suction) of applicable cylinder end:

VE = Ls x100 L

where VE = volumetric efficiency (suction) (%)

Ls = distance from suction toe to expansion line at terminal inlet (suction toe) pressure (in.)

L = length of P-V diagram (in.)

g. Piston Displacement of applicable cylinder end:

PD = (Ap) (S) (N)

1728

where PD = piston displacement (CFM)

Ap = effective piston area (in.2)

S = Stroke (in.)

N = rotational speed (RPM)

h. Volumetric Rate of Flow through applicable cylinder end:

QA = (PD) (VE) (1440) (10-6)

where QA = volumetric rate of flow at suction conditions (MMCFD)

PD = piston displacement (CFM)

VE = volumetric efficiency (suction)

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Page 6 of 11

i. Capacity pumped by applicable cylinder end:

Qs = QA x Pt x

Tsc x 1

Psc TS Zs

where QS = capacity at standard conditions (MMSCFD)

QA = volumetric rate of flow at suction conditions (MMCFD)

Pt = terminal inlet pressure (PSIA)

Psc = standard base pressure (14.7 PSIA)

Tsc = standard base temperature (520° R)

TS = suction temperature (°R)

ZS = compressibility of gas at suction conditions

j . BHP/MMSCFD of applicable cylinder end:

BHP/MMSCFD = BHP

Q S

where BHP = brake horsepower used by cylinder end

QS = capacity pumped by cylinder end (MMSCFD)

k. Valve losses in each cylinder end:

SVL = ASVL

DVL = ADVL

A A

where SVL = suction valve loss (% of BHP)

DVL = discharge valve loss (% of BHP)

ASVL = discharge valve undertow area of P-V diagram (in.2)

ADVL = discharge valve overhead area of P-V diagram (in.2)

A = total area of P-V diagram (in.2)

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22. Summarize all calculations on the ES 4010 calculation summary sheet, a sample ofwhich is shown at the end of this standard.

23. Prepare a written report to describe the test results and include all P-T cards, P-Vdiagrams, data sheets, and calculation summary sheets arranged in a logical sequence.

Page 7 of 11

103



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107



ES 4100Compressor Field Performance TestSpecification1.0 Scope

This standard outlines the requirements, procedures and calculations necessary to perform,interpret and properly report field performance tests on Ajax, Superior or Joy reciprocatingcompressors and to ensure that results are valid.

2.0 Purpose2.1 The requirements of this specification are mandatory where verification of

guaranteed compressor capacity and/or power by field testing is required by thecustomer.

2.2 This test procedure is to be used for accurate assessment of:

2.2.1 The capacity of the individual compressor cylinders,

2.2.2 The brake horsepower demand of the individual gas compressor cylinders,

2.2.3 Overall compressor capacity, horsepower and efficiency.

2.3 This procedure is also recommended for diagnosis of actual or suspected operatingproblems or discrepancies, such as valve plate or spring failures, pulsation-inducedvibration, high discharge temperature, low capacity, low efficiency (BHP/MMSCFD) ordriver overload.

2.4 Supplemental specifications ES4101 and ES4102 provide general requirements for fieldperformance test instrumentation and for analysis and interpretation of results.

3.0 Pre-Test Requirements3.1 Preliminary Investigations

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3.1.1 Prior to undertaking a field performance test, it is important to review the unit’soperating history and the process which the compressor supports. This canuncover errors that may invalidate the test. In the case where a test is to beconducted to evaluate an operating problem, this review may uncover the actualproblem without expending the time and expense involved in a rigorousperformance test. Preliminary investigations should focus on a number of areasas listed in paragraphs 3.1.2 through 3.1.9. Many of these investigations can bemade by plant operations or maintenance personnel, with direction from Ajax-Superior technical representatives.

3.1.2 Process piping should be inspected for errors, faulty valves and improperly sizedvalves.

3.1.3 A recent gas sample should be analyzed to assess whether the compressor isworking with a gas composition that is the same as, or at least similar to, the gason which performance curves and or representations were based.

3.1.4 Recent plant operating log sheets should be reviewed and operating conditionscompared with the performance curves.

3.1.5 Since performance is represented at the compressor flanges and based on suctionflow, look for excessive system pressure drops before and after the individualcompressor cylinders. Investigate whether the operators have checked andcleaned piping screens, and determine what the history of cleaning has been.

3.1.6 Verify whether the specified clearance plugs, valve spacers and other clearancedevices are installed and adjusted according to the performance curves.

3.1.7 Investigate whether suction pressure is stable or varies with time, as compressorthroughput is very sensitive to suction pressure.

3.1.8 Particularly in services other than gas transmission, investigate whether thereare significant amounts of liquid drop-out at the interstage scrubbers.

3.1.9 Determine the location and type of the flow meter being used to ascertain thatflow is accurately measured upstream of the compressor.

3.2 Verify Compressor Mechanical Condition

3.2.1 For design confirmation and performance guarantee demonstrations prior toconducting a performance test, it is important to confirm that the compressorand cylinders are in good mechanical condition. Compressors that have operated

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for some period of time may have worn piston rings, worn packing, deterioratedcompressor valves or other wear that can adversely affect performance. Evennew compressors should be checked, since it is possible that dirt or other foreignmaterial, ingested at the time of process start-up, can cause rapid and prematuredeterioration of cylinder internal components.

3.2.2 The checks listed below in paragraphs 3.2.3 through 3.2.10 will require asignificant amount of time and labor prior to the test. However, they willgenerally save time overall.

a. These inspections shall be mandatory prior to conducting a performancetest for the purpose of verifying a performance guarantee with standard threepercent tolerance.

b. These inspections are recommended prior to conducting a performance testfor reasons other than verifying a performance guarantee. Failure to performthem may lead to costly repeat testing, after remedial mechanical corrections arecompleted. It is recognized that it may not be feasible to make every check in allcases; however, exceptions must be made with care and with consideration ofthe risk of invalidating the performance test results.

c. Where previous maintenance analyzer records have been maintained, skilledtechnicians may be able to verify the condition of compressor cylinders throughthe use of a maintenance analyzer, rather than by physical checks. This approachmay be an acceptable alternative to the requirements of paragraphs 3.2.3 through 3.2.6.

3.2.3 All valves must be inspected and reconditioned to like-new condition. Any seatsor guards with flaws must be reconditioned, and new plates and springs installedwhere needed. Valve cap O-rings should be carefully checked and replaced ifthere is any sign of mechanical or chemical distress.

3.2.4 Inspect valve pocket bores in the cylinders for damage which might lead toexternal leakage or internal leakage around the compressor valves.

3.2.5 The condition of the piston rings and ring grooves must be checked. At least onepiston per stage must be removed so that the rings can be inspected to ensurethat they are not in a deteriorated or leaking condition. While the piston is out,the cylinder bore should be inspected for any scratches or wear that might causeleakage in operation. If rings or pistons are found to be worn or deteriorated,they must be replaced, and all other pistons from that stage removed andinspected similarly. Cylinder bore damage should be honed smooth, if minor. If

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cylinder bore damage is substantial, other reclamation procedures or cylinderreplacement must be considered.

3.2.6 Packing ring condition must be checked to make sure that the rings, case andpiston rod are in good condition and won’t cause abnormal or excessive leakage.Check the packing drain/vent for leakage and the crosshead guide packingcavity for gas leakage and ring debris. Verify that the packing is receiving properlubrication and is properly aligned. Worn or damaged components must berepaired or replaced as appropriate.

3.2.7 With the compressor operating, check the variable volume pocket (VVP) balanceline for high temperature. If the temperature is high, the VVP piston ring may bebroken or worn, requiring inspection and repair. The scale readings on each VVPshould be verified. The VVP must be screwed all the way in and the position ofthe rod checked against the scale to ensure that it is set and reading accurately(i.e., the scale should read “0” when the VVP is closed).

3.2.8 Outer dead center of at least one compressor throw must be determined usingthe procedure specified in ES4009 (contact Superior Marketing). Usually, thisshould be the number one or number two throw.

3.2.9 If the cylinder head end (HE) or crank end (CE) clearance volume is in question,at least one of each cylinder size on the compressor must be checked using theprocedure specified in ES4008 (contact Superior Marketing).

3.2.10 All unloading devices should be cycled to check for proper operation. In caseswhere oil or dirt may be trapped in an unloader, it should be drained or cleanedas necessary to ensure that the full clearance volume is available.

3.3 Inspect Process System and Piping

3.3.1 All piping and valves should be checked to determine that they are properlyopen or closed, and that there is no bypassing or recycling of gas.

3.3.2 Check scrubber and other vessel drain systems for evidence of liquid drop-outduring operation. If drop-out is evident, this will have to be measured during theactual testing.

3.3.3 Confirm that cylinder cooling water is unrestricted and at proper temperature.

3.3.4 Determine the location of the system flow meter and ascertain what flow itmeasures, e.g., suction or discharge. Note that Ajax-Superior performance curvesand guarantees are based on suction flows unless otherwise specified.

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3.4 Other Pre-Test Requirements

3.4.1 Prior to conducting a field performance test for the purpose of verifying aperformance guarantee, there should be agreement between Cooper and thecustomer as to the guarantee or design point(s). If the customer will not be ableto run the guarantee or design condition, there should be prior agreement on theconditions that will be run to evaluate the compressor performance.

3.4.2 The system flow meter must be calibrated or otherwise certified prior to the startof testing. Flow meters should meet AGA standards or equivalent. It is generally thecustomer’s responsibility to provide this verification. The method of calculatingflow from measured data shall be provided to Ajax-Superior prior to the test.

3.4.3 Calibrated pressure and temperature gauges (or electronic transmitters) must beinstalled before and after each stage as close to the cylinders as possible. It mayalso be necessary to install pressure gauges at various points in the gas system todetermine the magnitude and location of system pressure drops.

a. The range of each gauge should be properly selected for the operating testconditions. See ES4101 (contact Superior Marketing) for specific recommendations.

b. Each pressure and temperature gauge must be calibrated in the range forwhich it will be used in the test. See ES4101 for specific recommendations.

c. An official record of each device’s calibration should be documented forfuture reference.

3.4.4 Provision must be made for a gas sample during the test. This should be obtainedin a pre-purged sample bottle and the composition analyzed as soon as possiblein a lab. Preferably, gas samples should be obtained both upstream anddownstream of the compressor if drop-out is suspected. In some cases wheredrop-out is substantial (more than one percent of mass flow) it is necessary toobtain samples after each scrubber, as well as at the first cylinder suction.Samples should be taken from locations that will prevent dirt and liquidcontamination of the gas sample.

a. Where available, station on-line gas analyzers can be used to take continuoussamples. In such cases it is important that the analyzer samples the actual gas inthe same condition as it passes through the compressor suction (i.e., not aftermixing of a side-stream, drop-out of water or hydrocarbon liquids, etc.)

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b. Gas analyses will usually be reported dry, i.e. any water vapor content willnot be indicated. Visual observations of scrubber drains and inside thecompressor intake (with the compressor shut down and depressurized) will needto be made to ascertain whether the gas is really dry or saturated. Thisinformation must be noted on the test log sheet and the gas composition willhave to be adjusted for any water content prior to determining the finalcompressor performance from the test data.

3.4.5 Verify the presence of, and add as necessary, cylinder indicator passages andappropriate analyzer connections and valves per ES4101 (contact Superior Mar-keting). Most Ajax-Superior cylinder bodies have test ports at the suction anddischarge flanges of the cylinder and on the horizontal center line of thecylinder to read internal pressures during the compression cycle.

WARNING: Adding any drillings or weldments to, or otherwisemodifying, compressor cylinders, piping or pressure-containingvessels or components must be done with proper consideration ofthe effects on mechanical strength and integrity, certificationrequirements and safety. Improper alteration of pressurizedvessels or components can result in explosions, damage toequipment, and injury or death to personnel.

a. Some forged steel cylinders do not have internal indicator test ports. ConsultAjax-Superior Engineering for recommendations if it is necessary to field testsuch cylinders.

b. With the compressor shut down and cylinders de-pressurized, remove plugsfrom each indicator connection and insert a wire into the passage to ensure thatit is actually present and clear.

c. If a suction oil flushing system is present, the flange port may not beavailable for testing. If this is the case, the flushing system can be temporarilydisconnected during the test, or a suction bottle port can be used instead if thereis no restriction, such as an orifice, between the suction bottle port and thecompressor suction flange.

3.4.6 Indicator test ports should also be installed in suction and discharge bottles andaccompanying piping. These are used to measure pressure drops and toinvestigate any pressure pulsations that may be present during operation. Fordiagnostic purposes, test ports should be located upstream and downstream of

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orifices, choke tubes, in bottles and bottle nozzles so that pressure drops andpulsation levels across these restrictions can be measured. Obtain details of eachinternal bottle construction to determine where pressure test ports should be located.

3.4.7 With the compressor shut down and de-pressurized, test valves should beinstalled at each test port. Full-ported ball valves are preferred and must have apressure rating higher than the cylinder working pressures. Kiene valves andneedle valves should not be used, as they have internal flow restrictions thattend to dampen the pressure signal causing inaccurate indicator results on mosthigh speed compressors.

WARNING: Many ball valves will not be suited for long term usein this service. They should therefore be removed at theconclusion of the indicator test. This should be done with thecompressor shut down and depressurized.

3.4.8 A drive coupling, connected to the end of the compressor crankshaft, must beprovided for the rotary encoder. This must be a torsionally rigid coupling asexplained in ES4101 (contact Superior Marketing).

3.4.9 Provide for appropriate analyzer and calibrated transducers per ES4101.

3.4.10 Provide for an accurate on-site barometric pressure indication. This isparticularly important for accurate performance assessment on compressorswith suction pressures below 300 psi. This may require taking a barometer to thesite. Barometric pressure readings reported by airports and radio stations areusually corrected to sea level and thus are not valid for use in calculatingcompressor performance, unless properly readjusted to site conditions. Forcompressors driven by Superior CleanBurn™ gas engines with CleanBurn™ II air-fuel control panels, the barometric pressure read-out in the panel may be used ifno other barometric pressure indication is available.

3.4.11 Prepare a set of log sheets. Generally, the standard log sheets provided in ES4102should be used (contact Superior Marketing).

3.4.12 Identify the personnel who will be involved in performing the test. Determineeach person’s role and review the test procedure with them. Make a “dry-run” ofall tasks before actually starting the test. Make sure that assignments are clearlyunderstood so that testing time can be minimized and conditions can be heldstable for the duration of each test point.

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3.5 Safety

3.5.1 Prior to conducting any type of tests, review all customer’s, operator’s andowner’s safety procedures with cognizant site personnel.

3.5.2 Always make sure that the above safety procedures are followed during theactual testing.

3.5.3 Prior to testing, review equipment instruction manuals and become generallyfamiliar with the operation of the equipment to be tested and its operating systems.

3.5.4 Avoid specifying or running at any operating conditions that might expose person-nel to risk of injury or death, or plant machinery or other equipment to damage.

4.0 Indicator Test Measurement Standards,Instrumentation & Equipment4.1 See supplemental standard ES 4101

5.0 Test Procedure & Requirements During The Test5.1 Analyzer Set-Up

5.1.1 Transducers must be calibrated using a dead weight tester (See ES4101) beforeeach test run and after each transducer change. Care should be taken to ensurethat the transducer is calibrated across its range and that the range is appropriatefor the pressure being measured. Also, the transducer must be a cooled type toreduce the effects of thermal drift.

5.1.2 The zero should be checked at each reading.

5.1.3 Position the analyzer such that it is in a cool area and so that it doesn’t have to bemoved during testing.

5.2 Gas Samples

5.2.1 When testing with a suction flow meter, a gas sample should be taken just upstream of the meter to confirm gas composition and properties.

5.2.2 When testing with a discharge flow meter, gas samples should be taken in thesuction line before the compressor (prior to any scrubbers or vessels) and in the

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ALLOWABLE DEVIATIONSVariable Allowable

Deviations

Average suction pressure +/- 1%Average discharge pressure +/- 1%Suction temperature +/- 2°FSpeed +/- 0.5%Cooling water inlet temperature +/- 2°FCooling water flow rate +/- 3%Metering temperature +/- 3°F

discharge line just prior to the meter to determine if the gas compositions are thesame. If they are not, then liquid has probably dropped out during thecompression and cooling processes.

5.3 Liquid Drop-Out

5.3.1 If the gas properties do not agree in step 5.2.2 or if the system scrubbers aredraining liquids, then liquid drop-out is occurring and must be measured orotherwise accounted for in the test results.

5.3.2 To measure the drop-out, the scrubber manual dump valves can be closed whenstarting the test. This will allow the drop-out to collect in the scrubber. For ameasured period of time at constant operating conditions, by marking thestarting position and ending position of the liquid levels, and by knowing theinternal diameter of the scrubber (for cylindrical vessels), the liquid volumedrop-out rate can be calculated.

5.4 Bypass Valves

5.4.1 Using a temperature sensing device, make sure that the system bypass is notleaking. If the bypass line temperature changes significantly from when thecompressor is not running, then the bypass valve is probably leaking and the testresults will be invalidated. An ultrasonic transducer can also be placed on thebypass valve during the test to check for leakage.

5.5 Stable Operating Conditions

5.5.1 During the data collection phasedescribed in section 5.7, theoperating conditions must notvary significantly for the durationof the test. The data must bewithin the allowable deviationslisted in Table 1, which are basedon SGA-PCRC 84.10a. If conditionsvary more than this amount, theaccuracy of the test will becompromised and it will have to be rerun.

Table 1

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5.6 Unit Warm-Up

5.6.1 Prior to recording data, the compressor must be allowed to warm up to reach thestable operating conditions described in section 5.5. This usually requires sixty(60) minutes after a cold start or thirty (30) minutes after a warm start.

5.7 Data Collection

5.7.1 At the beginning and end of each test, and every fifteen (15) minutes in between,the data shown on the log sheet (see ES 4102) should be recorded so that all stagepressures, temperatures, etc. are known. This may require an extra person forrecording this data.

5.7.2 Each cylinder should then be indicated, taking pressure-volume (P-V) cards as aminimum.

a. When using the ENSPEC 3000 or 1400, the transducer is first attached tothe suction line, then the discharge line and next the head end (HE). Then thetransducer is connected to the suction line, discharge line, and the crank end(CE) connection, in that order. This process is then repeated for each cylinder.

b. These cards should be inspected to make sure the suction and dischargetraces are located reasonably and the IHP is close to that expected. If any aspectof the card is suspect, the measurement equipment should be checked and thetest rerun.

5.7.3 It is often advisable to take pressure-time (PT) cards in the HE and CE valvepockets to study valve opening and closing events.

5.7.4 PT cards should be taken on the suction and discharge if excessive pulsation issuspected. These traces will aid in determining the significance (frequency andamplitude) of the pulsation.

5.7.5 Additional PT cards can be obtained at various points, such as in pulsationvessels, before and after vessels, etc., to check for pulsations.

5.7.6 When investigating pulsations, indicator cards should be taken as close to thecompressor valves as possible, i.e., in the cylinder body through the suction anddischarge flanges and through the valve caps.

5.7.7 The distance from the measured pressure to the transducer should be as short aspossible and the fittings should conform to the requirements shown in ES4101.

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6.0 Analysis & Interpretation of Results6.1 See supplemental standard ES 4102

7.0 Reporting Of Results7.1 At the conclusion of the analysis and interpretation of the test results a report should

be written to summarize conclusions and provide any necessary recommendations.Stated opinions and conclusions must be supported by factual data or documentedobservations.

7.2 The report should include copies of important indicator cards, log sheets, calculateddata and other pertinent information that will allow the reader to understand how thetest was run and to interpret the results.

7.3 A copy of the report should be sent to the local CES Branch Office and to the Manager,Product Engineering at Ajax-Superior in Springfield, Ohio.

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ES 4101Ajax-Superior CompressorField Performance TestInstrumentation1.0 Scope

1.1 This standard defines the instrumentation required to accurately do fieldperformance tests on Ajax, Superior, or Joy reciprocating compressors. Calibrationprocedures for the instrumentation are also listed.

1.2 This standard is a supplement to ES4100, Ajax-Superior Compressor FieldPerformance Test Specification.

2.0 Purpose2.1 This supplement lists the instrumentation accuracies and calibration methods

required for field tests that involve compressor capacity or horsepower guarantees.These requirements are also recommended for maintenance testing.

2.2 Testing procedures are listed that will insure accurate performance data.

2.3 Techniques for operating analyzers vary between analyzer manufacturers. Unlessotherwise noted, the procedures listed are for the Entronics En-Spec 1400 and En-Spec 3000 analyzers. The required accuracies and calibrations apply, however, toindicating testing done with analyzers from any manufacturer.

3.0 Compressor Analyzers3.1 Modern cylinder analyzers are data acquisition systems that read pressures from an

analog pickup and convert this reading to a digital signal. These pressures can thenbe saved and processed by a microprocessor which is part of the analyzer. The resultscan also be saved to a computer.

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3.2 The pressures in the cylinder and in the suction and discharge nozzles are saved as afunction of crank angle. Analyzers use the compressor dimensions to calculate theswept volume at each angle reading and then produce pressure-volume diagrams andcalculate compressor horsepower. Pressure-crank angle plots are also made todetermine system pressure drops and gas pulsations.

3.3 The analyzer records the cylinder and nozzle pressures in relation to the crankshaftposition and a starting point or out dead center is required.

4.0 Out Dead Center4.1 The analyzer uses a pulse from a magnetic pickup to signal out dead center. The

magnetic pickup must be rigidly mounted to sense a steel pin or a drilled hole ineither the flywheel or coupling hub. The pin or hole should be located in the largestdiameter available. With a large diameter, out dead center is easier to locateaccurately and the higher velocity at this point will generate a stronger signal for theanalyzer. Out dead center is established according to Superior Engineering StandardES 4009. Out dead center must be accurately located. A one-degree error in out deadcenter will typically result in a three percent error in indicated horsepower. For a 12-inch diameter coupling hub, one degree is only 0.1 inch of travel around the hub.

4.2 It has been suggested that bearing clearance could cause the out dead center duringrunning to be different than the out dead center found using ES 4009. Superior didlaboratory testing to compare both methods and determined that out dead centerdid not change on either the Ajax or Superior units.

5.0 Encoder5.1 The speed of a compressor changes throughout each revolution due to the torque

change within each revolution. To obtain accurate pressure-volume cards, anencoder must be used to phase the pressure readings to the crankshaft position.Analyzers that use a one-per-revolution signal and divide each revolution into equaltime intervals cannot compensate for the speed change within each revolution.

5.2 The encoder drive must be attached to the compressor crankshaft; friction drivescan slip and cause errors. A torsionally rigid coupling is used to connect the encoderto the compressor crankshaft drive. Sections of rubber or plastic tubing will notallow accurate phasing. The encoder shaft must be parallel to the crankshaft to

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maintain the correct angle location and to prevent breakage of the coupling.Renbrandt Fleximite is a recommended low inertia, torsionally rigid coupling.

5.3 For frames that drive a lubricator off the end of the crankshaft, a lubricator driveshaft is provided that permits driving an encoder on the free end of the shaft. Thecrankshaft to drive coupling must also be torsionally rigid. The Thomas Style CC,Size 62 flexible coupling supplied by Superior is recommended for the crankshaft todrive coupling.

5.4 An adaptor must be used between the lubricator drive and the encoder coupling dueto the different shaft sizes.

5.5 The encoder drive assembly for an SW frame with a lubricator drive off the end ofthe crankshaft is shown for reference in Figure 1 and its bill of material in Table 1.

ES 4101

Bill Of Materials

Item Description Comments Part Number

1 Drive on crankshaft ----

2 Thomas size 62 coupling 1/2" lubricator shaft5/8" lubricator shaft

B-909-524-00 B-909-524-002

3 Lubricator drive ----

4 Drive adaptor 1/2" to 1/4" ----

5 Encoder coupling Renbrant 1/4" x 1/4" C25C25S

6 Encoder 1440 pulses/rev. ----

Table 1

121



Figure 1

Encoder drive arrangement when lubricator is driven from thecrankshaft.

6.0 Pressure Pickups6.1 Pressure pickups must be accurate and stable. Accuracy and stability are affected by

linearity, hysteresis, repeatability, resolution, thermal zero shift and thermalsensitivity shift.

6.2 Non-linearity will cause inaccurate readings since the analyzers use a calibratedpressure at one point or an input of a known millivolts per psi. The analyzer thenuses a linear fit to determine intermediate pressures. Pickups should be checked fornon-linearity using a dead weight tester to pressurize the pickup and with outputreadings taken throughout the pickup pressure range.

6.3 Hysteresis results in an output that is dependent upon the direction of pressurechange. Due to the construction of the pickup, increasing pressures will read lowerthan actual and decreasing pressures will read higher than actual.

6.4 Hysteresis and non-linearity are normally listed as a percent of the full scale readingof the pickup and combined, they should not be greater than 0.35% of the full scalereading.

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6.5 Repeatability is a measure of how accurately the pickup can duplicate an output andis important since the output during testing must repeat the output at calibration.The pressure transducer repeatability should be within 0.1% of the full scale reading.

6.6 Resolution of strain gage pickups is infinite; however, the resolution of the digitalanalyzer is not. The analyzer resolution is discussed below.

6.7 Thermal zero shift is the shift in the output voltage at zero pressure as the pickuptemperature changes, and can be a source of error since the pickup will normally beused at a different temperature than the calibration temperature. Thermal zero shiftshould not be greater than 0.015 percent of the full scale reading per degreeFahrenheit of temperature change.

6.8 Thermal gain shift is the shift in the sensitivity or gain of the pickup as the pickuptemperature changes and is also a source of error due to the fluctuation in operatingtemperature. Thermal gain shift should not be greater than 0.0075 percent of the fullscale reading per degree Fahrenheit of temperature change.

6.9 Non-cooled pickups can be temperature compensated to reduce thermal gain shiftand zero shift; however, for indicating, cooled pickups should always be used. Cooledpickups can be designed for either liquid coolant or air/inert gas cooling.Calibrations should be done with the coolant on.

6.10 Using pressure pickups with a range far greater than the pressures measured results inusing only a small portion of the pickup and analyzer range. The analyzer is a dataacquisition system and therefore uses the full range of the pickup being used anddivides that range into increments depending on the design of the data acquisitionsystem. A “12 bit” D.A. system would divide the full scale voltage into 4096 steps. Fora 2000 psi pickup, pressure can be measured in 2000/4096 or 0.49 psi steps. A 500 psipickup can measure in 0.12 psi steps.

6.11 Precise Sensors Model 70222 pressure pickups for the En-Spec analyzers are availablein the following ranges: 500, 1000, 1500, 2000, 3000 and 5000 psig. Precise Sensorsmodel 141-1 pressure pickups are available for measuring low pressures. Formaximum accuracy, always use the lowest pressure range pickup suitable for themeasured pressure.

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6.12 Pickups should be calibrated using a dead weight tester. Several calibrationtechniques are available for the En-spec analyzers. The following calibration isrecommended for the En-Spec 1400.

6.12.1 Install the transducer on a dead weight tester of the proper pressure range.The maximum dead weight tester pressure rating should not be greater thanfour times the rating of the transducer being calibrated.

6.12.2 After zeroing, load the dead weight tester to a pressure in the range of themaximum pressure to be recorded by the transducer. Using the analyzer,measure the millivolts per psi calibration of the pickup.

6.12.3 Using the quick calibration, enter the millivolts per psi calibration obtainedabove.

6.12.4 With the analyzer in the pressure gage mode and using the dead weighttester, apply pressures in the range to be measured and check the transduceroutput. Approximately 5 pressures should be checked and any pressure errormust not exceed the following:

Max TransducerRange (psig) Max Error (psig)

50 0.5200 0.8500 21500 62000 83000 125000 20

6.12.5 Provided the transducer error is within the above limits, the millivolts per psivalue can be used for the quick calibration.

6.12.6 When the indicating tests are complete the transducer should again becalibrated to insure that the calibration has not changed.

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7.0 Indicator Valves7.1 Valving is required to isolate the pressure transducer from the cylinder pressure to

allow moving and zeroing the transducer. The transducer is normally installed in aquick-change adaptor to speed data taking. The adaptor is normally drilled andvalved to permit zeroing the transducer. The adaptor, valving, cylinder drilling andconnecting fittings make up the indicator passage. Any restriction in this indicatorpassage will distort the indicator traces. To keep the distortion to a minimum theconnecting piping should be as short as possible and full ported ball valves should beused. The pipe and valve hole size should be as close to the cylinder indicator tubesize as possible. Refer to Figure 2 for indicator tube components available fromSuperior.

Table 2

ES 4101

Bill Of Materials

Item Description Comments Part Number

1 Drive on crankshaft See Paragraph 6 ----

2 Adaptor 1/4" NPT for vent valve 7/8"-18 UNS for transducer 1/2" NPT for quick connect

A-904-015

3 Vent valve 1/4" NPT A-061-680

4 Quick connect body 1/2" NPT A-061-678

5 Quick connect stem 1/2" NPT A-061-679

6 Ball valve 1/2" NPT A-903-707* A-904-016**

7 Nipple (stainless sch. 80) 1/2" NPT 21TN0409SS#

8 Cylinder body ---- ----

* 0-3000 psig @ 100° F** 3000-6000 psig @ 100° F# Rated for 6250 psig @ 300° F

125



ES 4101

Figure 2

1 4 52

3

6 7

8

Transducer Piping Arrangement

7.2 The indicator tube valving must not be partially closed to reduce tube resonanceand “smooth” the pressure traces. This restriction will distort the card and result ininaccurate data.

7.3 Warning: Many ball valves will not be suited for long term use in this service.They should therefore be removed at the conclusion of the indicator test. This mustbe done with the compressor shut down and depressurized.

8.0 Indicator Tube Phase Delay8.1 Methods have been proposed to compensate for indicator tube phase lag by rotating

out dead center. Superior did laboratory testing on compressors with speeds up to1500 rpm showing that if unrestricted indicator tubes are used, the most accuratedata is obtained if the out dead center is not rotated. Comparisons were made usingcards taken at the indicator tube to cards taken at the same time with a pickupburied in the cylinder. Data should not be rotated to compensate for indicator tuberestrictions.

126



Elevation (ft) Correction (in. Hg) Elevation (ft) Correction (in. Hg)

100 .108 3,000 3.105

200 .216 5,000 5.025

500 .537 8,000 7.696

1,000 1.066 10,000 9.344

2,000 2.100

ES 4101

9.0 Pressure Gages9.1 Pressure gages are used to establish operating conditions and although performance

will be based on pressures recorded by the analyzer, accurate gage pressures arerequired to set conditions and evaluate pressure drops in the system. Pressure gagesshould be calibrated using a dead weight tester with at least four pressures checkedin the range that will be used during test. Calibration records should be maintainedwith the other test data.

10.0 Thermometers/Thermocouples10.1 Thermocouples are available that are accurate to within one degree of the measured

temperature and are the preferred method of measuring temperatures forperformance testing. Glass thermometers, although fragile, can also be used. Metallicdial thermometers should not be used.

11.0 Barometric Pressure11.1 The barometric pressure at the job site is required to convert gage pressures to

absolute pressures. It is recommended that a barometer at the job site be used forlocal barometric pressure. Barometric pressures that are listed by airports have beencorrected to sea level to allow pilots to set their altimeters and must be correctedback to the job site elevation before using for performance tests. The followingcorrections must be subtracted from the sea level readings to obtain the barometricpressure at the job site:

127



11.2 For indicating test where the compressor suction pressure is above 300 psig andtherefore changes in atmospheric pressure are small in relation to the measuredpressures, the barometric pressure can be estimated by subtracting the above altitudecorrection from 29.9 inches of mercury.

12.0 Gas Flow12.1 Orifice flow meters are the preferred method of measuring gas flow. Calculations

and requirements are listed in AGA Report #3. This report is generally accepted as theindustry standard. The meter should be located on the suction side of thecompressor with pressure taps and distance from valving and elbows as listed in AGAReport #3. The orifice plate should be removed, inspected and measured to anaccuracy of .001 inch. The meter pipe diameter should also be measured to anaccuracy of .001 inch. When reinstalling the orifice plate, insure that the sharp edgeof the orifice is facing upstream. Flowing pressure and orifice differential pressuremust be recorded using a calibrated pressure gage and manometer or calibratedtransducers. Pressure pulsations at the orifice meter or in the pressure lines will causethe metered flow to be in error. Orifice delta pressure excursions in excess of 10percent of the average delta pressure should be corrected before testing. This can bedone by reducing the pulsation or by installing a smaller orifice plate to increase theaverage delta pressure across the orifice plate.

13.0 SummaryThe accuracy of performance testing requires accurate equipment, carefulcalibration and diligent testing. It is the responsibility of the analyzer operator toinsure that the testing is properly done and that the instrumentation is in goodworking condition. Any required maintenance should be completed before testing isstarted.

ES 4101

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ES 4101AField Performance Test Specification1.0 Scope

This standard lists the steps required to record compressor cylinder pressure volumecards using the EN-Spec 1400 analyzer. The specification is an addendum to ES 4100and ES 4101.

2.0 Purpose2.1 The standard is intended to list the procedures required to operate the En-Spec 1400

analyzer to obtain basic pressure-volume cards. It was written to provide a consistentmethod for taking field data that have the required accuracy to address fieldperformance guarantees.

2.2 Instructions for operating the En-Spec 3000 are included in the En-Spec 3000operating manual.

3.0 Procedure3.1 Each step for analyzer setup, pickup calibration and operation is listed, showing

what will be on the analyzer display and what inputs need to be performed.

4.0 Analyzer Setup4.1 Frame and cylinder data and identification must be entered into the analyzer. This

can be done before going to job site or any time prior to taking data.

Display Action Display Action

[Blank] POWER ON [0.0 % IDs used] [0.0 % Memory used] EXIT

[Clear all memory?] YES

[Clear all memory?] [Are you SURE??] YES [10-10-94 8:30]

[Mode?]KEYBOARD

DATA ENTRY

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129



Enter the following data for up to 40 cylinder ends:

ES 4101A


[Eng _ 1 /01C] [Enter Engine ID]

XXX/XXC (or H)ENTER

[Comp. Rod Dia.] [X.XXX Inches]

X.XXXENTER

[Eng _ 1 /01C] [Enter Cyl ID]

XXX/XXC (or H)ENTER

[Main Rod Length] [XXX.XXX Inches]

XXX.XXXENTER

[Eng _ 1 /01C] [New ID-Continue?] YES [Radius]

[XX.XXX Inches]XX.XXXENTER

[Degs. Outer Dead] [Center _ 0.00]

X.XXENTER

[Do Valve Losses?] [YES/NO X]

YESENTER

[Sample Size] [10 to Rpm]]

10ENTER

10-10-94 8:32

Repeat keyboard data entry until all cylinder ends are entered into the EN-Spec 1400 [Comp. Bore]

[XX.XXX Inches]XX.XXXENTER

130



5.0 Pickup Calibration

5.1 The following assumes that the identities have been loaded into the EN-Spec 1400and that you are starting with the analyzer off:


Blank [Clear all memory?]

POWER ONNO

[Enter PSI you can supply XXXX.]

XXXENTER

[Clear memory by engine number?] NO [Apply XXXX PSI]

[Push Enter]XXXXENTER

[Clear memory by cylinder number?] NO [Trans. Sens.]

[X.XXX Push Exit][EXIT] **Record sensitivityfor future reference

[XX.X % IDs used] [XX.X % memory used] EXIT [10-10-94 8:36]

[Mode?]PRESSUREGAUGE

[10-10-94 8:34] [Mode?]

DEADWEIGHTCALIBRATE

[Remove and zero Transducer]

ZEROTRANSDUCER

[Apply 0 PSI] [Push Enter] ENTER [Remove pickup

and push Enter] ENTER

[Remove pickup and push Enter] ENTER [Actual 0]

[Lo 0 Hi 0]

[Transducer Range] [PSI ? XXXX.]

XXXX.ENTER

Using the dead weight tester, apply pressure to the pickup in the range the pickup will beused. Five pressures in this range should be checked. The pressure reading on the En-Specshould agree with the dead weight tester within the limits listed in 6.12.4 of ES 4101. If thepickup is acceptable, the millivolts per psi number that were determined during calibrationmay be used with the QUICK CALIBRATE feature of the analyzer. If this feature is used, thepickups should be deadweight calibrated at the end of the test to insure that the calibrationhas not changed.

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6.0 Taking Pressure-Volume CardsIf different pickups are being used, the calibration must be re-entered using QUICKCALIBRATE.

6.1 Calibration


[12-12-94 8:40] [Mode?]

QUICKCALIBRATE

[Remove Transducer] [Push Enter] ENTER

[Transducer Range] [PSI? _XXXX]

XXXXENTER

[Calibration] [Done. Push Exit.] EXIT

[Trans. Sens.] [MV/V?]

X.XXXENTER

6.2 Begin taking cards (including nozzle traces).


[12-12-94 8:40] [Mode?]

USE PRELOADEDDATA [Working]

[Eng X /XXC] [Ready to start] START [Remove and zero]

[Transducer] ZERO

[Remove and zero] [Transducer]

ZEROTRANSDUCER

[Connect Trans. to Cyl. Push Start] START

[Connect Trans. to Suc. Push Start] START [Working]

[Working] [Remove and wait for results]

[Remove and zero] [Transducer] ZERO TRANSDUCER 1HP = XX.XX

SPEED = XXXX.XX ENTER

[Connect Trans. to Disch. Push Start] START

ES 4101A

6.3 Using preloaded data, continue indicating the remaining cylinders.

132



ES 4102Analysis And InterpretationOf Compressor Field PerformanceTest Results1.0 Scope

This standard provides guidelines for analyzing and interpreting the results of compressorfield performance tests. Section 3.0, On-Site Review of Indicator Cards, is an in-processcheck to assure that accurate, high quality data is generated during the testing process.Regardless of how the data will be analyzed it is highly recommended that this in-processcheck be performed so that data quality problems may be quickly resolved and repeattesting avoided. Section 4.0, Indicator Test Data Analysis and Troubleshooting, is a basicapproach to interpretation of indicator cards. A step-by-step procedure is provided forpreparing the measured indicator card for comparison to the ideal case and sampleindicator cards illustrating more common problems.

2.0 Purpose2.1 This standard is intended to be used with Engineering Standards 4100 and 4101, Ajax-

Superior Compressor Field Performance Test Standard and Test Instrumentation.

2.2 Section 3.0 shall be used during all compressor performance tests.

2.3 Section 4.0 should be used for basic interpretation of indicator cards. If an unusualor special condition exists that is beyond the scope of this standard, the Ajax-Superior Engineering Department should be consulted.

3.0 On-site Review Of Indicator Cards3.1 It is important to perform an on-site review of the indicator cards during the test to

determine if good, usable data is being generated. Sometimes problems that affectthe quality and usefulness of the data can be easily corrected such that the tests maybe immediately re-run and good data made available for a full analysis later. The

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following sections describe how to recognize some of the more common problemsand the necessary corrections. Figure 3.1 is a data sheet that should be used to recordpertinent information during each indicator test. Figure 3.2 is an example of atypical pressure volume (P-V) diagram that can be used to compare with abnormalP-V diagrams shown in this standard.

3.1.1 Measurement Channel Restriction - Excessive flow restriction in thepressure measurement channel produces indicator diagrams of marginalusefulness. Figure 3.3 is an example of a P-V diagram exhibiting excessiverestriction in the measurement channel. As can be seen in this figure, thecorners are rounded and very few, if any, pressure pulsations are evident.Channel restrictions may be present anywhere along the length of thepassage, from the internal cylinder pressure port through the adapters,fittings and valves up to the transducer. Refer to Engineering Standard 4101for more details on causes and corrections.

3.1.2 Measurement Channel Pulsation/Resonance - The gas dynamicsbetween the interior of the cylinder pressure port and the measurementtransducer can produce significant distortion of the apparent dynamiccylinder pressure. These dynamic effects range from quarter-wave acousticresonance of the indicator passage to a time lag between the pressure in thecylinder and sensing of the pressure by the transducer. The recommenda-tions provided in Engineering Standard 4101 are intended to minimize theeffect of channel resonance. An example of a pressure time (P-T) curve withchannel resonance is shown in Figure 3.4. A manual technique to “filter-out”the channel resonance is also shown in this figure. Channel resonanceshould not be confused with external piping and bottle pulsations which iscovered in Section 4.0, “Indicator Test Data Analysis and Troubleshooting.”Channel resonance may be a good indication of a non-restrictive channel;however, its disadvantage is that it sometimes masks signatures of externallycaused pulsations occurring in the cylinder and signs of abnormal valveaction. If an abnormal condition is suspected that can not be explained aschannel resonance, consult with Ajax-Superior Engineering Department.

3.1.3 Pressure Transducer Drift - Sometimes a pressure transducer will drift,resulting in incorrect pressure readings. This can be detected by reviewingthe P-V diagram for evidence of a shift in cylinder suction and discharge

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134



pressures compared to the normally expected pressures in the suction anddischarge flanges. Figure 3.5 shows a P-V diagram where the pressuretransducer drifted upward. This causes the suction toe pressure to appear tobe higher than the suction pressure trace and the discharge toe pressurehigher than the discharge pressure trace. The discharge valve loss appears tobe abnormally high. In this example the drift was found to be caused byimproper cooling of the pressure transducer. It is very important to eliminatetransducer drift to allow proper diagnosis of compressor performance.

3.1.4 Incorrect Pressure Transducer Range - Inaccurate or distortedpressure data can be caused by the use of a pressure transducer with a rangeinappropriate for the pressures to be measured. Figures 3.6 and 3.7 show pressuretransducers whose ranges are too low and too high for the pressures beingmeasured. Refer to Engineering Standard 4101 for specific recommendations forselecting pressure transducers of the correct range.

3.1.5 Incorrect Out Dead Center Reference - An incorrect Out Dead Centerreference is a common problem. If the error is sufficiently large it can bedetected by inspecting the indicator cards. Small errors may not be easilydetected by inspection of the cards although they can create significanterrors in the apparent performance of the compressor. It is very important toset the Out Dead Center reference accurately and in a manner that providesaccurate dynamic reference signals. Refer to Engineering Standard 4101 formore information regarding accurate Out Dead Center reference signals.Figure 3.8 shows an indicator card with a gross error in Out Dead Center reference.

4.0 Indicator Test Data Analysis And TroubleshootingThis section to be provided in a future revision

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135



Figure 3.1Indicator Test Data Sheet

Customer Date

Location Test Data By

Register No. Frame Serial No.

Cyl. #1 Serial No. Cyl. #5 Serial No.




Driver Model Serial #

Test number

Indicator card no.

Time

Stage

Cylinder no. (throw)

Cylinder dia. (inches)

DA/SAHE/SACE

HE/CE

VVP opening

PS (PSIG - D.W.T.)

PS (PSIG - D.W.T.)

TS (°F)

TS (°F)

PB (PSIA)

Speed (rpm)

Eng. Mnfld. (HG)

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136



Figure 3.2Typical P–V Diagram

Clearance Volume(including pockets)

Pd

2

1

3—Discharge valve—closes—Minimum cylinder—volume

Dischargevalveopens

Suctionvalveopens

—Suction valve closes—Maximum cylinder—volume

VOLUME

PRES

SURE

Discharge Volume

Re-expansion Compression

Suction Intake Volume

Piston displacement of swept volume

Total cylinder volume (including pockets)

4

ES 4102

Ps

137



ES 4102

Figure 3.3

P–V Diagram with rounded corners, indicating excessive channel restrictionor pressure transducer with a slow response time


Pd—Discharge valve—closes—Minimum cylinder—volume

Discharge valve opens

Suctionvalveopens —Suction valve closes

—Maximum cylinder—volume

VOLUME

PRES

SURE

Discharge Volume

Re-expansionCompression




The indicated horsepoweris less than the actual

Ps

138



ES 4102

Figure 3.4

P–T Curve with channel pulsations/resonance manual correction shown bydrawing envelope lines and finding average curve

TDCANGLE (DEGREE)

PRES

SURE

(PS

I)

Envelope

Averagecurve

Envelope

TDC

Averagecurve

Averagecurve

Envelope

Actual P21134 psig

Actual P1610 psig

P1

P2

-150 -120 -60 0 60 120 150

450

600

750

900

1050

1200

1350

139



ES 4102

Figure 3.5

Typical P-V Diagram indicating pressure transducer drift

—Discharge valve—closes—Minimum cylinder—volume

Dischargevalve opens

Suctionvalveopens


VOLUME

Discharge Volume

Re-expansion Compression





Pd

PRES

SURE

Ps

Indicated Pdpredictsexcessivevalve loss

Indicated Pspredicts zerovalve loss

140



ES 4102

Figure 3.6

P-V Diagram indicating a pressure transducerwith a range too low for the pressures measured




Suctionvalveopens


VOLUME

PRES

SURE

Discharge Volume





Gap in pressures

Ps

141



ES 4102

Figure 3.7

P-V Diagram indicating a pressure transducerwith a range too high for the pressures measured




Suctionvalveopens


VOLUME

PRES

SURE

Discharge Volume





Valve losses indicatedhorsepower toe pressureserroneous

Ps

142



ES 5011Hydrostatic and Helium Test ofCompressor Cylinders, CylinderHeads, and Valve Covers1.0 Scope

This procedure outlines the necessary operations required for hydrostatic and helium testingcompressor cylinders and other related pressure retaining components which, when secured tothe cylinder, can be considered as part of the cylinder or part of an unfired pressure vessel.

2.0 RequirementsCompressor cylinders and pressure retaining auxiliary parts, which are secured to thecylinder, shall be hydrostatically tested with water and a water soluble rust-preventative(Chem-Lub X-058, DuBois 915, or equal) in accordance with the following standards:

Part Test Pressure

Cylinder (gas wetted surfaces) (MAWP) 1.5 times maximum allowable working pressure

Cylinder Heads (gas wetted surfaces) (MAWP) 1.5 times maximum allowable working pressure

Valve Covers (gas wetted surfaces) (MAWP) 1.5 times maximum allowable working pressure

Bonnets and/or clearance pockets 1.5 times maximum allowable working pressure(MAWP) (gas wetted surfaces) (See Note)

Cylinder (Water Jackets) 115 PSIG minimum - 150 PSIG maximum

Superior Cylinder (Water Jackets) 115 PSIG minimum - 150 PSIG maximum

Ajax Cylinder (Water Jackets) 100 PSIG minimum - 115 PSIG maximum

Note: For bonnets/unloaders, blueprints will designate if specific areas are to be hydro testedand any specific pressure requirements for these areas.

The part number drawing denotes the required test pressure for each cylinder or componentand should be reviewed before each test. Compressor Performance Data Sheet (Form 1041-4) canbe consulted for maximum allowable working pressure (MAWP) and required hydrostatic testpressures on individual jobs. Engineering should be contacted for any discrepancies orquestions on test pressures, or if data sheet pressures do not agree with the pressuresindicated on the part number drawing.

Page 1 of 5

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3.0 Hydrostatic Test Procedure3.1 The test pressure shall be maintained for a period of not less than thirty (30)

minutes; longer if necessary to allow for complete examining of parts. In someinstances, such as after rework and/or special request, the hold time and/or pressuremay be increased (see ES5026 and ES5016).

Note: For valve covers (caps) only, the test period is fifteen (15) minutes minimum.

3.2 The test pressure is specified in Section 2 and also on each component drawing.

3.3 All surfaces to be inspected for leaks should be dry prior to inspection.

3.4 Inspection is performed with a flashlight, mirrors, and/or fiberscope, and is a visualcheck for evidence of water leaks. No leakage is allowed.

3.5 In the case of leaks around the quill (when a quill is used), the quill is re-tightened, theunit is blown clean, wiped dry, and retested. Any leakage into the bore, into the gaspassages, into water jackets, or out of the body results in cause for rejection.

3.6 When customer specifications do not prohibit impregnation, cylinders which leakwithin the limits established by Engineering Standard ES 5026 can be impregnated perES 5026. Cylinder must be re-hydrotested and helium or air tested after impregnationper ES 5026. All testing data is to be recorded on Form SI 411.

3.7 Joints are to be sealed, where possible, with gaskets as designed and specified on the Billof Material. Common, readily available joint sealing compounds can be used in theevent of joint leakage problems.

3.8 Cylinder bodies are to be stamped “TESTED” to identify acceptance of hydrostatictesting. They should not be stamped if they leak.

3.9 All cylinder bodies and all cast iron, nodular iron, and cast steel compressor heads/unloaders, bonnets, valve caps, unloader bottles, and other pressure retainingcomponents must be tested on all gas wetted surfaces. Therefore, the component iseither tested in a cylinder or in a pot fixture which allows water pressure to reach all gaswetted surfaces. Compressor heads and all other pressure retaining components are tobe stamped “TESTED” to identify acceptance of hydrostatic testing. They should not bestamped if they leak.

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3.10 Parts (other than cylinder bodies) machined from steel plate, bar, tubing, or forgings areexempt from hydrotesting, except those fabricated by welding, where a defective weldjoint might leak directly to the atmosphere, or for those heavily machined parts thatmay have potential problems as deemed by Engineering. All cylinder bodies are to behydrotested!

3.11 For hydrotesting and air or helium testing, electronic digital pressure sensinginstruments (accuracy and capacity to 15,000 psi) are to be used, regardless of the testpressure up to the maximum capacity.

3.12 All pressure gages shall be certified per established frequency.

4.0 Helium Testing4.1 The following additional helium test procedures will be required when specified by the

sales release (standard hydrostatic test to be completed first) or when used to verify animpregnated body or prove out the results of a hydrotest.

4.1.1 Prior to filling with helium, all gas wetted surfaces shall be wiped and/or blowndry with air.

4.1.2 The pressure test will be performed using helium at the cylinder maximumallowable working pressure (MAWP), or less if specified on the sales release.

4.1.3 Leakage detection is to be accomplished by submerging in water. No leakage mayoccur over the required time period.

4.1.4 Test time is thirty (30) minutes minimum, or as specified by the sales release.

4.1.5 Helium test is to be certified and documented (see attached form).

4.1.6 After a successful helium test, the acceptable cylinder bodies and heads arestamped with a capital “H” right next to the “tested” stamp.

5.0 Air TestingAir testing can be used in place of helium to air test an impregnated cylinder. The steps usedshould be the same as in Section 4 above. Impregnated cylinders designated for sour gasapplications must be tested with helium only.

6.0 Cleaning and Rustproofing

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6.1 Upon completion of all testing, the components shall be immediately drained andthoroughly dried.

6.2 All unpainted surfaces of the parts will be sprayed with a light rust preventive oil (Tectyl511-M or equal).

7.0 Documentation7.1 The hydro test of each cylinder is recorded on a test log and filed by the supervisor.

Each cylinder is recorded by the foundry code number, date of test, part number, andtest results.

7.2 All cylinders (rejected and accepted) are recorded in the log.

7.3 A hydrostatic test data sheet (Form S.I. 411 - Rev. 4) must be completed (see attached) oneach cylinder and filed with the register number in the Inspection office. Copies ofthese can then be provided to Marketing when requested by the Sales Release.

7.4 When a helium test is performed, the appropriate section of the test sheets is to befilled out.

7.5 If a unit is considered scrap, a scrap transaction is recorded and the part identified asscrap. If a unit is considered salvageable or meets the impregnation criteria (ES 5026), aHold transaction is recorded, the part identified as held for salvage.

8.0 Repair Procedures8.1 Hold transactions recorded on potentially salvageable rejects should contain the serial

number, part number, date, and reason for rejection. These are reviewed by QualityControl and Engineering and the appropriate disposition made.

8.2 ES 5026 controls the repair procedure for impregnated cylinders and need not haveEngineering review. Impregnated cylinders must be hydrotested and helium or airtested per ES 5026 procedures.

8.3 Retest pressure and time of a repaired unit is the same as the original test as a minimum.More stringent testing is sometimes used to confirm the integrity of the repair(i.e., ES 5026). In no case shall the test pressure exceed two times the maximum workingpressure of the cylinder body, cylinder head, or other component. In no case shall thewater jacket test pressure exceed 200 psig.

8.4 Retest results are to be recorded in the log and on the test data sheet.

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Ajax-Superior Division/Compressor PlantWest Burgess StreetMount Vernon, Ohio 43050

Inspection Form S. I. 411Date: 3/94

Revision: 3

Hydrostatic and Helium Test Sheet(Tested per ES 5011)

1. Hydrostatic Test

Shop Order Number Size

Cylinder Part Number Hydrostatic LubeTest Pressure Holes

Register Number (Gas Passages) Drilled

Water JacketSerial Number Test Pressure

Inspected By Tested By

Date Date

2. Hydrostatic Retest

Reason for Retest

Hydrostatic Test Pressure Water Jacket(Gas Passages) Test Pressure


Date Date

3. Helium Test

Helium Test Pressure* (Gas Passages)


Date Date

* Helium Test Pressure is maximum allowable working pressure as stated on blueprint (unlessotherwise agreed to by customer and Quality Assurance Manager, and stated on theQuality Plan).

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