MH-WH Instruction Manual

WH/MH Instruction Manual

Cooper Energy Services Ajax-Superior

Page a

SuperiorWH/MHCompressor

InstructionManual


Page b



Page c

WH/MH Instruction ManualTable of Contents

Page

Section 1Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Who We Are...a brief history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Ajax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Superior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Warnings, Cautions, and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Compressor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Section 2Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Unit Identification - Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Compressor Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Crankshaft Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7Balancing AJAX-Superior Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7Compressor System Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8Compressor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Section 3Lubrication And Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Lubricating Oil Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Compressor Frame Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Compressor Cylinder Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Lubrication Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5Pump Per Point System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Proportional Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6


Page d

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Lubricator Worm And Gear Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Compressor Frame Lube Oil Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Cylinder Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9Packing Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Coolant Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Section 4Sour Gas Compressor Applications . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Hazards of Hydrogen Sulfide or Sour Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Concentration Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Trim Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3Hydrogen Sulfide (H2S) Concentrations Up To 2% By Volume: . . . . . . . . . . . . . . . . . . . . . . . 4-3Level 1-11p Trim (H2S Concentrations of 2% - 5% By Volume) . . . . . . . . . . . . . . . . . . . . . . . 4-4Level 2-11p Trim (H2S Concentrations > 5%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Enhanced H2s Trim Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Section 5Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Preparing The Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Foundation Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3Placement And Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Preparing The Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5Grouting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5Coupling Installation And Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5Crankshaft Web Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8Cylinder Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Sliding Rod Through Packings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10Setting Piston End Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10Installation Of Cylinders To Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Section 6Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Preparation for Initial Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1Initial Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3



Page e

Normal Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4Normal Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Recommended Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Section 7Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1Acceptable Tolerance Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2Torque Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Critical Bolt Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Component Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6Base (Crankcase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6Crankshaft, Thrust And Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6Connecting Rod And Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7Crosshead Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8Crosshead Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8Auxiliary End Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9Drive End Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10Lube Oil Supply (Sump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10Drive Coupling Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11Flexible Drive Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Troubleshooting Thomas Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13Elongated Bolt Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13Scored Body on Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13Misalignment Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13Fatigue Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14Compression. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14Elongation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15Torque Overload (Visible only with strobe light while running) . . . . . . . . . . . . . . . 7-15

Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17Piston, Piston Rings And Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17Piston Rod Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24


Page f

Alarms And Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24Recommended Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

Section 8Parts Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1Ordering Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Instructions For Ordering Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2Parts Listings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Using The Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Aftermarket Service Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3United States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5South America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5United Kingdom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6Mexico . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6Middle East . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6Far East . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

WH/MH Instruction ManualSection 1Introduction

Who We Are...a brief history

AJAX

The first Ajax steam engine was produced in Corry, Pennsylvania, in the late 1870s. This engine quickly became popular for use in oil well drilling. The company was incorporated as Ajax Iron Works in 1892, and, in 1895, Ajax was producing its first gas engine.

Both Ajax steam and gas engines were in great demand in the early 1900s as oil finding operations expanded westward. In the early 1920s, Ajax faced capacity restraints and decided to discontinue production of its gas engine to focus exclusively on steam engine production. At this time, the National Supply Co. became the exclusive distributor of the Ajax steam engine for the oil fields. When oil well drilling slowed during World War II, Ajax developed a special steam engine used in the marine applications.

After the war, Ajax returned to production of natural gas engines for use in the growing secondary oil recovery market. Ajax first came in contact with Superiors operations in 1945 when it purchased a line of slow speed horizontal gas engines from the Superior Engine division of the National Supply Co. In the late 1950s, Ajax introduced its popular integral gas engine-compressor to meet the market need for a durable, long life product in gas gathering and boosting applications. Cooper Industries purchased Ajax Iron Works in 1963.

SUPERIOR

Shouvlin Manufacturing Co. was founded in 1889 in Springfield, Ohio, and became the Superior Gas Engine Co. in the early 1890s. It originally produced gas engines for drilling rigs and oil pumping units during the development of Ohio and Pennsylvania oil fields. In 1928, Superior was acquired by the National Supply Co., previously Superiors exclusive agent in the oil production industry.

During the 1920s, the Superior diesel engine line was introduced. This engine was used in commercial marine applications and in military vessels during World War II. During the economic boom of the 1940s and 1950s, Superior concentrated on selling diesels for use in locomotives, power plants, factories, ocean vessels, and other energy-intensive applications. In 1955, Superior was purchased by the White Motor Co. By the late 1950s, a great number of Superior engine-generator sets were being sold for military defense use.Cooper Energy Services Ajax-Superior

Page 1-1

The Superior natural gas compressor was introduced in 1960, and the company rapidly became one of the leading suppliers of natural gas compression equipment for markets in the U.S., Canada, and South America. Superior became a part of Cooper Industries in 1976.

Ajax and Superior were previously separate divisions of Cooper Energy Services Group, with manufacturing locations in Corry, Pennsylvania, and Springfield, Ohio. In 1987, the Ajax and Superior divisions were consolidated in the Springfield facility to form the Ajax-Superior Operations of CES which in 1995 became a unit of Cooper Cameron Corporations Cooper-Bessemer Reciprocating Products Division.

Note

This manual contains confidential proprietary information of the Ajax-Superior division of Cooper Energy Services, an operating division of the Cooper Cameron Corporation. This manual is provided to you for the limited purpose of providing information to facilitate your use and maintenance of your equipment. This manual should only be used for the stated pur-poses, and by receiving this manual you agree not to disclose such information to others.

WARNINGS, CAUTIONS, AND NOTESThese safety instructions and procedures are to prevent injury in the operation and maintenance of Ajax-Superior engines, compressors, and auxiliary equipment. These safety procedures should not be considered as the only precautions to be taken. Good judgement and careful safety practices should always be used.

DO NOT OPERATE OR ATTEMPT TO REPAIR THIS EQUIPMENT UNLESS YOU HAVE HAD THE PROPER TRAINING APPROVED BY AJAX-SUPERIOR. FOR TRAINING INFORMATION, CONTACT THE COOPER ENERGY SERVICES TRAINING DEPARTMENT IN MOUNT VERNON, OHIO, 43050; PHONE (614) 393-8200.

GENERAL1. Follow all safety rules and operating procedures put in place by the company that owns

and operates this equipment.

2. Read and understand the instruction manual prior to operating this equipment to become familiar with the safety, design, and operating features. If you do not have a manual, call Ajax-Superior at (513) 327-4200.

3. Always wear safety glasses or goggles, steel-toe safety shoes, and hearing protection.

NoteAdditional equipment may be required by the equipment owner.Cooper Energy Services Ajax-Superior

Page Intro-2

WH/MH Instruction Manual4. Do not wear loose fitting clothing, neckties, scarves, watches, rings, etc., near operating equipment as they can be caught in the moving machinery. Keep long hair tied back.

5. Locate nearest fire extinguisher to area where maintenance is to be performed. Ensure a clear path to fire extinguisher in case it should be needed for an emergency situation.

6. Do not open cooling or lubrication systems when engine or compressor is hot, as steam or hot liquids can be released, which can cause severe burns. Be aware that some surfaces can remain hot for several hours after the unit has been shutdown.

7. When draining the coolant and lubricants, prevent contamination of the environment by the equipment fluids. Refer to equipment owners material safety data sheets for addition-al information. (Remember: Antifreeze/Glycol solutions, as well as most lubricants, are flammable.)

8. Keep the area around the unit clean and orderly with ample space to walk safely around the unit. Clean up spills and leaks quickly to prevent accidents caused by slipping and falling.

9. Use only non-flammable, non-toxic cleaning solvents. NEVER USE GASOLINE OR OTH-ER FLAMMABLE PRODUCTS FOR CLEANING PURPOSES. REFER TO EQUIPMENT OWNERS MATERIAL SAFETY DATA SHEETS FOR EACH CLEANING PRODUCT FOR ADDITIONAL PRECAUTIONS.

10. Use fans, blowers, etc. during maintenance and clean-up work in enclosed areas to remove fumes from cleaning solvents and vented gases.

11. Use ladders, platforms, etc. where possible when working on elevated work surfaces. Al-ways stand on stable surfaces when working on this equipment.

12. Before starting any equipment, make sure all nearby personnel are aware of the start up and are clear of the equipment.

13. Do not use bare hands when checking for leaks of fluids under pressure, as fluids or par-ticles can penetrate skin. Use cardboard or a similar material to check for leaks.

COMPRESSOR MAINTENANCE1. Shut down the compressor first, then prevent it from being started before the work is

done. (See ENGINE MAINTENANCE section previously if engine driven.) If electric mo-tor driven, the electric power supply must be disconnected and locked out. THIS IS VERY IMPORTANT IF THE UNIT HAS REMOTE START CAPABILITY - a remote operations center may try to start a unit without knowing that work is being performed on it. Suction and discharge block valves (see site plan for location) must be closed to prevent gas from flowing into the compressor during maintenance. (Gas pressure could rotate the compres-Cooper Energy Services Ajax-Superior

Page 1-3

sor and cause injury if not shut off and vented properly - see compressor section of man-ual.) Note: After maintenance work is done, some adjustments may need to be done with the compressor running. Stay clear of moving parts and follow instruction manual proce-dures as required.

2. Before attempting any maintenance or repair on the compressor, vent all gas pressure from the cylinders, piping, and other pressurized components or chambers. Know the piping system associated with this compressor. Open discharge blowdown and/or by-pass valves to vent system to atmosphere. ALLOW COMPRESSOR TO COOL FOR AT LEAST 15 MINUTES BEFORE OPENING SUCTION OR INTERSTAGE VENTS. Atmo-spheric air can be drawn in if a vacuum exists and can create an explosive mixture. CHECK LOCAL OR PANEL PRESSURE GAUGES FOR ZERO READING BEFORE RE-MOVING ANY GAS PASSAGE COMPONENTS SUCH AS VALVES, VALVE CAPS, OR CYLINDER HEADS. Note: UNLOADER CONTROL PRESSURE IS TYPICALLY NOT SHOWN ON GAUGES. Vent unloader control pressure line by loosening control line tub-ing fitting.

3. IF POISONOUS OR SUFFOCATING GASES ARE BEING COMPRESSED, FOLLOW ALL PLANT SAFETY PROCEDURES PRIOR TO AND DURING MAINTENANCE ON ANY GAS EQUIPMENT OR PIPING TO AVOID INJURY OR DEATH DUE TO INHALATION OF SUCH SUBSTANCES.

4. Regularly check around compressor and piping gaskets and joints for leaks which could result in a fire or an explosion.

5. Test all pressure gauges on a periodic basis (see maintenance schedule) to ensure accurate pressure readings. Likewise, check all relief valves for design opening pressure (see man-ufacturers data for each relief valve in packaging section of manual).

6. Check all safety shutdown devices (low oil pressure, high and low gas pressures, vibra-tion, etc.) per the schedule in the maintenance section of this manual.

7. Remove electrical lockout function if motor driven when maintenance is completed and REMOVE MANUAL BARRING DEVICE, if used during maintenance, before starting unit.

8. Before replacing any studs, measure stud height from machined surface and position re-placement stud to the same height.Cooper Energy Services Ajax-Superior

Page Intro-4

WH/MH Instruction ManualWARRANTY

The Seller warrants to the Buyer that the equipment to be delivered hereunder will be free from defects in material, workmanship and title and will be of the kind described in the contract. THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES WHETHER WRITTEN, ORAL OR IMPLIED (INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR PURPOSE). If it appears within one year from the date the equipment is placed in service but no later than eighteen (18) months from the date of delivery to the Buyer, whichever first occurs, that the equipment does not meet the warranty specified above and the Buyer notifies the Seller promptly, the Seller shall correct any defect, at the Sellers option, either by repairing any defective part or parts or by making available, at the Sellers factory, a repaired or replacement part. The liability of the Seller to the Buyer (except as to title) arising out of the supplying of the equipment, or its use, whether on warranty, contract or negligence, shall not in any case exceed the cost of correcting defects in the equipment or part thereof and upon expiration of the warranty period all such liability shall terminate. The foregoing shall constitute the sole remedy of the Buyer and the sole liability of the Seller.

The preceding paragraph shall not apply and the Seller assumes no liability whatsoever for breach of warranty when there is evidence that the defect arose as the result of (a) abuse or negligence in the operation of the equipment, (b) failure to maintain the equipment properly, (c) overloading or overspeeding, or (d) use of repair parts not approved by Seller.

The warranty given to the Seller by its supplier of special equipment, including but not limited to generators, is hereby assigned without recourse by the Seller to the Buyer. AS TO THIS SPECIAL EQUIPMENT, WHICH GENERALLY BEARS THE NAMEPLATE OF THE SELLERS SUPPLIER, THE SELLER ASSUMES NO LIABILITY WHATSOEVER FOR BREACH OF WARRANTY, WHETHER WRITTEN, ORAL OR IMPLIED (INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR PURPOSE).Cooper Energy Services Ajax-Superior

Page 1-5


Page Intro-6

WH/MH Compressor Instruction ManualSection 2Specifications

General InformationYour Ajax-Superior instruction manual has been carefully prepared to assist in the proper installation, operation, and maintenance of the equipment. It is difficult to accurately describe every type of installation. However, this manual, along with the drawings included in the parts list contains sufficient basic information to effectively operate and maintain this equipment.

This manual represents todays typical design and is subject to change without notice. If additional help is needed, contact the closest Cooper Energy Services Group Aftermarket office or the Ajax-Superior Field Engineering Department in Springfield, Ohio.

This manual is divided into sections listed in the Table of Contents. Each begins with a general description of the equipment or system discussed and includes operating data, clearances, and information vital to operation.

Reference may be made in the text to other manufacturers literature contained in the Auxiliary Equipment section which must be consulted, along with drawings or diagrams in the Parts List, for clarification of specific systems and components. Obtain the most recent versions of all referenced Engineering Standards and Service Bulletins before using this equipment.

Sufficient operating manuals, including parts lists for the installation, are included with every Superior product. Additional copies can be obtained by contacting any Energy Services Group Aftermarket office. It will not always be possible to duplicate the original manuals over a period of years due to revisions made in the manuals. However, every effort will be made to give you information that will be helpful and will closely duplicate the original manuals.

Unit Identification - Serial NumbersCorrespondence concerning your compressor and related equipment must include the serial numbers of the frame and cylinders.

1. The Compressor Frame Serial Number applies to the frame and running gear parts. It is located on the frame nameplate which is attached to the top cover.Cooper Energy Services Ajax-Superior

Page 2-1

2. Each Compressor Cylinder has its own serial number which is stamped on a name plate attached to the cylinder.

3. These serial numbers should be included in all requests as a reference for Ajax-Superior.

Figure 2-1 Frame Nameplate

00744

Figure 2-2 Cylinder Nameplate

00743Cooper Energy Services Ajax-Superior

Page 2-2

WH/MH Compressor Instruction ManualCompressor DescriptionThe Ajax-Superior Compressor has been engineered for reliable, continuous, heavy duty and long life with trouble free operation. These ruggedly constructed, balanced-opposed type compressors are built to match the high speed, high precision, high quality, field proven standards as the Superior Engines. Ready accessibility of all wearing parts mean simplified maintenance and dependable service. The balance-opposed design, with two crank throws separated by a crank cheek, has become the modern standard for reciprocating compressors.

Main and connecting rod bearings are of thin wall, steel backed, split, precision design. The crankshaft can be removed through the top of the base without disturbing the cylinders. The lube oil pump and the force feed lubricator are gear or shaft driven and mounted on the auxiliary end cover. Either may be maintained independently.

Lube oil is drawn from the sump through a strainer which protects the lube oil pump. A full-flow lube oil filter with a differential pressure indicator to indicate a plugged filter, protects all frame running parts.

Although piston and rod lengths may vary according to the stroke and model, all cylinders will fit interchangeably on the standard crosshead guide. Careful attention has been given to the cooling of cylinders designed for a 1.5 to 5:1 pressure ratio.

Variable Volume Pockets are furnished as standard equipment on all cylinder classes, except the model #602 through #605 forged steel cylinders. On these cylinders, other methods of adding clearance, such as fixed heads (some with center plugs), fixed volume heads, or valves spaces can be furnished when required.

The purpose of this manual is to familiarize operating and maintenance personnel with the design and construction of the compressor. Thus, they can understand the functions of the various parts and know how to care for them in order to obtain the most satisfactory compressor performance.

The MH6 and WH6 compressors are all of the same basic configuration but vary in size and rating of certain components. The general configuration of each compressor and various cylinder head options are shown in Figure 2-3, Figure 2-4 and Figure 2-5.Cooper Energy Services Ajax-Superior

Page 2-3

Figure 2-3 WH/MH Transverse Cross Section

Rod

Pis

ton

Pla

teV

alv

e

Va

riab

leV

olu

me

Poc

ket

Pla

te V

alv

eP

ac

kin

g

Co

nne

cti

ng

Rod


Page 2-4

WH/MH Compressor Instruction ManualFigure 2-4 WH Compressor Longitudinal Cross Section

00746

Bre

ath

er

Cra

nk

sha

ft

Co

upli

ng H

ub

Re

lie

fV

alv

e

Ha

nd

Pri

min

g P

um

pCooper Energy Services Ajax-Superior

Page 2-5

Figure 2-6 WH/MH Cylinder Head Options

00747

Cylinder Head Plug

Typical Variable Volume Pocket

00749

00748

Pneumatically Operated PocketCooper Energy Services Ajax-Superior

Page 2-6

WH/MH Compressor Instruction ManualCrankshaft RotationWhen facing the oil pump end of the frame, counterclockwise rotation is standard.

Balancing AJAX-Superior CompressorAjax-Superior manufactures balanced opposed reciprocating compressors having 1 to 6 cylinders. The cylinders range in size from 3" to 26.5" diameter and may be mounted on the frames in various combinations.

Since the goal is to produce a balanced opposed compressor, it is necessary to make the reciprocating weights on each pair of opposing throws approximately the same. This is quite a task, in view of the large number of cylinder sizes and throw location combinations that are possible, and because each piston and rod assembly (piston, rings, piston rod and cap screws) has a certain combined weight which will probably be different from the weight of the piston assembly that it will oppose.

Balancing of the unit is accomplished by using both an appropriate weight crosshead assembly and a piston rod jam nut (balance nut) to obtain a maximum weight difference not exceeding 2 pounds on the opposing throws. The crosshead assembly consists of a pair of shoes, the bolts and nuts to attach the shoes, and the crosshead. There are two different weight crossheads available. Also available are balance nuts in 5 lb. increments. Consult Ajax-Superior Engineering for details concerning the use of the special weight nuts. In addition to the above mentioned balance parts, the connecting rod weight is also involved in the balance. Connecting rods vary in weight and when the units are assembled at the factory, care is taken to select the connecting rods so that the weight variation for opposing throws does not exceed 1 lb.

Every effort should be made to achieve as near equal balance between opposite throws as possible.

Caution!The maximum allowable variation is two pounds on the reciprocating weights and one pound on the connecting rod weights for each pair of opposing throws.

This does not apply to adjacent throw pairs, which sometimes vary by 100 lbs. or more, depending on cylinder sizes.

The estimated balance for the original assembly of a compressor is recorded on the Compressor Torsional and Balance Data Sheet. A copy of the data sheet for this compressor is included in the Instruction Manual, and should be referred to in the event a change which would affect the balance is contemplated. The actual weight of parts can vary from the estimated weights. Also, when replacing crossheads, connecting rods, pistons, or changing Cooper Energy Services Ajax-Superior

Page 2-7

piston ring material, the new parts should be weighted in order to reaffirm the actual unit balance.

Warning!Failure to verify and correct compressor balance can result in excessive mechanical vibration, frame cracking, piping vibration, foundation cracking and other damage to the compressor. It also creates a potentially UNSAFE operating condition for the operator.

Compressor System VibrationDue to the nature of the horizontal compressor design, the reciprocating weights generate some vibrational forces. Proper balance of reciprocating weights on opposing throws will minimize this effect.

Compressor systems including skids, bottles, piping, valves and other components are subject to vibration. The design goal is to have a system free of vibrations in the normal operating speed range.

Operators and maintenance personnel should be alert for excessive system vibrations that can cause damage to equipment. Normally, clamping or adding additional support to a vibrating component will raise its natural frequency and eliminate the vibration problem.

Compressor cylinder mounting can be stiffened, if necessary, by attaching additional supports directly to the cylinder from the skid or foundation. Most cylinders now have a machined boss with drilled and tapped holes for attaching an outboard cylinder vibration suppression device. This is the preferred method of attachment.

Compressor SpecificationsTable 2-1 Compressor Specifications*Specification Type Of Unit

MH6 WH6Number of Throws 2-6 2-6Stroke Inches (mm) 6 (152.4) 6 (152.4)Speed Range - RPM 600-1200 600-1200Horsepower Per Throw @ 1200 RPM-hp (kw)

900 (671) 900 (671)

Rod Load-kips (kg) 38 (17,237) 50 (22,680)Rod Diameter - inches (mm) 2.25 (57.15) 2.5 (63.5)Connecting Rod LengthCenter to Center - inches (mm)

14.5 (368.3) 15.0 (381.0)Cooper Energy Services Ajax-Superior

Page 2-8

WH/MH Compressor Instruction ManualCrosshead Guide Bore Diameter - inches (mm)

10.5 (266.7) 12.75 (323.85)

Crosshead Pin Diameter - inches (mm)

4.0 (101.6) 4.75 (120.65)

Crosshead Shoe - Oiling Method

External Internal

Lube Oil Filter Differential Pressure - Normal

< 5 psi --

Lube Oil Filter Differential Pressure - Alarm Point

15 psi --

Lube Oil Filter Differential Pressure - Shutdown

25 psi --

Maximum Limit for Recriprocating Weights

397 lbs 397 lbs

* Subject to change without notice.

Table 2-1 Compressor Specifications*Cooper Energy Services Ajax-Superior

Page 2-9


Page 2-10

WH/MH Instruction ManualSection 3Lubrication And Cooling

GeneralThe responsibility for selecting the proper lubricant is primarily that of the supplier. Use of only products with field proven reliability and merit, produced by responsible concerns will provide the best assurance for achieving effective lubrication. Use of such products should always be accomplished according to the manufacturers recommendations. If a compounded oil is used, the non-corrosiveness of this oil must be looked into very carefully. The oil must not contain substances which might be injurious to tin or lead base babbitts and should be non-corrosive to copper-lead alloys. Similar, synthetic lubricants must be reviewed for compatibility with compressor materials.

Compressor design, operating conditions, and the gases being handled all have a significant effect on how well a lubricant performs in the given application. The following will assist users in selecting the proper lubricant for each application.

Any lubricant that performs satisfactorily in a Superior engine will generally perform well in a compressor frame. Compressor frame lubricating oils should normally be the same as used in the engines and should be selected in accordance with Superior Engineering Standards ES 1001 and 1002.

In addition to the above requirements, the frame lubricant must be capable of operating with the type of gas being handled by the compressor cylinders. For most sweet natural gases and allied gas services, a lubricating oil with the minimum qualities specified in ES 1001 and 1002 will be suitable. In applications where the compressor cylinders are handling corrosive gases such as H2S or CO2, a lubricant with a higher TBN or method for adequate retention of the original TBN is recommended for service in the frame.

Lubricating Oil RequirementsA good mineral oil which provides resistance to oxidation and corrosion is generally satisfactory for lubrication in a reciprocating compressor which has its crankcase sealed off from the cylinders. However, there is no objection to the use of a detergent type oil if this is more readily available. The best assurance of obtaining a suitable oil is to use only products of well known merit, produced by responsible concerns, and used in accordance with their recommendations. Do not permit your compressor to be used as an experimental unit for trying out new or questionable lubricants.Cooper Energy Services Ajax-Superior

superior-frame-manual-mhwh-lubrication.fm Page 3-1

In some cases it may be convenient or practical to use the same type oil in the compressor as is used in the compressor drive engine. This is permissible as long as the engine oil is of proper viscosity. The oil should be selected per the recommendations of this section.

Compressor Frame Lubrication The frame lubrication system consists of a gear driven pump, pressure relief valve, oil cooler, and oil filter. (See figure 3-1 or 3-2).

Caution!Verify that the oil temperature in the sump is heated to at least 40F before attempting to use compressor.

Prior to start-up, the frame lubrication system should be primed by using the lube oil hand priming pump or automatic priming pump. Use of this pump will prevent oil starvation in the bearings during start-up, prolonging compressor life. Compressor design, operating conditions, and the gases being handled all have a significant effect on how well a lubricant performs in the given application.

Lube oil header pressure should be 50 psi (345 kPa) and is maintained at this level by the pressure relief valve. If adjustment is required, it can be done by removing the cap which provides access to the spring loaded adjusting screw. This should be adjusted while at normal operating speed and temperature.

Figure 3-1 Lube Oil System Schematic


Page 3-2 superior-frame-manual-mhwh-lubrication.fm

WH/MH Instruction ManualWhen starting the compressor, verify a lube oil header pressure of 20 psi (138Kpa) or greater occurs within 5 seconds of compressor start-up. To prevent damage to the crankshaft and other lubricated parts, all compressors are equipped with low oil pressure shutdowns. This is triggered when the oil pressure falls below 20 psi (138 kPa).

The oil level in the frame is normally at the center of the sight glass. An alarm should sound if the oil level rises 1 inch during compressor operation, this will submerge the gaskets on the bottom of the front and rear covers. A shutdown should occur if the oil level rises an additional 2.5 inches (1.5 on MH62) or if the oil level falls 1 inch from normal level.

Any lubricant that performs satisfactorily in a Superior engine will generally perform well in a compressor frame. Compressor frame lubricating oils should normally be the same as used in the engines and should be selected in accordance with Superior Engineering Standard ES 1001.

The frame lubricant must be capable of operating with the type of gas being handled by the compressor cylinders. For most sweet natural gases and allied gas services, a lubricating oil with the minimum qualities specified in ES 1001 and 1002 will be suitable. In applications where the compressor cylinders are handling corrosive gases such as H2S or CO2, a lubricant with a higher TBN or method for adequate retention of the original TBN is recommended for service in the frame.

The oil level in the frame sump should be checked while the compressor is running. The correct level is shown by the round sight gauge on the auxiliary end of the compressor. Oil level (while running) should be no higher than the top and no lower than the bottom of the sight gauge. Oil may be manually added through the breather cap hole in the top cover. The breather cap is designed to be threaded into its bushing by hand and no wrenches should be used. Make up oil may also be continuously added through an optional, frame mounted oil level controller connected to an oil supply tank.

NoteThe regulator is not designed to make up large quantities of oil in a short time period, such as refilling the crankcase after oil or filter changes. Its function is to compensate for small losses that occur during normal operation.

Oil change periods, in general, may be longer than the period required for compressor drive engines. An initial break-in period of 300 to 500 hours is recommended. Thereafter, the filter element should be changed and the drainage periods can be increased to 2000 hours or longer, providing the filter element remains in good shape and the oil stays reasonably clean. However, if the oil is badly discolored and loaded with insolubles, it should be drained off and replaced when the filter element is changed.Cooper Energy Services Ajax-Superior


Compressor Cylinder LubricationSome cylinders require cylinder bore lubrication and rod packing lubrication. A force feed lubricator is used to provide this. See figure 3-2.

IT IS IMPORTANT to provide safe and ample lubrication by the properly adjusting the force feed lubricator pumps. Observe the detailed instructions, given in Section 5, when first starting up the compressor. With all lubricator pumps set at full stroke, bring the cylinder pressure up slowly until the unit is running at full rated speed and load. Watch for any signs of malfunction. After the first 48 hours at full load, the lubrication rate should be gradually reduced to the amount necessary for correct lubrication. Adjustment should be made slowly, a little each day, and should take several days to accomplish.

Because of the variety of gases and operating conditions encountered by Superior compressor cylinders, the lubricant must be selected with the proper characteristics to be suitable for the application involved. Contact Superior Engineering for a copy of ES 1002 for detailed information on selecting lubricants. In all applications, the oil used for compressor cylinders should have the following qualities:

Good wetting ability.

Oxidation and corrosion inhibitors not required, but may be beneficial.

Clean and well refined.

High film strength.

Figure 3-2 Force Feed Lubricator



WH/MH Instruction ManualPour point must be equal to gas suction temperature minus 15-20F.

Good resistance to carbon deposits and sludging formation. If any carbon is formed, it should be the soft, loose, and flaky type.

Minimum flash point of 400F.

Lubrication Rate

The lubrication rate may be determined as follows: A fairly generous feed rate for a 6" stroke compressor running at 1200 rpm will be 1/5 pint per day for each inch of cylinder bore diameter. Piston rod packing is treated as a separate cylinder and the feed rate is doubled. That is, a 2-1/2" diameter rod packing is fed at the same rate as a 5" diameter cylinder.

As an approximate setting for the vacuum sight feed type lubricators, the feed rate of 1/5 pint per day per inch of cylinder bore is equivalent to one drop per minute per inch of bore for a very heavy oil, and ranges up to 2 drops per minute per inch of bore for a light oil.

EXAMPLE:WH62 Compressor with one (1) 10" cylinder and one (1) 20" cylinder operating at 1200 rpm:

2.5" Packing = 2 x 2.5 x 1/5 pint/day = 5/5 or 1.0 pint/day (5-10 drops per minute)2.5" Packing = 2 x 2.5 x 1/5 pint/day = 5/5 or 1.0 pint/day (5-10 drops per minute)10" Cylinder = 10" x 1/5 pint/day = 2 pints/day (10-20 drops per minute)20" Cylinder - 20" x 1/5 pint/day = 4 pints/day (20-40 drops per minute)Total Lubrication Rate = 1.0 + 1.0 + 2.0 + 4.0 = 8.0 pints/day

The feed rate specified for break-in and for normal operation may be approximated by adjusting the pumps as shown on the Cylinder Lubrication Sheet, but a check should always be made in terms of 24 hour oil consumption.

Pump Per Point System

If a cylinder has more than one feed point, and more than one pump, the requirements for lubrication should be split evenly. On a normal force feed lubricator, the proper proportioning of oil to cylinders and packing should, as a first approximation, be adjusted by the drops per minute method; but a check should be made in terms of actual 24 hour oil consumption, and the feed rate of all pumps adjusted up or down in the same proportion as the size of the cylinders being fed.

The check on lubrication rate which takes precedence over any other method is a visual inspection of the compressor cylinder. This should be done (by removing a valve at each end) after 48 hours of operation at the final lubrication settings. There should be a film of oil over the entire circumference of the ring travel section of the cylinder bore. Separate pumps may be adjusted up or down as indicated by this inspection.Cooper Energy Services Ajax-Superior


Proportional Lubrication System

This lubrication system of the distribution block type is a metered positive, displacement method of lubricating the compressor cylinders and packing. Since the system operates on a proportional basis, a single adjustment at the force feed lubricator pump increases or decreases the flow proportionally to every lubrication point.

Oil flow rates given in percent of lubricator pump stroke accompany each compressor. These settings must be followed and checked to provide adequate lubrication for both break-in and normal operation.

Description

The force feed lubricator pumps oil into a single main line leading to a proportional distribution block. Hydraulically balanced pistons in the block divide the oil into accurate metered amounts for each lubrication point it serves. Selection and make-up of the distribution block allows (1) accurately measured shot sizes, and (2) precise proportioning to meet different or equal oil requirements.

Because of the positive, metered operation, central warning equipment can sense trouble anywhere in the system.

Safety equipment includes pin fault indicators, in each outlet from the distribution block, a pneumatic or electric shutdown switch in the event of lubricant flow failures, and a rupture disc in the lubricator collector manifold.

Operation

The operation of a typical lubrication system is as follows:Lubricant flows into the collector manifold where the pump discharge lines are combined into one. It then is passed through a strainer, a shutdown switch, and into the proportioned distribution block.

Should blockage occur at one of the lubrication points in the cylinder or packing, the pressure build-up in the line will rupture an aluminum disc in the pin indicator. The pin will be moved forward indicating a problem in the line. The pin can re-seal if the pres-sure is removed.

As the pressure continues to build up, the safety rupture relief in the collector manifold bursts, relieving pressure throughout the entire system and causing the no-flow shutdown to activate and stop the compressor. The protruding pin in the indicator on the distribu-tion block gives a visual indication of the point where the blockage occurred. Before re-starting, new rupture discs of the same color and thickness as originally installed must be replaced at the location where rupture occurred. It is the thickness of the color coded Cooper Energy Services Ajax-Superior


WH/MH Instruction Manualdiscs that determine the rupture pressure. Refer to rupture disc data sheet inAuxiliary Equipment section of this manual.

Maintenance

In order to operate properly, the lubrication system must be completely purged of air. This is done by LOOSENING, BUT NOT REMOVING the nuts of the lube lines at the point of injection to permit purging of oil and air. The nut at the entry to the distribution block, all pin indicators and 1/8" pipe plugs in the face of the block must be loosened also, for the same reason.

Caution!High pressure oil streams may puncture skin. Use proper wrench and keep hands away from the immediate point where the system is purging air.

Loosen the vent screws in the top section of the distribution block. Continue to operate the lubricator pump manually until clear, air-free oil appears at either of the two loosened vent screws. Retighten this vent screw and continue pumping until air-free oil emerges at the other vent screw. When this occurs, retighten second vent screw. Continue to operate the pump manually until air-free oil has emerged from tubing nuts at every injection point. Then, and only then, tighten the nuts on the tubing lines, the pin indicators, and pipe plugs.

NoteIf distribution block must be disassembled for cleaning, observe the following:

(a) Record order of manifold sections and outlet positions in order to facilitate reassem-bly.

(b) Have a clean work area.

(c) Avoid vise marks; protect ground surfaces, and NEVER grip the ground mating sur-faces in a vise.

(d) Pistons are not interchangeable - - each piston is match-honed to its cylinder.

(e) Pistons are removed by hand-punching with a brass rod (either way).

(f) Clean all sections with an approved solvent.

(g) Do not disassemble check valves - - clean with compressed air. Replace defective parts, as required.

(h) Use all new gaskets when reassembling manifolds.

(i) Torque must be carefully observed when reassembling manifolds, as follows:Cooper Energy Services Ajax-Superior


Distribution Block Tie Rod Nuts 20-25 Ft. Lbs. Check Valves 15-20 Ft. Lbs.

End Plugs 15-20 Ft. Lbs.Alternate Outlets And Pin Indicators 10-15 Ft. Lbs.

Lubricator Worm And Gear Drive

When starting a compressor for the first time, or after servicing, be sure that the gear box is filled with Exxon TK-680 Cylesstic Worm Gear Oil (ISO680 AGMA-8). It is advisable to check periodically to be certain that the supply of gear oil is maintained. New units are filled with oil at the factory, and should not need filling.

Compressor Frame Lube Oil CoolingThe compressor frame is lubricated by the pressurized lubrication system. The oil must be cooled by the shell and tube cooler provided with the compressor (shipped separate for mounting by the packager). Oil should be circulated through the shell side and coolant through the tube side of the cooler.

The maximum recommended oil temperature for oil returning to the frame is 175F. To insure this oil temperature, coolant temperature and flow must be selected to remove heat according to the following:

Table 3-1 Oil Cooling Specification

Compressor Model Heat Rejection In BTU/Hr (At 1200 RPM)

Figure 3-3

Vent Fill Plug

UpperPlug

Drain Plug00752

Filling Instructions

1. Remove vent/fill plug.2. Loosen upper plug.3. Fill with Exxon TK-680 Cylessic

oil (ISO680 Agma-8) until it begins to leak at upper plug.4. Tighten plug, install/fill plug.Cooper Energy Services Ajax-Superior



Table 3-1 Oil Cooling SpecificationCooper Energy Services Ajax-Superior

Cylinder CoolingThe Ajax-Superior compressors cylinder jackets can be cooled by one of three ways: (1) Dry jacket, (2) Standpipe, or (3) Circulated water cooling.

1. Dry jacket cooling is generally used where the gas discharge temperature is less than 140F. and gas inlet temperature is greater than 60F. In this form of cooling, the air present inside the cylinder water jacket is the medium which transfers heat out of the cyl-inder. The cylinder jackets must be vented when this form of cooling is used.

2. In standpipe cooling, a water with corrosion inhibitor and/or antifreeze solution is used as the medium for heat transfer. The cylinder jackets are filled with the coolant and then vented to the atmosphere at their highest point. The vent (or standpipe) should be a 6" long vertical section of pipe which will contain the coolant when it expands. The pipe must be topped with a vented cap to prevent dirt from entering the coolant. This form of cooling may be used when the gas discharge temperature is less than 250F. and the rise between gas suction and discharge temperature is less than 170F. The temperature of the liquid coolant will reach a mean temperature somewhere between the suction and dis-charge gas temperatures. Accordingly, a coolant must be chosen whose boiling point is at least 25F greater than the mean temperature and whose freezing point is at least 25F less than the suction gas temperature (or ambient, whichever is lower).

3. The third form of cooling is by coolant circulation through the cylinder jackets. This form of cooling must be used on compressor cylinders having gas discharge temperatures greater than 250F. or a gas temperature rise greater than 170F.

For maximum performance, it is recommended that the cylinder coolant temperature be maintained 10F to 15F higher than the suction gas temperature. At lower coolant temperatures, condensation forms on the cylinder walls. This condensation must be avoided as it has a tendency to wash the oil film from the cylinder bore, promote corrosion (especially in non-lubricated cylinders), and cause internal damage by excessive wear on rods, rings, valves, and the cylinder bore due to lack of lubrication. Also, condensates are incompressible fluids which can cause damage to any cylinder part by creating forces well beyond the capability of the machine.

To control condensates and still maintain optimum cylinder performance, the coolant must be monitored and regulated. This is accomplished by monitoring the coolant in and out temperatures for each cylinder with thermometers and sight flow indicators. From these

MH62/WH62 42,000

MH64/WH64 65,000

MH66/WH66 110,000superior-frame-manual-mhwh-lubrication.fm Page 3-9

readings, the operator may regulate the water flow to each cylinder by using a water regulating valve until a coolant temperature differential of 10F (15F maximum) is obtained.

NoteApplications that require low suction temperatures (Below 40F) should be coordinated with Superior Engineering.

Packing CoolingIn the majority of applications, rod packings will perform satisfactorily without a coolant being circulated through the packing case and therefore dont have coolant passage. Some applications, however, do require that the packing cases be cooled in order to achieve adequate packing ring life. These applications usually involve high pressures and temperatures, marginal lubrication (characteristically encountered with wet and sour gases), and unclean gases. On these units, the packing cases are provided with internal coolant passages. (See Figures 3-4 and 3-5.)

Adequate cooling flow through the packing cases at a satisfactory temperature is required to properly conduct the heat out of the packing. Inlet coolant temperatures should be as cool as possible, but no higher than 90F. is recommended to achieve optimal cooling. The coolant flow required is normally 1 GPM for each inch of rod diameter with a minimum of 2 GPM. A pressure drop with water coolant of approximately 30 to 50 psig should be expected across each packing case at the required flows.

Coolant RequirementsThe most important consideration for cooling systems is good water quality. The following chart shows the range of limits for water quality. If raw water is tested and found to have higher concentrations than the chart allows, it should be treated or de-ionized. If concentrations are lower, then it should be suitable for use with the addition of inhibitors.

Table 3-2 Water Quality Specification

Standard System Ebullient/Steam System

pH 7.5 Min. 7.5 Min

Standard System Ebullient/Steam System

Total Hardness (PPM) 100-170 Maximum 5.0 MaximumChlorides (PPM) 25 Maximum 25 MaximumCooper Energy Services Ajax-Superior


WH/MH Instruction ManualA good industrial-type of antifreeze should be used in all closed-type cooling systems. All industrial antifreezes have some corrosive inhibitors; however, these inhibitors break down with heat. This requires periodic adjustments to maintain the corrosive protection of the coolant.

Corrosion inhibitors vary in their chemical make-up and concentrations, depending on the manufacturer. Most products will do their job with a good quality water (de-ionized or demineralized), but will not give adequate corrosion protection with hard or impure water. The key to good protection is clean water and a reliable water treatment specialist.

Periodic testing of the coolant, whether by the user or the vendor of the treatment system, is absolutely necessary in order to assure that a proper level of protection is maintained. The equipment user must obtain the specific instructions for the use and testing requirements of the inhibitor compounds from the supplier or manufacturer.

A clean system is a prerequisite for establishing protection of any cooling system. Adequately protected closed cooling systems seldom, if ever, present problems caused by scaling, corrosion, deposits, or cavitation.

There are three types of cooling systems used for stationary engines and compressors: open, closed, and combination.

Open systems involve cooling towers, spray ponds, and cool the water by evaporation.

Closed systems involve heat rejection through either shell and tube or radiator type heat exchangers.

Combination systems have the jacket water in a closed system using shell and tube-type heat exchangers to transfer the heat to an open system using cooling towers, etc.

Both closed and combination-type systems are commonly used and approved cooling methods. However, because the open-type systems involves not only large volumes of make-up water, but also ease air-borne contamination, we do not recommend them.

Superior recommends that the compressor coolant system should be pressurized. To pressurize the system, all radiators and surge tanks must have a 7 to 10 pound pressure cap.

Sulfates (PPM) 20-100 Maximum 20-100 MaximumTotal Dissolved Solids (PPM) 300-400 Maximum 300-400 MaximumSilica (PPM) ------ 50 Maximum

Table 3-2 Water Quality SpecificationCooper Energy Services Ajax-Superior


Figure 3-4 Crosshead Guide and Distance Piece - Lube and Liquid Cooled Package

00753

View Of Typical Distance Piece

00754 Cross Section Through Compressor Distance PieceCooper Energy Services Ajax-Superior


WH/MH Instruction ManualFigure 3-5 Crosshead Guide & Distance Piece - Lube & Non-Liquid Cooled

00755 View Of Typical Distance Piece

00756

Cross Section Through Compressor Distance Piece Cooper Energy Services Ajax-Superior


WH/MH Instruction ManualSection 4Sour Gas Compressor Applications

General InformationThis section defines additional compressor hardware and special materials for use when the compressor is applied in sour gas or corrosive gas service. The requirements listed are based on API-11P Standards, dated 1989, NACE MRO175, and Ajax-Superior experience. Additional specifications may apply to pulsation dampers, piping and other equipment used in conjunction with this compressor. (See API-11P for additional information.)

These specifications apply to equipment only. Follow safe operating and mainte-nance procedures associated with personnel around sour gas machinery as dictated by your company procedures. Sour Gas is poisonous and attacks the nervous system and can cause paralysis, permanent injury or death.

Hazards of Hydrogen Sulfide or Sour GasCaution should be taken when working in or around hydrogen sulfide (H2S). This chemical is dangerous and can cause harm to personnel. H2S is colorless and smells like rotten eggs. In higher concentrations it will kill your sense of smell and impede your ability to detect it. DO NOT rely on your sense of smell as a detection method.

The following information gives some general information on the concentrations levels of H2S and its effect on the body. This should be thoroughly read and understood before working in an H2S environment.Cooper Energy Services Ajax-Superior

superior-frame-manual-mhwh-sour-gas.fm Page 4-1

Concentration Levels

The equipment specifications are based on three levels of sour gas plus additional NACE requirements as defined by the following percentages of H2S:

Level I Less than 2% H2S (by volume)Level 1-11P 2% to 5% H2SLevel 2-11P Greater than 5% H2SEnhanced TrimNACE MR0175 Guidelines

Trim Requirements

Hydrogen Sulfide (H2S) Concentrations Up To 2% By Volume: For any concentration of H2S up to 2% by volume in lubricated service, special trim will

not be required. Standard material is acceptable and special lubrication practices are rec-ommended.

The frame lubricant used must have a total base number (TBN) of 15 or higher to help pre-vent the lubricant from turning acid and damaging bearings and bushings. This alkalinity

Table 4-1 Hydrogen Sulfide Effects

H2S Concentration Effects

1 ppm (.0001%) Detectable of Rotten Eggs Odor.

Protective Equipment Is Recommended For Any Concentrations Over 10 ppm (.001%)

100 ppm (.01%) Kills sense of smell in 3 to 15 minutes. May burn eyes and throat.

200 ppm (.02%) Kills sense of smell rapidly. Burns eyes and throat.

500 ppm (.03%) Loss of reasoning ability and sense of balance. Respiratory disturbances will occur within 12 to 15 minutes of exposure. Requires prompt artifi-cial respiration.

700 ppm (.07%) Rapid loss of consciousness and breathing. Death will result if not removed quickly. Immediate ar-tificial respiration is required.

1,000 ppm (.10%) Immediate unconsciousness. Permanent brain damage may result if not rescued immediately.Cooper Energy Services Ajax-Superior

Page 4-2 superior-frame-manual-mhwh-sour-gas.fm

WH/MH Instruction Manualmust be maintained during operation in the machine at no less than approximately 30% of the original TBN number by appropriate timely make-up or complete oil changes.

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

A complete oil analysis program on the frame lubricant is required to determine proper oil change intervals as well as to monitor the condition of the lubricant and the unit.

Compressor cylinder lubricants must adhere to the requirements of Ajax-Superior Engi-neering Standard ES 1002. Viscosities are to be on the high side of the pressure conditions normally required and a 3% to 5% compounding (similar to steam cylinder oils) is also re-quired.

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

All brass, bronze, copper and other copper alloys are to be avoided on hardware for all gas wetted parts.

The distance piece is to be properly vented in accordance with local safety standards to provide maximum safety to personnel.

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

The O-ring material used for standard equipment is Viton (Spec. 473) and this is also ac-ceptable for H2S service. For lower temperature operations (< 27F) Neoprene (Spec. 479) can be specified as an option.

Level 1-11p Trim (H2S Concentrations of 2% - 5% By Volume)All of the requirements applicable to concentrations of less than 2% apply plus the following additional requirements:

A suitable corrosion inhibitor should be added to the cylinder lubricating oil.

Cylinders are to be equipped with a suction flushing system (injection of cylinder lubri-cating oil into the suction nozzle of each cylinder). This is in addition to the regular cylin-der lubrication. This helps to resist the natural solvent action of the sour gas and insures a thorough distribution of oil for better lubrication. It also helps to better form a barrier to corrosion by coating all the valve surfaces with an oil film.

Oil slingers are to be used on each compressor rod in the distance piece compartment to insure that none of the H2S contaminated cylinder or packing lubricant works its way back into the crankcase and contaminates the frame lubricating system.

Packing and piston ring material shall either be non-metallic or contain no copper bearing metals.Cooper Energy Services Ajax-Superior


Compressor valves will be standard construction and hardness.

All carbon steel, alloy steel, or 12CR steel parts which are gas wetted (come into contact with the process gas stream) are to have a maximum hardness of 22 HRC. This is to in-clude all internal fasteners and V.V. pocket screws as a minimum, but excludes valve fas-teners.

The piston rods are 17-4 pH stainless steel with a hardness of 28 - 33 HRC (Heat Treat Spec ZA).

Forged steel cylinder bodies made of AISI 4142 are to have a maximum hardness of 235 HB. Engineering will evaluate these applications on an individual basis as some cylinder pressure ratings may have to be reduced because of the mechanical properties restrictions.

Level 2-11p Trim (H2S Concentrations > 5%)All of the requirements for H2S concentrations of 2%-5% apply plus the following:

Valve components made of carbon steel or AISI 4140 alloy steel shall have a maximum hardness of 22 HRC (Heat Treat Spec. H2S). This reduces the pressure differential capability of any specific valve design and thus the pressure differential capability of the cylinders. Engineering will evaluate these on an individual basis and select appropriate alternative designs to meet the application requirements.

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 with a maximum hardness of 22 HRC.

Valve plates wherever possible are to be plastic to better prevent seat wear against the softer valves seats.

When metallic plates are required, 410 stainless steel with a hardness of 17 to 22 HRC will be used.

Nimonic 90 valve spring material will be used.

Two compartment configuration of distance pieces is required. The outer compartment must be purged with inert gas to a pressure of 3 - 5" H2O.

All compressor cylinder and distance piece critical bolting, capscrew, studs, and nuts which come in contact with the process gas stream shall conform to ASTM A913-B7M (bolts and studs) and ASTM A194-2HM (nuts).Cooper Energy Services Ajax-Superior


WH/MH Instruction ManualAll instrumentation that comes into contact with the process stream (liquid level controls, shutdowns, bourdon tubes, process valving, relief valves, etc.) shall meet the full requirements of NACE MRO125 except stainless steel tubing fittings. This requirement is the packagers responsibility.

The distance piece shall be purged with inert gas. The packager is responsible for purging per these requirements. If other venting or purging systems are desired the details are to be negotiated between the purchaser and the packager (i.e., vacuum systems or sweet natural gas purge). The final detailed system should provide for the safety of persons around the equipment and should prevent contamination of the frame oil with sour gas. Packing cases will not be purged unless required by the customers.

Enhanced H2s Trim Requirements

This section covers H2S trim requirements based on guidelines established by NACE MR0175. This section specifies more rigid H2S trim levels than required for standard API 11P trim.

The following requirements should be followed when H2S trim in excess of API 11P requirements is needed to meet NACE. This enhanced level of trim can also be used for any concentration of H2S as required by the customer.

The requirements are as follows:

A suitable corrosion inhibitor should be added to the cylinder lubricating oil.

The cylinders are to be equipped with a suction flushing system (injection of cylinder lu-bricating oil into the suction nozzle of each cylinder).

Two compartment distance pieces are required. The outer compartment must be purged with inert gas to a pressure of 3 - 5" of H2O. The inner compartment can either be sepa-rately vented as described previously or purged with inert gas to a pressure of 3 - 5" H2O.

Oil slingers are to be used on each compressor rod in the distance piece compartment to insure that none of the H2S contaminated cylinder or packing lubricant works its way back into the crankcase and contaminates the frame lubricating system.

Compressor valve springs are to be Nimonic 90.

Packing garter springs are to be Inconel.

The piston rods are Stainless Steel with a hardness of 28 - 33 HRC (Heat Treat Spec. ZA).

Tungsten carbide coating is required in the packing travel area of the piston rods.

The valve components are to be made of carbon steel or AISI 4140 alloy steel with a hard-ness of 22 HRC maximum (Heat Treat Spec H2S). This reduces the pressure differential Cooper Energy Services Ajax-Superior


capability of any specific valve design and thus the pressure differential capability of the cylinders. Engineering will evaluate these on an individual basis and select appropriate alternative valve designs to meet the application requirements. Compressor valve com-ponents may also be made of AISI 416 stainless steel with a maximum hardness of 22 HRC.

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

Forged steel cylinder bodies are to be made of AISI 4142 with a maximum hardness of 235 HB. Engineering will evaluate these applications on an individual basis as some cylinder pressure ratings may have to be reduced.

All steel gas wetted parts are to have a maximum hardness of 22 HRC. This is to include all internal fasteners and V.V. pocket screws as a minimum.

Valve plates wherever possible are to be plastic to better prevent seat wear against the soft-er valve seats.

When metal plates are required, 410 stainless steel with a hardness of 17 to 22 HRC shall be used.

All compressor cylinder and distance piece critical bolting, capscrews, studs, or nuts which come into contact with the process gas stream shall conform to ASTM A193-B7M (bolts and studs) and ASTM A194-2HM (nuts).Cooper Energy Services Ajax-Superior


WH/MH Instruction ManualSection 5Installation

GeneralInstallation of the compressor will be determined by the fabricator and the end customer. Since the method employed will vary due to application, the following is offered as a guide to aid in the installation. These instructions are based on previous installations that have proven satisfactory.

There are two basic compressor mountings: the baseframe or skid mount and the direct to block mount. See Figures 5-1 and 5-2. The baseframe/skid mount is most commonly used whereby the fabricator sets up the complete installation as a package. This package is then moved to location and placed on a foundation. With the block mounting, there is no intermediate (baseframe) between the compressor and foundation, thus the compressor is mounted direct to the foundation (block). This type installation is of a somewhat more permanent nature.

If you have a choice as to the location of the compressor, select a site where the ground under and around the unit will be firm and dry at all times. Filled ground, wet clay, unconfined sand and gravel or similar soils provide poor support. Be sure that sufficient space is available for necessary maintenance. For instance, there should be ample space to permit removing the piston and rod assembly out the outboard end of the cylinder. See that provisions can be made for an overhead hoist, or that a portable crane can be moved into position as necessary for removal or installation of major parts or assemblies. Electrical outlets, lighting and cleanliness are other important factors. Adequate ventilation is essential to safety and the welfare of the operating personnel.

FoundationThe responsibility for an adequate foundation is that of the customer; thus, it is suggested that a foundation engineer be called in where soil conditions are questionable or where the location of the compressor is such that transmitted vibration would have detrimental effects not only to the compressor installation, but on surrounding machinery, buildings, or personnel. Often times, a neighboring installation on similar soil will serve as a clue to the soil conditions. However, unless the nature of the ground is well known, it is advisable to dig several test pits at the proposed site. Ajax-Superior will gladly furnish data on weights and unbalanced forces required for calculations by a foundation engineer. In any case where increasing the size of the standard minimum foundation is necessary, the area of the base should be increased to decrease the soil loading and the possibility of rocking. When Cooper Energy Services Ajax-Superior

superior-frame-manual-mhwh-installation.fm Page 5-1

freezing temperatures are likely to occur, the foundation must be carried well below the lowest expected frostline as determined by the foundation engineer.

Figure 5.0-1 Base Frame/Skid Mounting

00757

Figure 5.0-2 Block (Concrete) Mounting


Page 5-2 superior-frame-manual-mhwh-installation.fm

WH/MH Instruction ManualFoundation BoltsTo locate the foundation bolts, make a wooden template to temporarily position the bolts according to the dimensions given on the foundation plan. Set up the template in the exact position to be occupied by the compressor, allowing space for the grout as indicated. See Figure 5-3. Fasten the template firmly in position.

The next step is to attach the bolts to the template so that they will extend into the foundation. There are two important items which should be considered at this point: (1) Make sure the bolts project far enough through the frame hole to allow two full threads beyond the nut. Allow for thickness of grout, frame, nut, etc. (2) Provide allowance for misalignment. A piece of 2.5" to 3" pipe or metal tube positioned around each bolt, as shown will prevent the bolts from being cemented into a fixed position and thus allow slight movement of the bolts for alignment with the holes in the frame. Stuff paper or rags around the bolts at the top of the pipe to prevent cement from entering when the foundation is poured. The length that the bolts extend into the foundation is indicated on the foundation plans.

Figure 5.0-3 Foundation Bolt Positioning



Placement And LevelingAfter the foundation has been completed and the concrete has had ample time to thoroughly set, the unit is ready to be placed upon the foundation.

First, remove the template and chip off the top layer of pure cement and sand so that the grout will have a good solid surface for bonding. Then, clean the top surface of the foundation thoroughly. Soak the surface for several hours before pouring grout, but make sure there is no standing water. Remove the stuffing from around the foundation bolts. Next, screw each jackscrew through the frame (Figure 5-1 and 5-2) in a manner which would support the frame approximately 1" to 1.5" above the foundation. This provides for leveling, aligning and grouting. (There should be a jackscrew at each holddown bolt.)

With the compressor resting on the jackscrews, check to see that it is level. Place level on top side of frame as required to level in both directions all around. Bring frame to level by adjusting jackscrews. Keep all jackscrews snug. After levelling, foundation bolt nuts should be secure but NOT TIGHTENED. It is very important the unit is aligned as accurately as possible so that after grouting or shimming has been completed, the foundation bolts may be pulled down without any resulting stresses.

GroutingThe compressor frame may be grouted to a concrete or steel sub-base. In either case a grout form must be used. Some use a steel grout tray instead of wood. Do not remove stuffing from foundation bolts pipe casing before pouring grout. The bolts should not be encased so that they are free to stretch.

Before grout can be poured, a grout form or dam must be constructed on top of the foundation completely around the baseframe. This form should extend a minimum of 1" to 1.5" beyond the outer perimeter of the compressor baseframe and be deep enough (1.25") so that at least 1/4" of the grout will come up above the bottom edge. See Figure 5-2 and 5-3. On a block mounted installation the area under the center of the frame should not be grouted. Leave the space empty to aid cooling. Also, only the necessary amount of grout will be needed. A piece of hose or Styrofoam may be used to blank off this area. Whereas Styrofoam may be left in place, it is important that there is air space under the unit. An epoxy grout (or non-shrink grout) is recommended in preference to cement. Pour the grout into the area contained by the grout form so that it comes up at least 1/4" above the bottom edge of the base. Work the grout up under the inside of the base and into the sleeves around the anchor bolts. Work grout under frame or baseframe cross-members as well as outside members. Trowel off for smoothness and allow to set.Cooper Energy Services Ajax-Superior


WH/MH Instruction ManualCaution!Responsibility for the grout belongs with the customer or his contractor. Grouting material instructions should be carefully followed. Failure to comply with this warning may result in damage to your unit.

When the grout has completely hardened, LOOSEN THE JACKSCREWS and tighten down all the foundation bolt nuts evenly. Make sure that no stresses are set up when pulling down the nuts by checking alignment with a dial indicator.

Coupling Installation And AlignmentThe success of a compressor installation depends greatly upon the construction of the foundation and upon the care used to align the compressor with its driver. The standard flexible coupling used to drive the SUPERIOR compressor is shown in Figure 5-4. Installation is as follows:

a. Disassemble the flexible coupling. Note the arrangement of bolts, washer, and nuts. They must be replaced in their original position. Tie a string or wire through one bolt hole of the laminated rings (A) (Not shown) to retain the dialed position of individual discs.

Figure 5.0-4 Flexible Coupling Assembly



NoteLaminated rings must be re-assembled in the coupling exactly as received.

b. Mount flange (B) (Not Shown) on engine flywheel. Torque flange screws per Table 5-1 and lockwire together. Mount hub (C) on compressor crankshaft. (See instructions given in 7.13 DRIVE COUPLING HUB.)

c. With engine and compressor moved into position, as shown on the Outline Drawing, reassemble coupling. Dimension (D) (Not Shown) must be maintained during the following alignment procedure.

The recommended procedure for establishing final alignment is called the indicator method. Proper lining up may take a little time, but it is absolutely essential. Flexible couplings should not be required to compensate for any misalignment that can be eliminated. The closer the initial alignment, the greater the capacity of the coupling to take care of subsequent operational misalignment.

d. After attaching dial indicator as shown in Figure 5-5B, rotate coupling 360 degrees to locate point of minimum reading on dial; adjust indicator to zero.

e. Rotate coupling 360 degrees. Observe misalignment reading.

f. Move engine or compressor, or both, until dial indicator reading does not exceed .0003" for each inch of diameter at indicator stem. This is approximately .006" (.15 mm) at outside diameter of flange B (Figure 5-4). This corrects angular misalignment.

g. Reset indicator to zero and repeat steps d e and f if either the engine or compressor is moved during aligning trials.

h. The coupling should be turned several revolutions to make sure no end-wise creep in the crankshaft is measured.

Figure 5.0-5 Indicator Method of Alignment



WH/MH Instruction Manuali. Mount dial indicator as shown in Figure 5-5C to check for parallel misalignment. Set indicator stem on outer diameter surface of flange (B) and adjust to zero.

j. Rotate coupling 360 degrees. Move and/or shim the units until the indicator reading comes within the maximum allowable variation of .004" (.10 mm).

k. Torque all bolts. See Table 7-2 for recommended torque values.After several hours of operation, recheck both alignment and bolt torque.

l. When proper alignment is attained within the previously specified limits, the laminated rings (A) must appear vertical and undistorted. There must be no end thrust due to poor initial assembly of the coupling.

n. Alignment should be checked periodically. Realign unit when parallel misalignment exceeds .014" (.36 mm) T.I.R. and/or angular misalignment exceeds .020" (.51 mm) T.I.R.

NoteCouple bolts are tightened at the factory for shipping purposes only. When installing cou-pling, the above values apply to bolts and locknuts as they are received from the factory. If any additional lubricant is used or if the threads are wiped dry, these values must be modi-fied.

NoteBolt heads should be held and locknut only turned, when tightening coupling bolts.

Table 5-1 Thomas Flexible Coupling Torque Valves

Coupling Size Bolt Size Threads/Inch Torque(Foot-Lbs)

Dimension-DFigure 5-4

500 3/4 16 260 8-3/4

550 7/8 14 350 9-7/8

600 1 14 490 10-7/8

700 1-1/8 12 630 12-7/16

750 1-1/4 12 830 13-1/2

800 1-3/8 12 1100 14-3/4

850 1-1/2 12 1400 15-3/4Cooper Energy Services Ajax-Superior


Crankshaft Web DeflectionThe compressor should be aligned to the driver according to the instructions given above. During the alignment procedure, the crankshaft web deflection should be measured on the number one throw

MH-WH Instruction Manual

Documents

Transcript of MH-WH Instruction Manual