Engineering Specs

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Contact Technical Publications Dept. for current version. (937) 327-4279
Compressor Cylinder Technical Data Book
ENGINEERING STANDARDS
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ES 2 Protection Of Non-Lube Compressor Cylinders For Shipment & Extended Storage

1.0 Scope
This procedure explains the necessary steps required to protect non-lube compressor cylinders from rust and oxidation during shipment and subsequent storage before startup.
2.0 Requirements
All non-lubricated compressor cylinders shall be prepared according to the following procedure 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. Remove all cylinder heads, fixed volume pockets, and/or variable volume pockets. Also, remove all distance piece covers. Remove all valves and valve retainers and suction valve unloaders from the cylinder bodies. Be very careful to identify from which location the valves came in case the valves are non-interchangeable designs. If they are such, they will only fit in the locations where installed and should not be mixed in order to prevent difficulty in reinstalling them. Remove the piston rod and packing assembly, including the oil scraper, packings from each cylinder body, and distance piece. Through all the exposed openings in the cylinder body and distance pieces, wipe all moisture from the cylinder bores, gas passages, and distance pieces using a synthetic sponge or lint-free cloth. Spray all cylinder bodies and distance pieces internally with a MIL-C-23411 rust preventative. The cylinder bore and all gas passages should be covered with this corrosion inhibitor. Place a sufficient layer of VPI paper in the cylinder bore and set a number of desiccant bags on top of the VPI paper in the cylinder. Do the same thing in all distance piece compartments.
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h.
Reinstall all cylinder heads, fixed volume pockets, variable volume pockets, distance piece covers, and all valve caps. Do not reinstall the piston rod packings and valves. Seal the suction and discharge flanges or nozzles of the cylinder body by making gaskets of VPI paper and waxed paper. Install a steel cover plate over each suction and discharge opening, making sure to install the paper gaskets between the cover plate and cylinder body (for shipping only). Wrap all of the removed parts with waxed and VPI paper and pack for shipment or storage. Each box containing these wrapped parts should contain a sufficient quantity of desiccant bags and should then be sealed. When the overall compressor unit is shipped or stored, it is recommended that the cylinders in particular be adequately covered with a heavy tarp or canvas cover.
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ES 11 Rod Load Limitations On The W Series Compressor

1.0 Scope
The purpose of this standard is to clearly define the application limits of the various compressor piston rods such that Marketing and Engineering will have firm guidelines when calculating the compressor performance.
2.0 Requirements
External Rod Rod Dia. () 2 2-1/4 (MW6) 2-1/2 (SW6) 2-1/2 (W7) 2-1/2 (W7) 2 2-1/4 (MW6) 2-1/2 (SW6) 2-1/2 (W7) 2-1/2 (W7) 2 2-1/4 (MW6) 2-1/2 (SW6) 2-1/2 (W7) 2-1/2 (W7) Load (Lbs.) 30,000 35,000 42,500 45,000 55,000 22,500 26,000 41,250 33,570 41,250 23,000 27,000 42,500 34,750 42,500 Net Rod Load (Lbs.) 35,000 40,000 46,500 52,500 60,000 26,000 30,000 44,500 39,000 44,500 27,000 30,750 46,500 40,250 46,500 Comments Standard*
Colmonoy coated in packing area (Spec 207 or 204)
Reduced hardness for H2S service (Spec 204 or 207 heat treated per Spec H2S)
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2 2-1/4 (MW6) 2-1/2 (SW6) 2-1/2 (W7) 2-1/2 (W7)
30,000 35,000 42,500 45,000 55,000
35,000 40,000 46,500 52,500 60,000
Custom 450 Stainless Steel (Spec 239 heat treated to 30-34 HRC) or 17-4 PH stainless steel (Spec 246-A heat treated to 28-35 HRC). Both good for H2S and CO2 Service.
*Note: The standard rod is Material Spec 207 (forging) and 204 (bar) and may include any of our standard finishes in the packing area (except Colmonoy) without affecting the rating of the rod.
3.0 Procedure
Marketing is responsible to size applications such that the external rod load is lower than the limits listed above. In the event that the external rod load is exceeded but it appears to be a borderline case, Engineering will, at Marketings request, evaluate the internal rod loads in an attempt to arrive at a suitable application and still not exceed the limits set above.
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ES 13 Trimming Superior And Ajax Compressors For Sour Gas Applications In Lubricated Service
1.0 Purpose
1.1 To define and clarify the compressor design criteria to be used in applying compressors in sour gas service to prevent the occurrence of sulfide stress corrosion cracking and untimely failure of compressor components. To establish compressor design criteria that follow the guidelines of API 11P and NACE MR0175 for sour gas service. To establish Ajax and Superior Packaging design criteria that follow the guidelines of API 11P and NACE MR0175. To establish and define different levels of protection depending upon the customers requirements. 1.4.1 The standard protection level will be per guidelines established by API 11P and described in Section 4.0. 1.4.2 For more rigid protection requirements the guidelines used will be NACE MR0175, described in Section 5.0. This stricter protection may be needed to comply with stricter regulatory controls or customer requirements. 1.4.3 Since the customer knows the application details of his process much more thoroughly than does Ajax-Superior, the customer may determine that higher levels of H2S trim are required and opt to buy these. Ajax-Superior will make every effort to accommodate these special requirements.
1.2
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1.4
2.0 Application
2.1 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 guidelines of API 11P. a. Section 4.1 for H2S concentrations up to and including 2% by volume applies to Ajax and Superior model compressors, including RAM and JOY. b. Section 4.2 for H2S concentrations between 2% and 5% (Level 1-11P) applies only to Ajax and Superior model compressors, including RAM. c. Section 4.3 for H2S concentrations greater than 5% (Level 2-11P) applies only to Ajax and Superior model compressors, including RAM.
2.3
Section 5.0 designates the trim requirements when units are designed to more nearly meet the guidelines of NACE MR0175 and applies only to Ajax and Superior model compressors, including RAM. Section 6.0 designates the trim requirements for Ajax Packaging when it is designed to meet the guidelines of API 11P. Section 7.0 designates the trim requirements for Ajax Packaging when it is designed to more nearly meet the guidelines of NACE MR0175 and more stringent customer requirements. When CO2 concentrations greater than 5% are present with an H2S concentration greater than 2%, the units should be trimmed per the Level 2-11P requirements in Section 4.3 as a minimum. In addition, the requirements in Section 7.0 of CO2 trim standard (ES14contact Ajax-Superior Marketing) will be required.
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2.5
2.6
3.0 Responsibilities
3.1 Marketings responsibilities are: 3.1.1 To acquire reliable gas analysis; and to identify, to both engineering and the customer, all sour gas applications as early as possible (hopefully in the prequotation 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 for sour gas compressors. 3.2 Engineerings responsibilities are: 3.2.1 To define and specify properly designed components in accordance with the guidelines set herein. 3.2.2 To review all sour gas applications forwarded by Marketing and assist them as required in tailoring individual applications to requirements. 3.2.3 To set the standards for design and proper maintenance and keep them updated as 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 products are 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 trim requirements in this specification are not considered adequate and to negotiate what is required prior to order release. 3.3.2 To maintain the sour gas compressors in accordance with the standards set herein and to adhere to the particular minimum lubrication recommendations specified. 3.3.3 To assure that maintenance and operating procedures are well understood and followed and that all required safety training and safety procedures for handling sour gas have been addressed. Those safety procedures must be enforced for all persons working at or visiting the unit site.
4.0 Standard Trim Requirements

Unless otherwise required by specific customer requirements, sour gas units will be trimmed using 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 other constituents 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 H 2S below .005% (50 ppm) no special requirements are necessarily relative to the trimming of the equipment. 4.1.2 For any concentration of H2S from .005% (50 ppm) up to and including 2% by volume in lubricated service special trim will not be required. Standard material 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 higher to help prevent the lubricant from turning acid and damaging bearings and bushings. This alkalinity must be maintained during operation in the machine by appropriate timely makeup or complete oil changes. At no time should the lubricant 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 determine proper oil change intervals as well as to monitor the condition of the lubricant and the unit. 4.1.6 Compressor cylinder lubricants must adhere to the requirements of AjaxSuperior Engineering Standard ES1002 (page 1-70) for Superior models and ESS-L811 and ESS-L-168 for Ajax models. Viscosities are to be on the high side of the pressure conditions normally required and a 3 to 8% compounding with acidless tallow (similar to steam cylinder oils) is also required. 4.1.7 The compressor cylinder lubricant rate is to be double the normal rate for equivalent non-sour gas applications. 4.1.8 Brass, bronze, copper, and other copper alloys shall not be used on hardware for gas wetted parts. On external components, and other components that are not normally gas wetted, yellow metals are to be avoided where practical or as specified by agreement with the customer. This requirement shall be followed 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 with local 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 (<275F.) 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 this standard. 4.1.13 For RAM compressors, an auxiliary distance piece or an acceptable purged packing design is required to keep cylinder oil from contaminating the frame oil. For Ajax and Superior models, the standard crosshead guide/distance piece is acceptable. 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 additional requirements listed in Section 4.2. 4.2.3 A suitable corrosion inhibitor should be added to the cylinder lubricating oil as defined by the users oil manufacturer. 4.2.4 Cylinders are to be equipped with a suction flushing system (injection of cylinder lubricating oil into the suction nozzle of each cylinder). This is in addition to the regular cylinder lubrication. This helps to resist the natural solvent action of the sour gas and insures a thorough distribution of oil for better lubrication. It also helps to better form a barrier to corrosion by coating all the valve surfaces with an oil film. Superior RAM cylinders and Ajax cylinders are excluded from this requirement as 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 is available on each compressor rod in the distance piece compartment to assure that none of the H2S contaminated cylinder or packing lubricant works its way back into the crankcase and contaminates the frame lubricating system. An auxiliary 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 if space 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 piece to 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 nonmetallic 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 are gas wetted (come in contact with the process gas stream) are to have a maximum hardness of 22 HRC. This is to include all internal fasteners and V.V. pocket screws, but excludes compressor valve assembly fasteners. 4.2.10 Piston Rod: The piston rods are to be either AISI 4140 alloy steel with a hardness of 15-22 HRC (Heat Treat Spec H2S) or Custom 450 stainless steel with a hardness of 30-34 HRC (Heat Treat Spec Z) or 17-4 PH (Spec 246-A) stainless steel with a hardness of 28-33 HRC (Heat Treat Spec ZA). The reduced hardness 4140 material will have lower mechanical properties and for some Superior compressors will require deration of the rod load capacity of the machine as detailed in AjaxSuperior Engineering Standard ES11 (contact Superior Marketing). Using the Custom 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 Superior rods tungsten carbide coating is used. For Ajax rods Colmonoy coating or tungsten carbide coatings are used. 4.2.11 Forged Steel Cylinders: Forged steel cylinder bodies made of AISI 1045, 4140, or low alloy steel 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. 4.2.12 Piping and Vessels: All process piping, pulsation drums, scrubbers and coolers will comply with NACE MR0175 and shall have a minimum 1/16" corrosion
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allowance. This requirement is the packagers 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 process stream (liquid level controls, shutdowns, bourdon tubes, process valving, relief valves, etc.) shall be suitable for corrosion gas service (i.e., plated fittings are acceptable). This requirement is the packagers responsibility. Sections 6.0 and 7.0 define Ajax Packaging requirements in this level. 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 the additional requirements listed in Section 4.3. 4.3.3 Compressor Valves: Valve seats, guards, and valve bolts made of carbon steel or AISI 4140 alloy steel shall have a maximum hardness of 22HRC (Heat Treat Spec H2S). This may reduce the pressure differential capability of specific valve designs 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. For Superior compressor valves free-machining carbon or alloy steel material shall not be used for this level H2S. For Ajax compressor valves, free machining material shall be used unless H2S levels 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 with a maximum hardness of 22HRC. 4.3.4 Compressor Valve Plates: Valve plates wherever possible are to be plastic to better prevent seat wear against the softer valve seats. For discharge temperatures to 280F., thermoplastic plates (Spec 484A) can be used; for higher discharge temperatures, 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-compartment configuration is required with pressure packing located between the distance piece and the compressor frame. This means an auxiliary distance piece must be added to the standard crosshead guide/distance piece. The outer compartment must be purged with inert gas to a pressure of 3-5" H2O (see Section 4.3.10). The inner compartment can either be separately vented or purged with inert gas to a pressure of 3-5" H2O. The packing case is to be tubed to an external point on the distance piece for these 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 shall conform 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 post heat-treated and shall have a minimum 1/8" corrosion allowance. Threaded connections over 3/4" are not allowed. 100% ASME inspection criteria are to be used. This requirement is the packagers responsibility. Sections 6.0 and 7.0 define Ajax Packaging requirements in this level. Also, for Ajax Packaging, threaded connections up to and including one inch will be specified; all connections above this shall be flanged. 4.3.9 Instrumentation: All instrumentation that comes in contact with the process stream (liquid level controls, shutdowns, bourdon tubes, process valving, relief valves, etc.) shall meet the full requirements of NACE MR0125 except that stainless steel tubing fittings are required. This requirement is the packagers responsibility. Sections 6.0 and 7.0 define Ajax Packaging requirements in this level. 4.3.10 Purge Systems: 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
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should prevent contamination of the frame oil with sour gas. Packing cases will not be purged unless required by the customer. 4.3.11 Cooler Tubes: The gas cooler tubes shall be furnished in 304 or 316 stainless steel. This requirement is the packagers responsibility. Sections 6.0 and 7.0 define Ajax Packaging requirements in this level.
5.0 Enhanced H2S Trim Requirements

5.1 These sections cover H2S trim requirements based on guidelines established by NACE MR0175. These sections specify more rigid H2S trim levels than required for standard API 11P trim. When a customer requires H2S trim in excess of API 11P for requirements meeting NACE, the Ajax and Superior equipment will be trimmed using the guidelines known as Class IV and described in the remaining sections. This enhanced level of trim can be used for any concentration of H2S as required by the customer. Trimming to this level may be required for even very low concentrations of H2S (500 ppm) if regulations controlling the equipment require strict adherence to NACE MR0175. Class IV H2S Trim 5.4.1 A suitable corrosion inhibitor should be added to the cylinder lubricating oil as defined by the users oil manufacturer. 5.4.2 All the special requirements specified and recommended in Section 4.1 of this standard should be followed. 5.4.3 The cylinders are to be equipped with a suction flushing system (injection of cylinder lubricating oil into the suction nozzle of each cylinder). 5.4.4 Two-compartment distance pieces are required. The outer compartment must be purged with inert gas to a pressure of 3-5" H2O (See Section 5.4.16). The inner compartment can either be separately vented as described previously or purged with inert gas to a pressure of 3-5" H2O. 5.4.5 For Superior model compressors, oil slingers are to be used where adequate space is available on each compressor rod in the distance piece compartment to insure
5.2
5.3
5.4
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that none of the H2S contaminated cylinder or packing lubricant works its way back into the crankcase and contaminates the frame lubricating system. For Ajax model compressors, oil slingers are not required but can be added as an option. 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 hardness of 15-22 HRC (Heat Treat Spec H2S) or Custom 450 stainless steel with a hardness of 30-34 HRC (Heat Treat Spec Z), or 17-4PH (Spec 246-A) stainless steel with a hardness of 28-33 HRC (Heat Treat Spec ZA). The reduced hardness 4140 material will have lower mechanical properties and for some Superior compressors will require deration of the rod load capacity of the machine as detailed in AjaxSuperior Engineering Standard ES11. Using the Custom 450 or 17-4PH material will 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 Superior piston 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 of carbon steel or AISI 4140 alloy steel with a hardness of 22 HRC maximum (Heat Treat Spec H2S). This may reduce 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. For Superior and for Ajax guards and seats in this classification, free machining carbon or alloy steel shall not be used. Compressor valve components may also be made of AISI 416 stainless steel with a maximum hardness of 22 HRC. This reduced hardness requirement also includes steel valve cages (retainers) when they are used. 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 will evaluate these applications on an individual basis as some cylinder pressure ratings 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 of 22 HRC. This is to include all internal fasteners and V.V. pocket screws, and also includes compressor valve assembly fasteners. 5.4.12 Compressor Valve Plates: Valve plates, wherever possible, are to be plastic to better prevent seat wear against the softer valve seats. For Superior compressors with discharge temperatures to 280F, thermoplastic plates (Spec. 484A) can be used; for higher discharge temperatures, PEEK (Spec. 490) material shall be used as 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 shall conform 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 process piping, pulsation drums, scrubbers and cooler headers will be 100% radiographed and post heat-treated and shall have a minimum 1/8" corrosion allowance. Threaded connections over 3/4" are not allowed. 100% ASME inspection criteria are to be used. This requirement is the packagers responsibility. Section 7.4 defines the Ajax Packaging requirements in this level. Also, for Ajax Packaging, 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 process stream (liquid level controls, shutdowns, bourdon tubes, process valving, relief valves, etc.) shall meet the full requirements of NACE MR0175 except where stainless steel tubing fittings are required. This requirement is the packagers responsibility. 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 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
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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 packagers 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. 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 (spiral wound 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, for scrubber level switch, level controller, and automatic dump valve; stainless steel for expanded metal in scrubbers; 304L mesh; and stainless steel ball valve for scrubber 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 with stainless 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, and cooler gas headers shall be 1/8".
6.2
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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 level switch. 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 following are 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 per ANSI B31.3. f. Magnetic particle test threaded connections (couplings, etc.) in pressure vessels and process gas piping per ANSI B31.3. 6.4.3 Use 316 stainless steel in place of plated steel fittings for panel instrument and lubrication 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 in contact 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 H 2S in the fuel gas. 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 handle the 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 For H2S Service (Special Customer Requirements)
7.1 This section covers H2S trim requirements for the Packaging portion of the Ajax model frames and compressors when special customer requirements or stricter adherence to NACE MR0175 are necessary. 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 are required whenever there is a trace or above concentration of H2S. This requirement 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 (spiral wound AISI 316 stainless). 7.2.3 Scrubbers used for H2S service should have 304L mesh which is normally standard. 7.2.4 Use stainless steel ball valve for scrubber manual drain which is normally standard. 7.2.5 All process gas wetted instrumentation to be suitable for H2S service with all yellow metal removed. 7.2.6 Remove yellow metals from the level controllers and dump valves.
7.2
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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 with stainless 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, and cooler headers, shall be 1/8". 7.3.3 Magnetic particle test of flanged connections in pressure vessels is to be performed per ANSI B31.3. 7.3.4 Magnetic particle test of threaded connections (couplings, etc.) in pressure vessels and 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 gas sections. 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 use stainless 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-gas wetted components (i.e., drains, valves, cooling systems, etc.)
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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 flanged connections. 7.4.4 Use 316 stainless steel in place of plated steel fittings for panel instrument and lubrication tubing. 7.4.5 Corrosion test connections (couplings) are to be fabricated in the cold side discharge 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 fuel gas. 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 handle the 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.
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ES 14 Trimming Compressors for Carbon Dioxide/Natural Gas Applications in Lubricated Service

1.0 Scope
1.1 This specification is to be used as a guide in trimming CES Superior manufactured compressors for the compression of gas having various percentages of carbon dioxide (CO2). 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. This specification follows the guidelines established in the latest edition of API Specification 11P. Where this specification deviates from 11P it will be noted. Some of the wording and graph data is taken directly from this API publication. Special trimming and materials other than those specified in this specification will be negotiated on an individual basis in order to meet a customers specific requirements. 1.4 Figure 1 in this specification shows the pressure and CO2 concentration parameters where special trimming is required.
1.2
1.3
2.0 Purpose
2.1 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 and decreases with increasing temperature. Water droplets are normally present in gas streams handled by Ajax-Superior equipment, and even when separation and dehydration equipment is used it is subject to system upsets. Therefore, this
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specification is written to limit the susceptibility of this equipment to potential carbonic acid corrosion. (See Section 5.2 below). 2.2 Carbonic acid is a fairly weak acid; therefore, general corrosion is normally not a problem on compressor materials except as concentrations increase. The real problem is in the areas that see higher gas velocities (i.e. valves around piston rod seals, etc.) where erosion of the protective film occurs and accelerates the corrosion.
3.1 Marketings responsibility: 3.1.1 To acquire reliable gas analysis and to identify, to both Engineering and the customer, 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 responsibility concerning the maintenance and operational procedures to be used for CO2 compression. 3.2 Engineerings responsibility: 3.2.1 To define and specify properly-designed components in accordance with the guidelines set herein. 3.2.2 To review all CO2 applications forwarded by Marketing and assist them, as required, in tailoring individual applications to requirements. 3.2.3 To set the standards for design and proper maintenanace, and to keep them updated 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:
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3.3.1 To maintain the CO2 compressors in accordance with the standards set herein.
4.0 Lubrication of Units

4.1 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 are found in Engineering Standard ES1002.
5.0 Gas Concentration Levels Requiring Special Trim

5.1 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 special trim is required. All metal gaskets should be soft iron or aluminum and o-rings should be nitrile, neoprene, or viton, depending on operating temperatures. Corrosion will not be a problem in dry CO2; therefoe, if the customer can guarantee that his dehydration equipment will absolutely prevent moisture dropout anywhere in the equipment downstream of the dehydration process, then special trim will not be required. This guarantee of bone-dry gas should be in writing and filed in the sales packet. For non-lubricated compression jobs, special trim will be required for any CO2 concentration above 2%. In the actual application of this standard, lubricated units having CO2 levels falling to the left of the curve in Figure 1 should be judged on an individual basis. If the gas is known to be extremely dirty, or if customer maintenance is known from past experience to be poor, or if the unit is designed to operate with more than normal stops and starts or complex unloading, then special trim may be necessary at lower CO2 concentrations and pressures.
5.2
5.3
5.4
6.0 Trimming for Carbon Dioxide

6.1 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.
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6.2 6.3
Valve Springs: springs shall be the Superior standard 17-7PH stainless steel. Valve Plates: plates shall be either plastic or Superiors standard AISI 410 (Superior Specification 243). This meets 11P requirements. Piston Rods: the standard shall be AISI 4140 rods at the standard hardness and with tungsten carbide coating. An alternative to this is AISI 416 stainless steel induction hardened in the packing travel area. The 11P specification calls for a maximum hardness of 22 HRC; we do not feel this is necessary if H2S is not present. Valve cap and seat gaskets are to be aluminum or soft iron. The 11P specification states gaskets are to be soft iron, but under typical CO2 conditions aluminum gaskets, where required, are not sensitive to the environment. Unloader Parts: it is recommended that unloader valves be Armoloy-plated on the stems in the bushing and seal travel area. This is not required by 11P but we have found it beneficial in supplying a reliable product. Stainless steel valves can also be used instead of plating. All other compressor cylinder components can be standard material.
6.4
6.5
6.6
6.7
7.0 Lubricated Sour Gas Compressors With Carbon Dioxide

7.1 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. Sour gas units having greater than 2% H2S and greater than 5% CO2 should be trimmed 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 valves are required, valve seats and guards and center bolt shall be made from AISI 416 stainless steel and reduced in hardness to 22 HRC maximum (Superior Specification 251 Heat Treat WD). 7.2.2 Valve Plates: plates shall be either plastic or Inconel X-750 (Superior Specification 241) for all levels of H2S above 2%.
7.2
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7.2.3 Unloader Parts: unloader valves should be reduced in hardness to 22 HRC maximum (ES 13) and then Armoloy plated on the stems in the bushing or seal travel area. Unloader valves can also be stainless steel with a hardness of 22HRC maximum.
Figure I Trimming Curve for CO2 Concentrations (Lubricated Units with < 2% H2S)
1200
Suction Pressure
900
Special trim required

600
300
Special trim not required

0 5 10 20 30 40 50 60 70 80 90 100
Percent CO2
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ES 19 Compressor Frame and Cylinder Assembly Criteria

1.0 Scope
This standard lists the assembly criteria for the MW, SW, W7, WH, MH, RAM and JOY frames and cylinders, along with the RAM, JOY, Superior (traditional and WH), Ajax, and pipeline cylinders.
2.0 Purpose
This standard defines the assembly criteria that establish a machine to be an acceptable product to be shipped to the customer.
3.0 Procedures
Machines are to be assembled and tested using the following: 3.1 3.2 3.3 Torque Table (pages 3 and 4). Clearance Table (page 8). Pressure testing of components. 3.3.1 Hydrotests are performed on all cylinder bodies, heads, bonnets, and valve covers per Engineering Standard ES 5011. Test procedures are determined from individual part drawings. 3.3.2 Helium tests are performed per ES 5011 when required by the sales release or for gases with molecular weights below 12. 3.4 3.5 Valve leak testing is done per ES 4023. 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 SI468 found in Procedure 10.1003.
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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 in Procedure 10.1003. 3.5.5 Air testing of all assembled cylinder bodies to make sure all seals are not leaking per Testing Standard 35.0903. 3.5.6 Pneumatically operated valve or head unloaders are bench-tested to make sure they operate properly per ES 4024. 3.6 Frame/Cylinder Balancing 3.6.1 Unless specified differently on the sales release, opposing throws are to be balanced 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. Parts are 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 balance weights. 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 end of the rod. 3.6.6 Crosshead weight is to include (stamp total weight on crosshead): Crosshead Crosshead shoes Crosshead shoe fasteners
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3.6.7 Connecting rod weight is to include (stamp total weight on conn rod so it can be seen from top of frame): Connecting rod (The connecting rod weight does not include the bearing shells or the crosshead 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 and shall be specified in the Sales Release. Special tests or inspections required by Engineering are documented on Form 60.04-17, Compressor Frame and Cylinder Special Test/Inspection Requirements (page 9). Unless otherwise stated on the Sales Release, all units are to be protected in accordance with ES 5 for North American shipments. Exported equipment is to be protected per ES 7.
3.8
Recommended Torques (Foot/Pounds) - Compressors

W7 Connecting Rod Main Bearing Cap Base Spacer Bolt/Nut Crosshead Pin Nut Soc. Head Capscrews Allen Screws-Rod Packing Crosshead Shoe Balance Weight Capscrew
1-1/8"-12 UNF nut 430-460
SW
1"-14 UNS nut 320-330
MW
1"-14 UNS nut 250-260 3/4"-10 UNC nut 180-200 1-1/8"-12 UNF 380-410 3/4"-16 UNF 105-115 Allen Screw 60-65
WH
1"-8 UNJ bolt 500
MH
1"-8 UNJ bolt 430-450
RAM
1"-14 UNS bolt 460 1"-8 UNC bolt 350 7/8"-9 UNC bolt 300 N/A
1-1/8"-12 UNF nut 3/4"-10 UNC nut 430-460 180-200 1-1/4"-12 UNF 640-700 3/4"-16 UNF 1-1/8"-12 UNF 380-410 UNF 105-115 Allen Screw 60-65
3/4"-10 UNC nut 3/4"-10 UNC nut 185-200 185-200 1-1/8"-7 bolt 380-400 N/A 105-115 5/8"-11 60-70 1-1/8"-7 bolt 380-400 N/A
5/8"-11 UNC Soc. Head 60-70 Grade 5
5/8"-11 60-70
3/4-10 120-140
1-1/2"-20 UNFFlat Head 35-45 N/A
Flat Head 25-30 N/A
Flat Head 25-30 N/A
3/8"-16 UNC 18-20 N/A
1/2"-20 UNF 30-35 N/A
1/2"-20 UNF Capscrew 20-25 5/8"-11 UNC 62
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W7 Balance Nut or Crosshead Jam Nut Piston-toPiston Rod Nut

2-1/2"-10 UN 2650-3250
SW
2-1/2"-10 UNS 2650-3250
MW
2-1/4"-8 UN 1500-2000
WH
2-1/2"-10 UNS 2650-3250
MH
2-1/2"-10 UNS 1900-2300
RAM
2"-8 UN 1100
2"-8 UNF 1180-1265 (for thru rod) For Multi-bolt, see misc. fasteners.
2"-12 UN 1760-2150
2"-12 UN 1760-2150
7/8"-9 UNRC Capscrew 200-220 2"-8 UN 1500-1600 (for Thru Rod) N/A
7/8"-9 UNRC Capscrew 200-220 2"-8 UN 1500-1600 (for Thru Rod) N/A
1-1/2"-12 UN 1100
Crankshaft Drive Gear Capscrew Cyl/Crosshead GuideCapscrew Valve Caps RAM Cylinder Half Bolting
N/A
N/A
N/A
5/16"-18 UNC 15
7/8"-9 UNC 200 See Note 1
7/8"-9 UNC 200-220 See Table for Valve Caps N/A
7/8"-9 UNC 200-220 See Table for Valve Caps N/A
7/8"-9 UNC 200 See Misc. Nuts See Table For RAM Half Bolting
N/A
N/A
N/A
WH6 Cylinder Half Bolting
N/A
N/A
See Table for WH6 Half Bolting
See Table for WH6 Half Bolting
N/A
Valve Size 2.375" 3.25" 4.00" Slotted Seat 4.00" Drilled Seat 5.25" 5.75" 7.00" 8.00" 9.125"
Center Bolt 3-5 3-5 13-15 29-32 13-15 18-20 18-20 18-20 18-20 3"-12UN 25-50 ft.-lbs
Hoerbiger Spiralock
Center Bolt Torque All Models
5/16"-24 3/8"-24 7/16"-20
22-26 41-45 58-62
Coupling Hub Lockout for Tapered Shafts Set Screw Size
5/8"-18 UNF
Torque per Misc. Fasteners
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RAM Cylinder Half Bolting

Cylinder Size (in)
15.50 16.00 17.50 18.00 19.50 20.00
Class
417CC 418CC 419CC 420CC 421CC 422CC
Fastener Size
7/8" - 8 7/8" - 8 1" - 8 1" - 8 1" - 8 1" - 8
Torque
300 ft-lbs 300 ft-lbs 375 ft-lbs 375 ft-lbs 375 ft-lbs 375 ft-lbs
Torques based on lubricated threads and S.A.E. grade fasteners or better
WH Cylinder Half Bolting

Cylinder Size (in)
117"/18" 19"/20" 22-1/2, 23-1/2, 25-1/2, 26-1/2"
Class
RD-#645/646 SD-#648/649 TD-#650/651/652/653
Fastener Size
1-1/8" - 7 1" - 8 1" - 8
Torque
590-610 see Misc. Fastener table see Misc. Fastener table
Model
Thomas Flex Coupling (coupling to hub bolting.) 500 550 600 700 750 800 850
Bolt Size
3/4" - 16 7/8" - 14 1" - 14 1-1/8" - 12 1-1/4" - 12 1-3/8" - 12 1-1/2" - 12
Torque
260 ft-lbs 350 ft-lbs 335 ft-lbs* 425 ft-lbs* 560 ft-lbs* 740 ft-lbs* 950 ft-lbs*
* These nuts are cadmium plated.
RAM Coupling Special Torque Values

Adapter to Hub Bolting 1" - 8 bolt 600 ft-lbs torque
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Miscellaneous Fastener Torques

Size
1/4" Miscellaneous Fastener Size (all models unless detailed otherwise under particular applications) 3/8" 1/2" 5/8" 3/4" 7/8" 1" 1-1/8" 1-1/4" 1-3/8" 1-3/4" Jackscrew (2500# Cylinder)
Torque (ft-lbs)
4-6 12 - 18 35 - 45 60 - 70 120 -140 200 - 220 260 -290 370 -410 520 -570 700 - 770 930 - 1030 850 - 900
WH/MH Valve Cap Special Torque Values

Cylinder Number
615 616 617 618 619 620 621
Cylinder Diameter
6.00" 6-1/4" 6-3/4" 5-3/4" 6-1/4" 6-3/4" 7-1/4"
Valve Cap Nut Torque (ft-lbs)

370 370 370 300 300 300 300
Notes: 1. On the W7, SW, and MW cylinders, torque valve cap nuts on 3-3/4" and smaller diameter cylinders or cylinders with working pressure of 4,000 psi or greater to 300 ft-lbs (all others use miscellaneous fastener table). 2. On the W7, SW, and MW, each crosshead pin to be checked two (2) hours after first being placed in service, 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 any
compounds containing molybdenum disulfide as a thread lubricant.
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Joy Compressor - Recommended Torques (ft-lbs) - Model (WBF)

Description
Connecting Rod Nut Main Bearing Cap Nuts Piston Rod Packing Nut Crosshead Nut Piston Nut 1-1/8" - 12 NF 380-400 ft/lbs 3/4" - 10 UNC 200 ft/lbs 5/8" -11 UNC 75 ft/lbs 2" - 12 UN 900 ft/lbs 1-3/4" - 12 UN 700 ft/lbs 5/8" - 11 UNC Hex Hd. Grade 2 3/4" - 1- UNC Hex Hd. Grade 2 3/4" - 10 NC Stud Valve Caps 7/8" - 9 NC Stud Grade B7 1" - 8 NC Stud Grade B7 1-1/8" - 7 NC Stud Grade B7 1-3/8" - 8 NC Stud Grade B7 5/8" - 11 UNC Hex Hd. Grade 2 5/8" - 11 UNC Soc. Hd. (1960 Series) 3/4" - 10 UNC Soc. Hd. (1960 Series) 7/8" - 9 UNC Soc. Hd. (1960 series) 1" - 8 UNC Soc. Hd. (1960 Series) Head Bolts for Gas Compressors 3/4" - 10 UNC Ferry Capscrew 3/4" - 10 NC Stud Grade B7 7/8" - 9 NC Stud Grade B7 1" - 8 NC Stud Grade B7 3/4" - 10 UNC Soc. Hd. (1936 Series) 7/8" - 9 UNC Soc. Hd. (1936 Series) 3/4" - 10 NC Stud Grade 2 Other Fastener Application Distance Piece to Frames Clearance Pockets, Caps, etc. 7/8" - 9 NC Stud Grade 2 1" - 8 NC Stud Grade 2 3/4" - 10 NC Stud Grade B7 7/8" - 9 NC Stud Grade B7 1" - 8 NC Stud Grade B7 Use W7, SW, etc., table of Miscellaneous Size Fasteners for torque value of any item not listed here. #10 - 32 UNF 1/4" - 28 UNF 5/16" - 24 UNF Valve Center Bolt 3/8" - 24 UNF 7/16" - 20 UNF 1/2" - 20 UNF 9/16" - 18 UNF 5/8" - 18 UNF 36 (in-lb) 86 (in-lb) 14 (in-lb) 25 (in-lb) 40 (in-lb) 65 (in-lb) 90 (in-lb) 130 (in-lb) 75 100 160 250 360 500 700 75 135 250 330 550 250 200 310 460 120 190 120 110 160 200 310 460
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Running Clearances
Joy Compressor Class
Description Crankshaft Thrust Main Bearing Connecting Rod Thrust Connecting Rod Bearing Crosshead Pin to Bushing Crosshead to Guide Crosshead Pin to Crosshead Crosshead Pin Bushing Interference Fit Drive Gear - Stub Shaft Interference Fit Lube Oil Pump Drive Gear Backlash Lube Oil Pump Rotor Gear Max. Tip Clearance W7 .012/.017 .004/ .0094 .016/.031+ .004/ .0094 MW/SW .011/.022 .004/ .0084 MH6 .011/.022 .004/ .0084 WH6 RAM 72XHD 74XHD 76XHD
.011/.022 .006/.014 .040/.055 .011/.028 .026/.042 .004/ .0084 .004/.008 .003/.006 .003/.006 .003/.006
.014/.027 .017/.029 .014/.027 .018/.032 .018/.022 .018/.022 .018/.022 .016/.031+ .004/ .0084 .004/ .0094 .004/ .0084 .003/ .0065 .004/.008 .003/ .0045 .003/ .0068 .003/ .0068 .003/ .0068
.003/.006 .003/.006 .003/.004 .010/.015 * .0025/ .004 .0035/ .005 .010/.015 * .0025/ .004 .0035/ .005
.005/.006 .005/.006 .005/.006
.011/.020 .008/.020 .008/.014 .007/.012 .007/.012 .007/.012 .0015/ .003 .0015/ .0035 .0015/ .0035 .0035/ .0060 .0005/ .0020 .0003/ .0010 .003/ .0010 .003/ .0010
.004/.008 .004/.008 .0005/ .0020 .0005/ .0020
.004/.007 .004/.007 .004/.007 N/A N/A .004 N/A N/ A .004 N/A N/A .004
.010/.014 .005/.007 .006/.010 .006/.010 .006/.010 N/A N/ A N/ A N/ A N/ A
W72 M/SW62 . 0 0 4 / . 0 0 7 . 004/.007 Lube Oil Pump Gear End Play 74/76 64/66/68 .003/.007 .003/.007 .005/.008 .005/.008 Piston End HE Clearance CE .080*** .040*** .080*** .040*** .080*** .040*** .080*** .040***
Later .080*** .040***
.004/.010 .005/.010 .005/.010 .070*** .060*** .070*** .060*** .070*** .060***
+ .001 allowed from print dimension for oil film on low tolerance * Uses tapered pin and as such is a metal-to-metal fit. ** It may not be possible to achieve these values in all cylinders; however, the head end clearance is to be .010 greater than the crank end clearance. *** It may not be possible to achieve these values in all cylinders; however, the clearances are to be divided 1/3 on the crank end and 2/3 on the head end.
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Compressor Frame and Cylinder Special Test/Inspection Requirements
Register Number Compressor Frame Cylinder Class/Type Customer Date Special Test and/or Inspection
Issued by
(Engineering Representative)
Date Date
(Engineering Representative)
Checked by
Tests/Inspections successfully accomplished Approved by

(Test Supervisor)
Form No. 60.04-17
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ES 20 Guard And Spring Reference List For RAM, WH, MH, & W7 Assemblies
1.0 Scope
This list has been put together to allow for the identification of parts required to convert one valve assembly to another.
2.0 Background
For 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 are listed, but they differ from the guard in that they include one or two locating pins, Part Number 757-135-001. Some guard assemblies use pins 757-135-004; these are marked by **.
After using this chart to change over a valve assembly, the party making the change has to re-identify the assembly (stamp-over or cover the original assembly part number with Xs and re-mark the valve with the new assembly part number).
RAM Valve Assembly Guard and Spring Reference List

Valve Size 4" (S) 4" (S) 4" (S) 4" (D) 4" (D) 4" (D) 4-7/8" 4-7/8" 4-7/8" 4-7/8" 4-7/8" 4-7/8" 5-1/4" 5-1/4" 5-1/4" 5-1/4" 5-1/4" 5-1/4" 5-1/4" 5-1/4" (S) (S) (S) (D) (D) (D) (S) (S) (S) (S) (D) (D) (D) (D) Type 9OCFT 9OCFT 9OCFT 9OCFT 9OCFT 9OCFT 116CGT 116CGT 116CGT 116CGT 116CGT 116CGT 127CGT 127CGT 127CGT 127CGT 127CGT 127CGT 127CGT 127CGT Assembly Part No. 600-394 600-389 600-392 600-395 600-393 600-390 600-352 600-354 600-356 600-353 600-355 600-357 600-287 600-289 600-291 600-408 600-288 600-290 600-292 600-409 Guard Part No. 757-830-179 757-830-179 757-830-179 757-830-180 757-830-180 757-830-180 757-830-149 757-830-149 757-830-149 757-830-150 757-830-150 757-830-150 757-830-109 757-830-110 757-830-110 757-830-110 757-830-111 757-830-112 757-830-112 757-830-112 Spring Part No. 757-833-051 757-833-050 757-833-041 757-833-050 757-833-041 757-833-003 757-833-045 757-833-012 757-833-003 757-833-045 757-833-012 757-833-003 757-833-008 757-833-044 757-833-045 757-833-012 757-833-008 757-833-044 757-833-045 757-833-012 Spring Qty. 18 18 18 18 18 18 12 12 12 24 24 24 13 13 13 13 26 26 26 26 Guard Assembly* Part No. 758-134-086 758-134-086 758-134-086 758-134-087 758-134-087 758-134-087 758-134-051 758-134-051 758-134-051 758-134-052 758-134-052 758-134-062 758-134-011 758-134-013 758-134-013 758-134-013 758-134-012 758-134-014 758-134-014 758-134-014
S = Suction Valve D = Discharge Valve * Includes Locating Pin 757-135-001; quantity varies.
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RAM Valve Assembly Guard and Spring Reference List

Valve Size 5-3/4" (S) 5-3/4" (S) 5-3/4" (S) 5-3/4" (S) 5-3/4" (S) 5-3/4" (D) 5-3/4" (D) 5-3/4" (D) 5-3/4" (D) 5-3/4" (D) 6-1/2" 6-1/2" 6-1/2" 6-1/2" 6-1/2" 6-1/2" 7" (S) 7" (S) 7" (S) 7" (D) 7" (D) 7" (D) 8" 8" 8" 8" (S) (S) (S) (S) (S) (S) (S) (D) (D) (D) Type 137CHT 137CHT 137CHT 137CHT 137CHT 137CHT 137CHT 137CHT 137CHT 137CHT 158CJT 158CJT 158CJT 158CJT 158CJT 158CJT 169CJT 169CJT 169CJT 169CJT 169CJT 169CJT 190CKT 190CKT 190CKT 190CKT Assembly Part No. 600-181 600-285 600-295 600-297 600-410 600-182 600-286 600-296 600-298 600-411 600-348 600-350 600-402 600-349 600-351 600-403 600-183 600-299 600-406 600-184 600-300 600-407 600-301 600-404 600-302 600-405 Guard Part No. 757-830-100 757-830-105 757-830-114 757-830-114 757-830-114 757-830-098 757-830-106 757-830-106 757-830-106 757-830-106 757-830-146 757-830-183 757-830-183 757-830-147 757-830-148 757-830-148 757-830-097 757-830-115 757-830-115 757-830-099 757-830-116 757-830-116 757-830-119 757-830-119 757-830-120 757-830-120 Spring Part No. 757-833-017 757-833-008 757-833-044 757-833-045 757-833-012 757-833-017 757-833-044 757-833-045 757-833-012 757-833-003 757-833-008 757-833-044 757-833-045 757-833-008 757-833-044 757-833-045 757-833-008 757-833-044 757-833-045 757-833-008 757-833-044 757-833-045 757-833-044 757-833-045 757-833-044 757-833-045 Spring Qty. 14 28 28 28 28 28 28 28 28 28 17 17 17 34 34 34 18 18 18 18 36 36 21 21 42 42 Guard Assembly* Part No. 758-134-001 758-134-007 758-134-172 758-134-172 768-134-172 758-134-002 758-134-008 758-134-008 758-134-008 758-134-008 758-134-049 758-134-095 758-134-095 758-134-050 758-134-096 758-134-096 758-134-003 758-134-016 758-134-016 758-134-004 758-134-117 758-134-117 758-134-020 758-134-020 758-134-021 758-134-021
S = Suction Valve D = Discharge Valve * Includes Locating Pin 757-135-001; quantity varies.
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WH Valve Assembly Guard and Spring Reference List

Valve Size 4-3/8" 4-3/8" 4-3/8" 4-3/8" 4-3/8" 4-3/8" 5-1/4" 5-1/4" 5-1/4" 5-1/4" 5-1/4" 5-1/4" 5-1/4" 5-1/4" 5-3/8" 5-3/8" 5-3/8" 5-3/8" 5-3/8" 5-3/8" 5-3/8" 5-3/8" 5-3/8" 5-3/8" 5-7/8" 5-7/8" 5-7/8" 5-7/8" 5-7/8" 5-7/8" 5-7/8" 5-7/8" (D) (D) (D) (S) (S) (S) (S) (S) (S) (S) (D) (D) (D) (D) (S) (S) (S) (S) (S) (D) (D) (D) (D) (D) (S) (S) (S) (S) (D) (D) (D) (D) Type 102CFT 102CFT 102CFT 102CFT 102CFT 102CFT 116CGT 116CGT 116CGT 116CGT 116CGT 116CGT 116CGT 116CGT 127CGT 127CGT 127CGT 127CGT 127CGT 127CGT 127CGT 127CGT 127CGT 127CGT 137CHT 137CHT 137CHT 137CHT 137CHT 137CHT 137CHT 137CHT Assembly Part No. 625-015-001 625-015-002 625-015-003 625-016-001 625-016-002 625-016-003 625-044-001 625-044-002 625-044-003 625-044-004 625-045-001 625-045-002 625-045-003 625-045-004 625-046-001 625-046-002 625-046-003 625-046-004 625-046-005 625-047-001 625-047-002 625-047-003 625-047-004 625-047-005 625-064-001 625-064-002 625-064-003 625-064-004 625-065-001 625-065-002 625-065-003 625-065-004 Guard Part No. 757-830-200 757-830-200 757-830-200 757-830-198 757-830-199 757-830-099 757-830-207 757-830-207 757-830-207 757-830-207 757-830-208 757-830-208 757-830-208 757-830-208 757-830-209 757-830-209 757-830-211 757-830-211 757-830-213 757-830-210 757-830-210 757-830-212 757-830-212 757-830-212 757-830-214 757-830-214 757-830-216 757-830-216 757-830-215 757-830-217 757-830-217 757-830-217 Spring Part No. 757-833-044 757-833-045 757-833-012 757-833-008 757-833-044 757-833-045 757-833-044 757-833-045 757-833-012 757-833-003 757-833-044 757-833-045 757-833-012 757-833-003 757-833-008 757-833-017 757-833-012 757-833-003 757-833-012 757-833-008 757-833-017 757-833-045 757-833-012 757-833-003 757-833-008 757-833-017 757-833-012 757-833-003 757-833-028 757-833-044 757-833-045 757-833-012 Spring Qty. 20 20 20 20 20 20 12 12 12 12 24 24 24 24 13 13 13 13 26 26 26 26 26 26 14 14 14 14 28 28 28 28 Guard Assembly* Part No. 758-134-107 758-134-107 758-134-102 758-134-105 758-134-106 758-134-106 758-134-114 758-134-114 758-134-114 758-134-114 758-134-115 758-134-115 758-134-115 758-134-115 758-134-116 758-134-116 758-134-118 758-134-118 758-134-120 758-134-117 758-134-117 758-134-119 758-134-119 758-134-119 758-134-121 758-134-121 758-134-123 758-134-123 758-134-122 758-134-124 758-134-124 758-134-124
S = Suction Valve D = Discharge Valve * Guard assembly includes guard and plate guide pins.
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WH Valve Assembly, Guard and Spring Reference List (cont.)

Valve Size 6-1/8" 6-1/8" 6-1/8" 6-1/8" 6-1/8" 6-1/8" 7" (S) 7" (S) 7" (S) 7" (D) 7" (D) 7" (D) 8" (S) 8" (S) 8" (S) 8" (D) 8" (D) 8" (D) 9-1/8" 9-1/8" 9-1/8" 9-1/8" 4-1/8" 4-1/8" 4-1/8" 4-1/8" 4-1/8" 4-5/8" 4-5/8" 4-5/8" 4-5/8" 4-5/8" (S) (S) (D) (D) (S) (S) (S) (D) (D) (S) (S) (S) (D) (D) (S) (S) (S) (D) (D) (D) Type 148CHT 148CHT 148CHT 148CHT 148CHT 148CHT 169CJT 169CJT 169CJT 169CJT 169CJT 169CJT 190CKT 190CKT 190CKT 190CKT 190CKT 190CKT 221CMT 221CMT 221CMT 221CMT 90CFT 90CFT 90CFT 90CFT 90CFT 102CFT 102CFT 102CFT 102CFT 102CFT Assembly Part No. 625-066-001 625-066-002 625-066-003 625-067-001 625-067-002 625-067-003 625-134-001 625-134-002 625-134-003 625-135-001 625-135-002 625-135-004 625-136-001 625-136-002 625-136-003 625-137-001 625-137-002 625-137-003 625-138-001 625-138-002 625-139-001 625-139-002 625-146-001 625-146-002 625-146-003 625-147-001 625-147-002 625-148-001 625-148-002 625-148-003 625-149-001 625-149-002 Guard Part No. 757-830-218 757-830-218 757-830-218 757-830-219 757-830-220 757-830-220 757-830-248 757-830-249 757-830-249 757-830-250 757-830-250 757-830-250 757-830-251 757-830-252 757-830-252 757-830-253 757-830-253 757-830-253 757-830-254 757-830-255 757-830-256 757-830-256 757-830-257 757-830-257 757-830-257 757-830-258 757-830-258 757-830-259 757-830-259 757-830-259 757-830-260 757-830-260 Spring Part No. 757-833-044 757-833-045 757-833-012 757-833-008 757-833-044 757-833-045 757-833-008 757-833-044 757-833-045 757-833-044 757-833-045 757-833-012 757-833-008 757-833-044 757-833-045 757-833-044 757-833-045 757-833-012 757-833-008 757-833-044 757-833-044 757-833-045 757-833-044 757-833-045 757-833-012 757-833-012 757-833-003 757-833-044 757-833-045 757-833-012 757-833-012 757-833-003 Spring Qty. 16 16 16 32 32 32 18 18 18 18 18 18 21 21 21 21 21 21 24 24 24 24 18 18 18 18 18 20 20 20 20 20 Guard Assembly* Part No. 758-134-125 758-134-125 758-134-125 758-134-126 758-134-127 758-134-127 758-134-155** 758-134-156** 758-134-156** 758-134-157** 758-134-157** 758-134-157** 758-134-158** 758-134-159** 758-134-159** 758-134-160** 758-134-160** 758-134-160** 758-134-161 758-134-162 758-134-163 758-134-163 758-134-164 758-134-164 758-134-164 758-134-165 758-134-165 758-134-166 758-134-166 758-134-166 758-134-167 758-134-167
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WH Valve Assembly, Guard and Spring Reference List (cont.)

Valve Size 5-5/16" (S) 5-5/16" (S) 5-5/16" (S) 5-5/16" (D) 5-5/16" (D) 5-3/4" 5-3/4" 5-3/4" 5-3/4" 5-3/4" (S) (S) (S) (D) (D) Type 116CGT 116CGT 116CGT 116CGT 116CGT 127CGT 127CGT 127CGT 127CGT 127CGT Assembly Part No. 625-150-001 625-150-002 625-150-003 625-151-001 625-151-002 625-152-001 625-152-002 625-152-003 625-153-001 625-153-002 Guard Part No. 757-830-261 757-830-261 757-830-261 757-830-262 757-830-262 757-830-263 757-830-263 757-830-263 757-830-264 757-830-264 Spring Part No. 757-833-044 757-833-045 757-833-012 757-833-012 757-833-003 757-833-044 757-833-045 757-833-012 757-833-012 757-833-003 Spring Qty. 24 24 24 24 24 26 26 26 26 26 Guard Assembly* Part No. 758-134-168 758-134-168 758-134-168 758-134-169 758-134-169 758-134-170 758-134-170 758-134-170 758-134-171 758-134-171
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ES 23 Superior Compressor Cylinder And Cylinder Class Designations

1.0 Scope
This standard describes the formats used for designating the compressor cylinder numbers and cylinder class names.
2.0 Purpose
The purpose of this standard is to explain the appropriate designations which are used to identify existing cylinders or cylinder classes, or which may be combined to identify a new cylinder or cylinder class.
3.0 Compressor Cylinder Designations

Standard 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) Piston/bore diameter, in inches, of the cylinder Number which defines a specific cylinder pattern and bore size. These numbers 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 three digits of the standard number. WH6 cylinders number range = 601 to 699 RAM cylinders number range = 401 to 499 First character: Letter which designates cylinder material and liner A = Cast iron body no liner B = Cast iron body with liner
Bore diameter: Digits:
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C = Ductile iron D = Ductile iron E = Cast steel F = Forged steel G = Forged steel (Old W6BS Class) H = Forged steel
no liner with liner with liner with liner with liner no liner
Second character: Letter which designates the external rod load rating A 25,000 lb (W6 and LW6 frame) 2" piston rod B C D E H M S X 27,500 lb 30,000 lb 35,000 lb 45,000 lb 50,000 lb 38,000 lb 42,500 lb 55,000 lb (W6 frames) (W6 and RAM frame) (MW6 frames) (W7 frames) (WH6 frames) (MH6 frames) (SW6 frames) (W7 frames) 2" piston rod 2" piston rod 2-1/4" piston rod 2-1/2" piston rod 2-1/2" piston rod 2-1/4" piston rod 2-1/2" piston rod 2-1/2" piston rod
4.0 Compressor Cylinder Class Designations

4.1 W6 Cylinder class format: (W6) + (one or more characters) Example: W6JD = W for White Motor W series frame 6 for the original 6" stroke design Last characters a combination of some or all of the following: Initial character(s) One or more letters which designate the order, by bore size, of the original classes, or subsequently, the order by which successive new classes are/were designed. Next character Letter A, designating that a cast class is linered Next character Letter D, designating a ductile iron body or Letter S, designating that the body is steel and/or Letter F, designating a forged steel body Historically, selection of the last characters did not always precisely follow the preceding rules, but generally did so. Exceptions include the W6AS, W6BSR, and W6BS which are all forged steel cylinder classes, and the W6ED class, some cylinders of which are linered.
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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 design Last character(s) A combination of some or all of the following: Initial Character(s) One or more letters which designate the order, by bore size, of the original classes, or subsequently, the order in which successive new classes are/were designed. Next character Letter D, designating a ductile iron body or 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 RAMs preliminary compressor product designation Last character(s) Letter which designates the order, by bore size, of the original classes, or subsequently, the order in which successive new classes are/were designed.
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ES 27 Compressor Performance Guarantee

1.0 Scope
This standard covers the acceptable compressor performance guarantee for all Superior compressors manufactured.
2.0 Requirements
The 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 Drops

The 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
Up to 100 100 - 500 500 - 1500 1500 +
Pressure Drop
5% but not less than 5 PSIG 4% but not less than 8 PSIG 3% but not less than 20 PSIG 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 above numbers.
4.0 Suction Pressure Drops

A pressure drop of 1% should be utilized for estimating the suction pressure drop through the gas piping and suction bottles. However, if the actual value is known, it should be used.
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5.0 Performance Guarantee

Cooper Energy Services will guarantee a single design point as calculated by the current version of the CASCADE performance calculation program for each compressor manufactured. All other performance calculations are expected, but are not guaranteed. However, it is possible to guarantee multiple operating points provided the operating conditions are established prior to final design. The guaranteed design point is based on gas conditions at the cylinder flange. In order to guarantee a design point at the packaged skid edge, all pressure drops need to be known and the performance will need to be calculated utilizing these pressure drops, as outlined in sections 3.0 and 4.0. A current process gas analysis is needed 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 performance 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. The capacity and brake power per flow are guaranteed to a tolerance of +/- 5% for the following operating conditions: 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. 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. The capacity and brake power per flow are guaranteed to a tolerance of +/- 5% for the following operating conditions:
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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. 5.2 Multiple Design Point Guarantee at all pressure ratios. For multiple point guarantees, the single design point guarantee, refer to 5.1, will hold for the design point and the other points can be guaranteed as follows: 5.2.1 All double acting conditions The capacity and brake power per flow are guaranteed to a tolerance of +/- 5% 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. The capacity and brake power per flow are guaranteed to a tolerance of +/- 10% for the following operating conditions: 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. 5.2.2 All single acting conditions at all pressure ratios. The capacity and brake power per flow are guaranteed to a tolerance of +/- 5% 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. The capacity and brake power per flow are guaranteed to a tolerance of +/- 10% for the following operating conditions: 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.
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ES 1002 Lubrication Recommendations For Superior Reciprocating Compressor Frames And Cylinders
1.0 Basic Requirements
1.1 The responsibility for selecting the proper lubricant is primarily that of the supplier. Use of only products with field-proven reliability and merit, produced by responsible concerns will provide the best assurance for achieving effective lubrication. Use of such products should always be accomplished according to the manufacturer's recommendations. Compressor design, operating conditions, and the gases being handled all have a significant effect on how well a lubricant performs in the given application. This standard has been prepared to assist users in selecting the proper lubricant for each application.
1.2
2.0 Compressor Frames

2.1 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 Standard ES 1001 (contact Superior Marketing). In addition to the requirements of paragraph 2.1, the frame lubricant must be capable of operating with the type of gas being handled by the compressor cylinders. For most sweetnatural gases and allied gas services, a lubricating oil with the minimum qualities specified in ES 1001 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.
2.2
3.0 Compressor Cylinders

3.1 Minimum Qualities of a Compressor Cylinder Lubricant
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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. In all applications, the oil used for compressor cylinders 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 is formed, 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-in oil should be a good straight mineral oil compounded with 3% - 8% acidless tallow (or other suitable fatty additives) and have a viscosity of 125 - 150 SSU at 210 F, or consistent with the oil selected for the specific service, whichever is higher. Usually a good grade of steam cylinder oil (containing 5% to 8% acidless tallow) mixed in equal proportions with the oil selected for extended service will be a good break-in oil. For cold 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) and the operating pressure conditions of the cylinder. For multi-stage applications, the viscosity required for the highest pressure cylinder can also be used in lower pressure cylinders. 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 may not necessarily have identical lubricating qualities. Periodic examination of the cylinder bores during the first few weeks of operation is recommended to assure that lubrication is adequate.
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3.4 Application Recommendations Many applications require special attention in addition to that given to most natural gas and similar services. The process in which a gas is being utilized will often influence the lubricating oil selected. The following recommendations will providebasic guidelines in selecting the proper lubricant for these special applications. Final selection should be made only after consultation with Superior and the desired oil supplier.
Service
a. Wet Air
Recommendations
Requires compounding with 3% - 5% acidless tallow or other 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.
b. High Pressure (psig)
c. High Discharge Temperatures (350 - 375 F) d. Natural Gases, Methane, Ethane e. Natural Gases saturated with water and/or wet with higher-ended hydrocarbons. f. Butane, Propane, Ethylene, Carbon Dioxide
Use viscosity table and 3% - 5% compounding with tallow if the gas is wet and/or water saturated. Requires compounding with 3% - 5% acidless tallow or other suitable fatty oils. Increase supply over normal.
These gases are diluents of oil. Use next higher viscosity over Table 1 recommendations. Increase supply quantities over normal. Lubricant must be dry. These are inert gases relative to lubricating oils. Use Viscosity Table.
g. Hydrogen, Nitrogen, Helium, Carbon Monoxide, Exhaust Gas, Ammonia Synthesis h. Ammonia i. Hydrogen Sulphide
Use a mixed base or napthenic straight mineral oil. Use dry, compounded, straight mineral oil. 3% - 5% compounding with acidless tallow and addition of corrosion and oxidation inhibitors is required. Viscosity selection per Table 1.
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3.5 Lubrication Rate a. Experience has shown that the quantity of oil required to properly lubricate compressor cylinders is dependent upon bore diameter, stroke, and speed. For the Superior 6" stroke compressors operating at 900 RPM, 1/5 pint per day for each inch of cylinder bore diameter has normally proven to be an adequate quantity. b. The piston rod and packing is considered as a separate cylinder but with double the lubrication rate required. Packings, then, require 2/5 pint per day for each inch of rod diameter. c. Sight feed lubricators are often used on compressors and can be used to check the lubrication rate. A quantity 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 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 be adequate for most compressor applications. The gas being compressed, its cleanliness and tendencies to act as an oil diluent, and the type of oil being used all influence the lubrication rate required. Many applications may require more or less than the calculated feed rates. To assure that adequate lubrication is being achieved, a periodic visual inspection of the cylinder bore and piston rod are recommended. Initial setting and adjustments to the feed rate should also be accomplished on a 24-hour basis since the drop size varies with the viscosity of the oil. g. Over-lubrication can be just as harmful as under-lubrication. Excess lubrication can cause valve deposits, valve breakages, and contamination of the gas stream and other down-stream equipment.
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4.0 Synthetic Lubricants

Synthetic lubricants have gained popularity in recent years primarily because of their higher flash points. This makes them highly desirable from a safety and fire reduction standpoint. However, synthetics impose problems which are usually not associated with natural mineral oils. They dissolve paints, are corrosive to common bearing materials such as lead and tin, and they have low viscosity indexes. For these reasons, when synthetics are considered for use in compressor cylinders or frames, Superiors Springfield office should be consulted.
5.0 Multi-Grade Lubricants

Recently, multi-grade oils have gained popularity because of their ability to provide the same protection as heavier single-grade oils without putting undue stresses on the compressor cylinder lubrication system. However, all multi-grade oils do not provide the same protection. For this reason, if a multi-grade oil is being considered for use as a cylinder lubricant, Superiors Springfield office should be consulted. Table 1
Viscosity Requirements for Superior Reciprocating Compressor Cylinders

Minimum Viscosity (SSU @ 210 F)
Pressure (psig) 0 - 500 500 - 1,000 1,000 - 2,000 2,000 - 4,000 4,000 & up 0 - 10" 60 - 70 70 - 80 80 - 100 100 - 150 150 - 200
Cylinder Diameters 10" - 15" 60 -75 70 -85 85 - 100 15" - 20" 65 - 75 75 - 85 above 20" 65 - 80 75 - 90
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6.0 Additional Recommendations

6.1 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 than normally used for the pressure conditions involved. For heavy hydrocarbon and sour gases, use the next higher viscosity over that shown in the table with a minimum of 85 SSU @ 210 F. For refrigeration service, use the highest possible viscosity that should be used, while still 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 maintain lubricator pump inlet oil temperatures at or above 120 F.
6.2
6.3
6.4 6.5 6.6
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ES 3002 Welded Clearance Volume Bottles for Compressors: Material and Fabrication Requirements
1.0 Scope
This standard covers bottle component material specifications and welding procedure requirements 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 bottle drawings. (Ref. Sheet 1342)
Yield Strength Minimum PSI

35,000 35,000 35,000 35,000 35,000 35,000 35,000
a. All straight pipe sections b. All reducers and caps c. Adaptor 3" - 600# WNF d. Adaptor 6" - 150# WNF e. Adaptor 1 1/2" - 300# WNF f. Adaptor B904-891 & B904-901 g. Adaptor B907-351 & B936-661 2.2
ASTM-A53, Type S ASTM-A234 ASTM-A105 ASTM-A105 ASTM-A105 ASTM-A181 ASTM-A515
Grade B Grade B Grade 11 Grade 70
The allowable pressure data shall be included on all drawings as shown in the example to the right for corrosion allowance. The data should be entered in the appropriate spaces. All drawings shall include the following note: A.S.M.E. Code Construction (No Stamping)
MAXIMUM ALLOWABLE WORKING PRESSURE CORR. ALLOWANCE 0" .062" .125"

This bottle for use on a cylinder of lower MAWP than the above pressures.
2.3
The above note will have the No Stamping words deleted only when a customer has requested complete ASME certification.
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2.4
All bottles shall be designed to have a maximum stress of 11,000 psi or less with reference to the static yield strength of the material of 35,000 psi. Stresses shall be calculated by ASME formulae as follows: P(R1 + 0.6t1) Et1 P(R2 - 0.4t2) 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 For Longitudinal Stress For Circumferential Stress
S1 =
S2 =
2.5
When lethal and/or corrosive gases are involved, determine the appropriate safety factor and corrosion allowance thickness to be used. Determine maximum allowable working pressure for the specific application.
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ES 3003 Outboard Cylinder Vibration Suppression Device: Installation Instructions For Head Or Cover Mounting
1.0 Scope
Outboard cylinder vibration suppression devices are only to be attached to heads or covers when bosses on cylinder bodies are not available. It is Ajax-Superiors intent to provide such bosses on all cylinders. This is the preferred area of attachment and must be used if available.
2.0 Purpose
To advise customers and Cooper Energy Services Group field service personnel of installation procedures for outboard cylinder vibration suppression devices.
3.0 Compressor Models

All Superior W-7, MW-6, and SW-6 compressors with subject devices furnished.
4.0 Design Philosophy

The outboard cylinder vibration suppression devices generically referred to as: Outboard Cylinder Supports Cylinder Head Supports Cylinder Support Plates A-Frame Supports and/or A-Frame Devices
are furnished by the packager when requested by customers and/or recommended by analog and/or mechanical analysis of vessels and piping. The purpose of the device is to mechanically tune the vibration frequency of the compressor manifold system higher (i.e. cylinders, pulsation dampeners and close sections of process piping). The goal is to insure that the natural mechanical frequency of the manifold system is at least 10% away from a first and second natural compressor order. Installation of the device will normally raise the natural frequency of the manifold system. In order to confirm that the goal has been achieved, a bump test must be performed.
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The outboard cylinder vibration suppression devices are designed such that when the compressor cylinders have reached normal operating temperatures, adjustment must be made to minimize strain so that there is no vertical, horizontal, or axial loading on the studs attaching the device to the cylinder. The adjustments must be made using means other than loosening the attaching stud nuts. Additionally, the design is such that a section of the device 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 may cause excessive loading on compressor components or bolting. The effects of such excessive loading may cause catastrophic failure of gas-containing components, leading to extensive property damage, personal injury or death from rupture and/or fire.
5.0 References
Appendix A - Recommended Torques for Model C Appendix B - Drawing SK-7370 Model C Outboard Cylinder Vibration Suppression Device for Cast Nodular Iron Cylinders Appendix C - Drawing SK-7369 Model FS Outboard Cylinder Vibration Suppression Device for Forged Steel Cylinders
6.0 Procedure
Outboard cylinder vibration suppression devices are furnished in two different configurations. Model C is for installation on cast nodular iron cylinders; Model FS is for installation on forged steel cylinders. Model C attaches to the cylinder at the lower cylinder head studs, while Model FS attaches to the cylinder at the lower two bolts of the gas passage cover. 6.1 Field Preparation 6.1.1 Anchor Bolt Installation Prior to installation of anchor bolts in the concrete, they should be completely coated with a release agent to prevent adhesion to the concrete or grout.
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6.1.2 Cast Cylinders Loosen all cylinder head nuts securing the head to the cylinder. Remove two nuts from the cylinder head studs that match the outboard cylinder vibration suppression device (OCVSD) bracket. Remove these two standard studs and install longer studs required to attach the OCVSD bracket. Re-torque all head nuts uniformly in a crisscross pattern according to torque table in Appendix C for 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. Install longer studs required to attach the OCVSD bracket. Re-torque the four nuts in a crisscross pattern evenly and uniformly according to the torque table in Appendix 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 a release 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 OCVSD lower mounting bracket. 6.2 Field Assembly and Installation 6.2.1 Install the lower mounting bracket onto the structural support beam furnished by the site contractor. The structural support beam should be installed over anchor bolts extending out of the concrete floor such that there is a 1" space beneath the bottom flange of the structural support beam for grouting. Thread the nuts finger tight onto the anchor bolts. 6.2.2 Install the upper mounting bracket over the cylinder head studs (on Model C) or gas passage studs (on Model FS). Assemble the upper mounting bracket to the OCVSD lower mounting bracket with .045" (three .010" and three .005" shims) of the shim pack between the shimming plates. Make sure all bolt holes are centered. If they are not, make adjustments at the structural support beam to center the studs in the upper mounting bracket holes.
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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 on the 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 any spacers 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 the structural 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 manufacturers instructions. 6.5 Post-Grout Assembly and Pre-Startup Check 6.5.1 Loosen the nuts between the upper mounting bracket and the lower mounting bracket at the shimming plates. 6.5.2 Torque the nuts on anchor bolts protruding through the structural support beam in accordance with anchor bolt manufacturers recommendations. NOTE: Pre-stress on anchor bolts exceeding 20,000 psi is not recommended (see Appendix 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 upward pressure. b. If space is present, insert shims between the upper and lower mounting brackets at the shimming plates to fill the space without causing upward pressure on the upper mounting bracket.
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6.5.4 Torque bolts and nuts connecting the upper and lower mounting brackets at the shimming 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 at normal operating temperatures, after which the unit should be shut down. 6.6.2 Loosen the nuts connecting the upper and lower mounting brackets at the shimming plates. 6.6.3 Repeat Steps 3 and 4 under Post-Grout Assembly Section. 6.6.4 Check all other nuts for correct torque.
Thread Diameter 3/4" 7/8" 1" 1 1/8" 1 1/4" 1 3/8" 1 1/2"
First Nut Second Nut Foot-Pounds Foot-Pounds 105 to 115 170 to 190 260 to 290 370 to 410 520 to 570 700 to 770 930 to 1030 60 100 150 215 300 395 530
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7.0 Appendix A - Recommended Torques For Cylinder Attachment Bolts

All torque values listed are for lubricated threads and nut seating surface. 7.1 J-Bolts Anchor NOTE: Torque per anchor bolt manufacturers 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.
Thread Diameter 3/4 10" 7/8 9" 1 8"
Foot-Pounds 60 100 150
NOTE:
Coat anchor bolts with anti-seize or other release agent to prevent concrete or grout adhesion during installation.
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Page 6-62
5.00
Model C Outboard Cylinder Vibration Suppression Device For Cast Nodular Iron Cylinders
LEGEND
TBA CTS NTS TI
To Be Advised Cut To Suit Not To Scale Temperature Indicator
8.0 Appendix B - Drawing SK-7370

Upper mounting 1 bracket (typ.) 8
1.00
Typ. (3) 4 places 6 2 (3) 3/4 N. C. bolts C/W 1 nut each by customer Typ.
3/8 3/8
Shimming plates (typ.) Lower mounting bracket (typ.)
3/8 3/8
Typ.
3/8 3/8
Typ.
TBA 5 3
TBA
To allow for clear reading of TI
2.00
.25 shim allowance
Structural support beam by customer
6.00
Anchors by customer. Note: anchor bolts to be coated with a release agent to prevent concrete or grout adhesion.
1.875
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1.00 grout allowance A
Top of concrete
Plate attached to bolt to anchor into concrete
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Drawing SK-7370 Model C Outboard Cylinder Vibration Suppression Device For Cast Nodular Iron Cylinders
Bill of Material
Item 1 2 3 4 5 6 7 8
1.50 Typ.
Quantity 1 1 1 3 1 1 1 1
Description 1" PL. x 7.75 x 14.88 LG. -CTS1" x 35.50 x TBA LG. -CTS1" PL. x 6.00 x 35.50 LG. 3/4 f Hex head bolt x 3.25 LG. C/W 1 nut ea. 6.00 f STD. SMLS pipe x 2.00 LG. 1" PL. x 5.00 x 16.50 LG. 1" PL. x 5.00 x 16.50 LG. Shim pack (3 ea. 0.005, 0.010, & 0.030)
Material ASTM A-36 ASTM A-36 ASTM A-36 GR-A ASTM A-106-B ASTM A-36 ASTM A-36 CS
Note: BOM qty's are for one support only.
TBA 7.75 Number & size of bolt hole to be determined upon receipt of cylinder TBA 14.88
ITEM #1 DETAIL
Cylinder Head
.875 thru 3-places
.875 thru 3-places 5.00 1.25 6.00 6.00 16.50
Cylinder Head Nut (First)
6.00
Bracket Nut (Second)
1.25
7.25
10.50 35.50
10.50
2.25
1 6 7 2
ITEM #3 DETAIL
ITEM #6 DETAIL
.875 thru 3-places
Assy. Detail NTS

.62 Typ. 3 slots 5.00 1.25 5.00 1.25 6.00
2.25 6.00 6.00 16.50
2.25
6.00 16.50
ITEM #7 DETAIL
ITEM #8 DETAIL
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Model FS Outboard Cylinder Vibration Suppression Device For Forged Steel Cylinders
9.0 Appendix C - Drawing SK-7369

5.00 1.00 1 Upper mounting bracket (typ) Typ. (3) places 4 6 8 Shimming plates (typ) 3/8 3/8 Typ. 2 7 Lower mounting bracket (typ) 3/8 3/8 Typ. (3) 3/4 N.C. bolts C/W 1 nut each by customer Typ. 3 3/8 3/8 2.00
5
Legend TBA - To Be Advised TI - Temperature Indicator
TBA
TBA
To allow for clear reading of TI
.25 shim allowance
Structural support beam by customer
6.00
Anchors by customer Note: anchor bolts to be coated with a release agent to prevent concrete or grout adhesion A Plate attached to bolt to anchor into concrete Note: 1. For use with forged steel cylinders
1.00 grout allowance
1.875
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Drawing SK-7369 Model C Outboard Cylinder Vibration Suppression Device For Forged Steel Cylinders
1.125 thru 2 places
8.75 4.38 .875 thru 3-places
8.12
6.50
6.00
TBA (Typ.) 14.88
1.25
7.25
10.50 35.50
10.50
ITEM #1 DETAIL ITEM #3 DETAIL

Cylinder Head
.875 thru 3-places
.875 thru 3-places
Cylinder Head Nut Passage Nut (First) Bracket Nut (Second)
5.00 1.25 2.25 6.00 6.00 16.50 6.00 16.50
5.00
2.25 6.00
1.25
1 6
ITEM #6 DETAIL
ITEM #7 DETAIL
2
Assy. Detail NTS

.62 Typ. 3 slots 5.00
2.25 6.00 6.00 16.50
1.25
Bill of Material
Item 1 2 3 4 5 6 7 8 Quantity 1 1 1 3 1 1 1 1 Description 1" PL. x 8.12 x 14.88 LG. -CTS1" PL.x 35.50 x TBA LG. -CTS1" PL. x 6.00 x 35.50 LG. 3/4 f Hex head bolt x 3.25 LG. C/W 1 nut ea. 6.00 f STD. SMLS pipe x 2.00 LG. 1" PL. x 5.00 x 16.50 LG. 1" PL. x 5.00 x 16.50 LG. Shim pack (3 ea. 0.005, 0.010, & 0.030) Material ASTM A-36 ASTM A-36 ASTM A-36 GR-A ASTM A-106-B ASTM A-36 ASTM A-36 CS
ITEM #8 DETAIL
Note: BOM qty's are for one support only.
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ES 3004 Ajax-Superior Packager Manual

1.0 Scope
This specification provides guidelines and requirements for packaging and interfacing with Ajax-Superior engines and compressors. It is not intended to encompass all necessary aspects of properly designed and constructed engine and compressor packages.
2.0 Requirements
2.1 Packagers of Ajax-Superior equipment are expected to follow good, generally accepted industry practices and applicable codes, as well as local, state and federal regulations for the design and construction of the packaged product. In addition, and for full warranty consideration, the packager is expected to follow application and safety guidelines as proposed herein, and to pass on to the customer appropriate warnings and safety procedures associated with the equipment. A label with operator warning statements will be issued for mounting on the equipment control panel where start-up of the unit is controlled. The label is to be mounted on the front face of the panel as close to operator eye level as practical. When specified by the customer or dictated by location, the safety guidelines of OSHA, NFPA, API or other governing codes are to be followed. It is intended that for non-refinery applications API-11P is the governing specification. Certain piping on Ajax-Superior engine and compressor fuel, oil, and water systems do not meet ANSI B.31.3 but are allowable exceptions due to their proprietary design. Cleanliness of piping is very important. The requirements of ES 3001 (page 1-77) and ES 3001A (page 1-79), or a mutually agreed upon alternative procedure approved by Ajax-Superior, should be followed by packagers. Other technical information relating to specific engine or compressor models can be found in the Engineering Technical Data Books and in Ajax-Superior Engineering Standards provided to packagers. When in doubt, consult the Ajax-Superior Engineering Department for recommendations.
2.2
2.3
2.4
2.5
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2.6
Specific guidelines are provided for the following categories of equipment, systems, and applications:
See Page 6-67 6-69 6-70 6-71 6-72 6-73 6-75 6-75 6-76 6-76
Item No. 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0
Application Compressors Superior Engines Ajax Engines Required Safety Shutdowns Gas Piping Systems Cooling Systems Skid Design Criteria Coupling Criteria Recommended Engine and Compressor Options Engine Mechanical Drive (non-compressor drive)
3.0 Compressors
3.1 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. While it is current industry standard to quote capacity and performance from compressor cylinder inlet flange to compressor cylinder discharge flange, it is the packagers responsibility to ensure that the design and construction of the package accommodates the system pressure drops. The interstage pressure drops (consistent with the pressure drops represented in the customer proposal and/or contract) and suction and discharge pressure drops must not overload the equipment or exceed pressure and temperature limits that would cause premature wear or dangerous operating conditions. If such pressure drops do not impose equipment problems but do adversely affect the compressor capacity or power required, it is the packagers responsibility to advise the customer accordingly. 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 on the equipment outline drawing. Manifolding of vents must meet API-11P standards
3.2
3.3
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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 on the outline drawing. 3.4 Cylinders and/or pulsation dampeners must be provided with adequate supports from the skid or foundation to avoid excessive bending movement of the compressor crankcase. Piston ring, packing and rod coating materials must be compatible with the gas to be compressed. 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 stock compressor cylinders are used, it is the packagers responsibility to see that necessary component changes are made. Material recommendations will be made by AjaxSuperior on request. The end user of equipment is to be provided with compressor operating curves where variable operating conditions are expected. Ajax-Superior will provide assistance on request. Packing cooling systems are required for all cylinders rated above 2000 psi and must be designed for adequate cooling under the most severe operating conditions specified. The packing cooling system typically must be sized for 400-500 Btu/min/packing and be a separate system from the jacket cooling system to prevent gas leaks from entering the engine or compressor cylinder jackets or intercooler circuit. The coolant pump and system must be capable of circulating 2 1/2 to 3 gpm per packing with a 30 to 40 psi pressure drop through the packings. The maximum coolant inlet temperature shall not be more than 120 F and the temperature rise across the packing is not to exceed 20 F. Coolant is to be treated to prevent corrosion or formation of deposits which could block the small passages in the packings; appropriate recommendations are to be provided in the packagers instruction manual. An appropriate pump lubricant shall be specified to the customer if required. Compressor cylinder lubrication systems must be designed and built for each application. 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 proper cylinder lubricant for Superior products or ESS-L-168 and ESS-L-811 for proper cylinder lubricant for Ajax products. Compressor cylinders, by serial number, must be mounted on the prescribed throw locations. The packager may make the initial cylinder location selection and forward the information to Springfield Engineering. However, once balance information is developed, it is imperative that the packager install the appropriate serial number cylinder on the throw location assigned, and that appropriate balance weights be installed on all throws.
3.5
3.6
3.7
3.8
3.9
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4.0 Superior Engines

4.1 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 prevent damage in the event of combustion of fuel in the exhaust system. A flex connector should be provided at or near the engine so as not to impose excessive flange loading on the engine or turbocharger exhaust outlet connection. Consideration must be given to both static weight loads and loading from thermal growth. Exhaust systems must be designed to not exceed 10 inches water column of back pressure at 110% engine load at the engine outlet connection to allow for full site rating of engine. A connection for measuring exhaust back pressure must be included in the exhaust piping just downstream of the engine. Exhaust silencers and heat recovery boilers must include an adequate fouling factor to allow for reasonable maintenance intervals. (This is particularly important for diesel and dual-fuel applications.) Location of the exhaust gas exit must be such that it does not adversely affect the cooling system and/or is not drawn into, or does not heat up, the air inlet system. Exhaust system designs having significant piping inside a building must include provision for relieving excessive exhaust gas pressure in the event of an engine backfire or combustion of fuel gas in the exhaust piping. Relief devices need to be located at elbows in order to be effective. The fuel gas analysis must be determined for each site, and appropriate engine deration applied. If the fuel is other than pipeline quality gas, consideration should be given for possible changes in fuel gas composition and the need for future derating. For all Superior turbocharged engines, the customer must be provided with the appropriate air/fuel ratio curve or constants for the engine panel. These will be supplied by Ajax-Superior once site information is received. If the engine is moved to a new location and/or fuel quality changes, it may be necessary to develop new control parameters. Such needs should be referred to the Ajax-Superior Engineering Department for review. Normal engine shutdown for spark gas engines is to be accomplished by interrupting the fuel supply with the ignition still on. This is to prevent combustible gas from remaining in the exhaust system. The ignition can then be grounded, either manually or with an automatic time delay, after 10-20 seconds. In general, the driven equipment must have some provision for unloading during the starting cycle. If bypass piping or unloading provision is not included as part of the
4.2
4.3
4.4
4.5
4.6
4.7
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package, then it must be included in the station piping. See ES 3007 (page 1-108) for bypass recommendation. 4.8 Turbocharged engines are required to have pre-post lube pumps to ensure adequate oil supply to the turbocharger on engine startup and shutdown. Auxiliary driven equipment such as coolers, special water pumps, etc., must be selected by the packager with consideration for the horsepower required, side loading where belt drive is used, plus any special sheave or coupling where power takeoff is required. All such auxiliary equipment interfaces must be compatible with engine hardware and systems.
4.9
4.10 Engine warm-up and cool-down cycles should be incorporated in the control logic whenever possible. On start-up, oil and jacket water temperature should reach 120 F before fully loading engine. For normal shutdown, the engine should be allowed to run a minimum governed speed and load for approximately 10 minutes before stopping.
5.0 Ajax Engines

5.1 Engine exhaust systems should be designed with heavy-duty steel pipe, preferably Schedule 40, with flanged connections and bolted joints to prevent damage in the event of combustion of fuel in the exhaust system. A flex connector or other provision for system expansion should be included so as not to impose excessive flange loading on the engine exhaust outlet connection. Consideration must be given to both static weight loads and loading from thermal growth. Exhaust systems must be designed not to exceed 7" water column back pressure at 110% rated load. Location of the exhaust exit must be such that it does not adversely affect the cooling system and/or is not drawn into, or does not heat up, the air inlet system. Satisfactory engine performance is highly dependent on properly tuned exhaust length. Interconnecting exhaust pipe lengths are to be in accordance with Ajax-Superior recommendations as shown in SK-8826. Exhaust system designs having significant piping inside a building must include provision for relieving excessive exhaust gas pressure in the event of an engine backfire or combustion of fuel gas in the exhaust piping. Relief devices or sensors need to be located at elbows in order to be effective.
5.2
5.3
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5.4
The fuel gas analysis must be determined for each site and appropriate engine deration applied. If the fuel is other than pipeline quality gas, consideration should be given for possible changes in fuel gas composition and the need for future derating. Normal engine shutdown is to be accomplished by interrupting the fuel supply with the ignition still on. The driven equipment must have some provision for unloading during the starting cycle. If bypass piping or unloading provision is not included as part of the package, then it must be included in the station piping. Auxiliary driven equipment such as coolers, special water pumps, etc., must be selected by the packager with consideration for horsepower required, side loading where belt drive is used, plus any special sheave or coupling where power takeoff is required. All such auxiliary equipment interfaces must be compatible with engine hardware and systems.
5.5
5.6
5.7
6.0 Required Safety Shutdowns

6.1 The following shutdowns are minimum requirements on Ajax-Superior products, either for protection of the equipment itself, or to meet the safety practices outlined in industry codes (OSHA, NFPA, ANSI, etc.). 6.1.1 Superior Compressors: Low lube oil pressure Cylinder lubrication no-flow Vibration Low suction pressure High discharge pressure, each stage High discharge temperature, each cylinder High jacket water temperature (if not included in engine circuit) * High suction temperature, each stage 6.1.2 Superior Engines: Overspeed Vibration High jacket water temperature Low lube oil pressure ** High lube oil temperature (uncooled) High turbine inlet temperature (turbocharged engines)
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6.1.3 Ajax Engine/Compressors: Overspeed Low oil level **High lube oil temp (uncooled) High jacket water temperature Cylinder lubrication no-flow (std. on 600 & 800, recommended on others) Low suction pressure High discharge pressure, each stage High 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 and in ways that ensure that they are not damaged from heat or vibration which occurs in normal equipment operation. * Required on compressor applications where there is extensive running in the unloaded 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 the fuel supply and shutting down lubricating oil pumps not directly driven by the engine. Appropriate control panel location may be sufficient to meet this requirement.
7.0 Gas Piping Systems

7.1 Pulsation dampener design must meet customer specifications and, where applicable, must comply with analog results. In addition, design must be such that pulsations at the compressor cylinder suction and discharge flanges do not adversely affect valve life, capacity and/or horsepower required. Pulsation dampeners are to be equipped with 1/2 NPT or larger taps in the cylinder neck for indicator testing. If dampeners are chambered, there should be an additional tap for each chamber. See ES 3005 (page 1-105) for additional guidelines for Superior compressor piping systems. Pulsation dampener and associated piping must be such that it does not impose undue loading on the cylinder flange and/or compressor crankcase. Consideration must be given for torque generated by piping size and weight as well as thermal growth and gas pressure forces. If the package design includes items outside standard designs (such as larger than normal pulsation dampeners, high gas pulsations, long straight piping
7.2
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from dampener flange, etc.), then contact Ajax-Superior Engineering for specific flange load calculations. 7.3 Adequately sized scrubbers are required upstream of compressor cylinders to prevent liquid and solid materials from entering the compressor valves and cylinders. Filtration beyond normal scrubbers and start-up screens may be needed to prevent the entry of fine abrasives. For sites where abrasive particles are present, a filter-separator should be considered to remove contaminants which could cause premature wear. Equipment damage or wear from abrasive solids or liquids will not be covered by Ajax-Superior warranty. The general layout and piping arrangement should be such that it does not interfere with reasonable access to and maintenance of compressor components. This includes control 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 and the package designed such that the views of these items are not obstructed. Provision is to be included in the piping and/or control system to unload the compressor for start-up (and cool down for engine drives). This can be done by using valve unloaders and/or a gas bypass system. If the bypass is not part of the package, it must be included in the station piping. See ES 3007 (page 1-108) for bypass recommendations. When a gas bypass is used in the system it should be such that the recirculated gas is cooled to prevent it from reaching harmful temperature levels. This is required for compressors driven by turbocharged engines that require a warm-up period before they can be loaded. It is recommended, but not mandatory, for compressors driven by naturally aspirated engines. In either case, if the startup requires more than 10 minutes running time before loading the compressor, consult Ajax-Superior Engineering Department for proper shutdown protection. Relief valves must be provided at the discharge of each stage of compression and be set within the tolerance limits specified in API-11P. Relief valves must be located upstream of each respective cooler section.
7.4
7.5
7.6
7.7
8.0 Cooling Systems

8.1 It is the packagers responsibility to adequately size radiators, coolers, piping, and other components of the cooling system to meet the requirements of the engine and driven equipment. Consideration should be given to the full range of ambient conditions, air
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flow relative to physical obstacles, closeness to exhaust systems, etc. Cooling systems may be required for any or all of the following: Engine jacket water Engine lube oil Engine intercoolers Compressor cylinder jackets Compressor lube oil Compressor rod packings 8.2 Superior engine cooling systems should be pressurized to 7 to 10 psi and include consideration for maximum engine horsepower (including 110% DEMA overload) and site elevation. Compressor jacket cooling systems may be of the thermo-syphon type for low temperature service. However, if the gas discharge temperature exceeds 210 F or the differential temperature from suction to discharge exceeds 150 F, a forced coolant system is required. If compressor cylinder ends are operated for extended periods unloaded, the forced system is required. General recommendations for the system coolant are given in the Instruction Manual. Additional information can be found in Engineering Service Bulletin #194. In the design of the coolant piping, care should be taken to avoid, where possible, the routing of piping directly over the exhaust components of the engine, as antifreeze and glycol solutions may be flammable. Components such as piping valves, pumps, etc., must be sized to maintain the required flow rates through the system. Pump net positive suction head must be adequate to ensure proper system performance at all operating speeds. Adequately sized surge tanks are required with free flowing vents from all high points to the tank. A balance line from the surge tank to the pump suction is also required on Superior engines. Additional information can be found in Engineering Service Bulletin #52. Where motor driven water pumps are used, there should be control panel indication to show that the pump is running. This can be either indication of signal being sent to motor or jacket water pressure indication.
8.3
8.4
8.5
8.6
8.7
8.8
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9.0 Skid Design Criteria

9.1 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 couples imposed on it. Allowance must be included for thermal growth of each of the components. Skid, piping and support design must be such that harmonic excitation is avoided by designing components that do not have natural frequencies near the unit natural frequency or harmonics of the rotating and reciprocating components. Vibration analysis (bump testing) should be used to confirm that new designs will not have vibration problems. Skid design must include proper guards for flywheel, pumps, pulleys, drive shafts, etc. to protect operators from moving components. Guard designs are to comply with OSHA 1910.219. Provision for shims must be included under the driver and/or driven equipment to allow for field alignment. Fixed location of properly aligned compressors by grouting is acceptable. Where fixed ladders and platforms are used, they must comply with OSHA Standard 1910.27 and applicable local codes. Placement of components on skid must not void compliance of ladders and platforms furnished by Ajax-Superior.
9.2
9.3
9.4
9.5
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 a coupling selection approved by Ajax-Superior Engineering. 10.2 When the torsional analysis dictates a single bearing design, the generator or electric motor is to be supplied with a forged flanged shaft and a self-aligning, free floating bearing. This is to prevent thrust loading and/or misalignment with the Superior equipment due to thermal growth of engine, motor, coupling, or generator components. 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 assembly procedures must be such that the units do not impose any thrust loading on the Superior equipment due to magnetic centering forces.
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10.4 Where rubber/elastomer coupling components are used, the coupling guards are to be designed 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 adversely affect the component life.
11.0 Recommended Engine And Compressor Options

11.1 Differential pressure gauges, where applicable, should be provided for lube oil, fuel, and air filters to indicate the need for replacement or cleaning. Turbocharged engines should have high quality, durable gauges for the on-engine gas manifold and air manifold pressure readings. All automatic start engines and compressors should have pre-lube and/or post-lube pumps with 2- to 3-minute timers. Startup should not take place until a positive pressure is sensed or observed at the lube oil header. Pre-lube pumps are especially important for electric motor driven compressors. Low oil pressure lockout for startup should not exceed 30 seconds. All engines should have exhaust pyrometers and/or high exhaust temperature shutdowns. Additional safety shutdowns recommended for engines include: Low jacket water pressure Low intercooler water pressure Exhaust scanning pyrometer, sensing high cylinder temperature and high cylinder differential temperature High 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 in excess of 85% of rating or where specified by Ajax-Superior Engineering).
11.2
11.3
11.4
11.5
12.0 Engine Mechanical Drive Applications

12.1 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 shutdown system. 12.3 Engine exhaust piping is to be heavy-duty steel or stainless steel, Schedule 10 or heavier pipe, with flanged connections and bolted joints to prevent damage in the event of combustion of fuel in the exhaust system. A flex connector should be provided at or near the engine so as not to impose excessive flange loading on the engine or turbocharger exhaust outlet connection. 12.4 Exhaust system designs having significant piping inside a building must include provision for relieving excessive exhaust gas pressure in the event of an engine backfire or combustion of fuel gas in the exhaust piping. Relief devices need to be located at elbows in order to be effective. 12.5 Each engine must have its own exhaust system; no manifolding of multiple exhausts will be approved by Ajax-Superior Engineering. 12.6 Engines operated with elevated jacket water temperatures (above 195 F) must have motor driven water pumps with appropriate controls for running the pumps for a cool-down cycle (not less than 20 minutes) after engine shutdown. A jacket water pressure sensor and shutdown are also required. 12.7 Diesel and Dual Fuel engines must have an overhead day tank with gravity feed of the fuel to the fuel supply pump. A separate fuel drip return tank and pump will be required to return the excess injector fuel to the day tank. 12.8 For normal shutdown, control logic provision must be included to first reduce the load in a controlled manner to prevent engine overspeed. This is particularly important for generator drive units where opening the breaker under load will cause an instant overspeed condition. 12.9 On Dual Fuel engines the shutdown logic should be to switch to full diesel operation under 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 accordance with ASME Boiler and Pressure Vessel Code Section VIII.
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ES 3006 Compressor Cooling System Design

1.0 Scope
1.1 The scope of this Engineering Standard is to present the requirements and tools to design a satisfactory cooling system.
2.0 Requirements
2.1 Cylinders 2.1.1 No cooling is required when the gas discharge temperature is below 140F and the gas inlet temperature is greater than 60F. 2.1.2 Either forced liquid cooling or thermal siphon or stand pipe cooling is required when the gas discharge temperature is between 140F and 250F and the gas temperature rise is less than 170F. 2.1.3 Forced liquid cooling is required when the gas discharge temperature is greater than 250F or the gas temperature rise is greater than 170F. 2.2 Frame Lube Oil Coolers 2.2.1 All Superior medium and high speed compressor frames require coolant between 140 and 160F for the oil coolers. 2.3 Piston Rod Packing Cooling 2.3.1 Lubricated packing must have cooling when cylinder discharge pressures are above 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 packing will vary with operating and ambient conditions. Add l0%, not including fouling factor, to the heat transfer requirements to select the coolers and chillers.
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3.0 Procedure
3.1 General 3.1.1 This cooling design procedure will apply to a wide range of compressor cooling systems, including the following: System 1. Motor or Turbine Drive 2. Generic Engine Drive 3. Matched Engine/Compressor Set Figure 1 2 3
All of the systems considered in this Engineering Standard are for ambient air cooling and a thermostatic coolant control to 180 F. The ambient air can vary from very cold to extremely hot. In very cold climates, the thermostat allows recirculation of coolant through the bypass to warm the fluid coming from the air cooler. The compressor will warm up faster and will start up with warmer oil. When the ambient temperature is very hot, the compressor oil temperature becomes hot also. All the systems include a compressor lube oil shut down at 190F. 3.1.1.1 The Motor or Turbine Drive compressor cooling system will have a coolant temperature shutdown in addition to all of the above system features. The Generic Engine Drive compressor cooling system is configured for engines that lack sufficient jacket coolant capacity in head or flow to supply cooling for the compressor. Diesel and gas engines developed from diesels are likely to have pumps too small to handle requirements of the compressor. If there is no pump information available, please use this system. In this case, a coolant pump and source of power will be required to cool the compressor. The existence of the compressor will add to the engine jacket heat load and coolant flow. An air cooler will need to be selected for the additional requirements. The Matched Engine/Compressor Set compressor cooling systems are used with engines which have jacket coolant pumps sized to accommodate the cooling requirements of the compressor
3.1.1.2
3.1.1.3
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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 maximum coolant temperature is 180 F. The air cooler is selected to remove all of the heat from the compressor frame. The sketch in Figure 4 shows the coolant flow circuit of a motor-driven compressor frame with three (3) cylinders. Selection of an air cooler requires that the heat loads and the coolant flow first be found. These can be determined using the following equations, along with information about the number and kind of cylinders, the frame on which they will be fitted, and the performance required from the cylinders.
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3.2.1.2 The heat load for each cylinder on a frame can be determined with the following relationship: Equation 1. where: q = H x ( (Td + Ts) / 2 - Tc - Tr / 2) BTU/HR BTU/HR - deg F deg. F deg. F deg. F deg. F
q = Cylinder Heat Load H = Cylinder heat transfer coefficient (see Table 3) Td = Gas Discharge Temperature Ts = Gas Suction Temperature Tc = Coolant Inlet Temperature Tr = Coolant Temperature Rise
The heat load for each is the calculated for a design of 160 F coolant inlet temperature and 10 F temperature rise through the cylinder. The coolant flow through the cylinder is found with Equation 2. 3.2.1.3 The coolant flow through any cylinder or lubricating oil cooler can be calculated for any temperature rise of the heat transfer fluid with the following formula: Equation 2. where: G = 0.1247 x q/Tr/Cp/Dc gallons / minute BTU / lb deg. F lb / cubic ft.
G = Coolant Flow Cp = Coolant Specific Heat (See Table 1) DC = Coolant Density (See Table 1)
The most common coolant used in the system is a mixture of 50% Ethylene glycol and 50% treated water. Table 1 shows densities and specific heats for various coolant temperatures.
Table 1
Coolant Temperature Tc 80 100 120 140 160 Density DC 66.2 65.7 65.3 64.8 64.4 Specific Heat Cp .797 .813 .828 .842 .854
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3.2.1.4 The frame model, which can be found in Table 2, will determine the size of oil cooler. The heat load and design flow is picked from the table. Now the total heat load and flow is determined and the air cooler can be selected. Next, calculate the resistance of the system to determine the actual 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 in a similar manner. For our circuit, the current law is a variation on Darcy s equation for friction loss. Equation 3. where: Pd=RxG2 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 system resistance to calculate the pressure rise across the pump. The oil cooler and cylinders of the compressor frame are piped in parallel flow paths while the 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.
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The total flow of the system is the sum of the oil cooler and cylinder coolant 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 the pump can be selected. 3.2.1.7 With the total flow of the system and the resistances of the oil coolerand the cylinders we can find out how the flow divides. Then we can calculate the temperature rise across the cylinders and the oil cooler flow. For the oil cooler: Equation 6. where: Goca = (Rcf/Roc).5 x Gt 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 listed in Table 2. If the flow is outside the range, adjustments to the system will be required. 3.2.1.8 The flow through each cylinder can be calculated in the same way. In the original assumptions, the temperature rise was 10F. the actual temperature rise can be calculated with the following equation: Equation 7. where: Tra = 10 x Gc/Gca Tra = Actual temperature rise across the cylinder Gca = Actual cylinder flow.
If the actual temperature rise is between 10 and 20F., no change is needed 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 jacket cooling 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 engine block and the exhaust manifold. The combined flow goes through the
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engine thermostat at 180 and through the customer's air cooler. A proper system design depends on the compressor oil cooler flow, cylinder coolant temperature rise, engine temperature rise, and the engine jacket coolant pump capabilities. Figure 5 is a flow circuit schematic for the cooling system. The heat into the system from the compressor is calculated with Equation 1. The engine heat load is obtained from the Superior Technical Data Book for the engine in question, or the engine performance prediction program. The coolant flow through the system is estimated with the design flow through the engine (obtained from the Water Pump Characteristics), the compressor oil cooler and the compressor cylinder flow for 10 F temperature rise. The customer's air cooler is then selected for the system. The air cooler flow resistance is added to the flow system. The total system resistance is determined and head loss versus the flow in the system are plotted on the Water Pump Characteristics Curve, the pump discharge pressure and total flow through the system for the application rpm. The flow obtained in this manner is what the pump and the system resistance will allow. This will usually differ from the original estimate. We need only to 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
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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 the following relation: Equation 10. Treb = Geb/Geba x 10
If the temperature rise is between 10 F and 2O F, the flow through the engine 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 obtained in the same manner as in the motor drive cooling system. They are evaluated 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 MW & SW62, RAM52 W72, MH & WH62 MH & WH64, MW & SW64, RAM54 MH & WH66, MW & SW66, W76 W74 MW&SW68 2" 2" 2" Header Pipe Size 1" 1-1/2" 1-1/2"
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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 coolant temperature to the packing is a maximum of 90 F. The heat rejection to the coolant is 3000 BTU/hr per packing. The coolant supply pressure to the packing should be 55 psig. The packing flow resistance is 8.8 psi/gpm2. A typical system is shown in Figure 6.
3.2.5.2 The system for a nonlube packing will be the same except for the coolant temperature. The coolant entering the packing must be 70 F for a suitable packing life.
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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 listed in Table 2.
Table 2: Oil Cooler Heat Load and Flow Resistance

BTU/ hr 42,000 51,000 96,000 23,100 46,200 68,100 92,100 37,500 75,000 112,500 16,000 32,000 Cooler Part # 620-162-001 620-162-002 620-162-003 919-142 919-144 919-141 919-141 919-144 919-144 919-169 919-142 919-144 Flow* Resistance 0.00107 0.00107 0.00227 0.00790 0.00107 0.00117 0.00117 0.00107 0.00107 0.00227 0.00790 0.00107 Allowable Flow Range (gpm) 30 - 50 30 - 50 50 - 7 0 8 - 15 30 - 50 30 - 5 0 60 - 80 30 - 50 50 - 70 50 - 70 8 - 15 30 - 50 Design Flow (gpm) 40 40 60 12 40 40 70 40 60 60 12 40 Pipe Size** 1-1/2" 1-1/2" 1-1/2" 3/4" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 3/4" 1-1/2"
Frame
RPM
MH & WH62 MH & WH64 MH & WH66 MW & SW62 MW & SW64 MW & SW66 MW & SW68 W72 W74 W76 RAM52 RAM54
1200 1200 1200 900 90 0 900 900 900 90 0 900 1200 1200
* The resistance includes 10 feet of pipe and two (2) ball valves. ** From Header to Cooler.
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3.3.2 Cylinders
Table 3: Cylinder Heat Transfer Coefficients and Flow Resistances

W6 Number 1-4 10 - 13 5-9 157 - 163 14-20 85-91 24-30 92-98 21-23, 83 31-34, 113 615-617, 683 76, 114 37 - 39 40 - 44 115 - 116 155 - 156 45-50 118, 119 123 - 124 667-682 627, 682 51-57, 120-122 143 - 140 629 102 - 106 5-62, 84 125-127 138-139 606 - 610 611 - 614 WH6 Number Cylinder Diameter Range 2.75-3.13 3.00-3.38 3.25-3.88 3.88-4.75 5.00-5.75 4.00-4.75 4.00-4.75 5.00-5.75 5.00-5.75 6.00-6.75 5.75 6.50-7.00 6.00-7.00 7.50-7.75 6.50-7.00 7.25-8.50 9.00-9.50 8.50-9.50 8.75-10.3 9.00-10.3 10.25 9.00-12.00 10.5-13.0 11.0-12.5 Class AS BS BSR BC F BDF CSF C DSF D ESF EAD E ED ED ED FD FD FD/FDA GD GD GD GH HD HD Heat Transfer Coefficient "H" BTU/hr-deg F 800 800 800 800 800 800 800 800 800 800 800 800 800 800 800 840 840 840 960 960 960 1000 1200 1200 * Coolant Flow Resistance "R" psi/gpm2 0.014 0.014 0.014 0.014 0.014 0.014 0.014 0.014 0.014 0.014 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.011 0.011 0.011
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Table 3, Continued
W6 Number WH6 Number 671 - 672 637 - 640 63-66, 133 112, 137-136 109 - 111 641 - 644 673 - 674 108, 68 135 - 134 78 - 80 70, 82, 129 71, 72, 77 73 - 75, 130 141, 132 662 - 663 618 - 621 659 - 661 664 - 666 625 - 626 668 - 670 630 - 670 675 645 - 646 648 - 649 650 - 651 652 - 653 Cylinder Diameter Range 11.0 - 13.0 13.5 - 15.3 15.0 - 15.8 13.5 - 14.5 14.0 15.8 18.0 - 18.5 17.5 - 18.5 18.0 - 19.0 20.0 - 22.0 22.0 - 23.0 24.5 - 26.0 22.5 - 26.5 5.75 - 7.25 6.00 - 8.00 9.00 - 12.00 17.0 - 18.0 19.5 - 20.5 22.5 - 23.5 23.5 - 26.5 Class Heat Transfer Coefficient "H" BTU/hr-deg F 1200 1200 1200 1200 1200 1500 1500 1500 1500 1500 1500 1500 1200 660 1080 1320 1500 2160 1920 * Coolant Flow Resistance "R" psi/gpm2 0.011 0.011 0.011 0.011 0.011 0.011 0.011 0.011 0.011 0.011 0.011 0.011 0.020 0.020 0.011 0.011 0.011 0.011 0.011
HD/HDA JD JD JD JD/JDA KD KD KLA KLD LD MD MD ND/ NDA** PD/ PDA** QD/ QDA** RD/ RDA SD TD TD
* The resistance includes ten (10) feet of pipe and two (2) ball valves. ** These cyls. have been converted to non-cooled, but remain here for service requirements.
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3.3.3 Superior Engines
Table 4: Flow Resistance

Engine 8SGTB 12SGTB 16SGT Engine Block 0.000046 0.000034 0.000014 Engine Thermostat 0.000009 0.000009 0.000009
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ES 4009 Determination of Compressor Cylinder Dead Center Position

1.0 Scope
This procedure describes the correct way to locate the head end dead center position for any compressor cylinder. It should be used to mark the flywheel wherever cylinders are indicated with a balance pressure indicator or an analyzer. Analyzers use a pulse from a magnetic 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 Procedure
2.1 Remove a crosshead cover on either #l or #2 throw cylinders. These cylinders are chosen for convenience, since they are closest to the flywheel. Manually bar over the unit until the selected (#l or #2) cylinder is approximately dead center. Install a dial indicator on the crosshead guide in such a manner that the stylus of the indicator rests squarely on one of the ends of the crosshead. On some units, it may be easier to install the indicator on the crosshead rather than the crosshead guide. In this arrangement, adjust the stylus so that it rests squarely on a vertical surface of the crosshead guide. Bar the unit over first in the actual direction of rotation until the piston is at the approximate head end (HE) dead center point (the dial indicator will stop moving at this point). With the cylinder resting on the approximate HE dead center, set the dial indicator to a zero reading. Back the crosshead away from HEDC by barring over the unit in the direction opposite normal rotation until the indicator reading exceeds +0.030".
2.2
2.3
2.4
2.5
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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 engine flywheel or the compressor flywheel, whichever is easier) in line with the pointer. (See Line 1 in previous sketch in Paragraph 2.5.) Continue to bar over the unit in the normal rotational direction until the crosshead travels through HEDC and the indicator reads +0.030" again. (The indicator reading will decrease to zero and then increase to +0.030). Then bar over the unit in the direction opposite normal rotation until the indicator reads +0.015". 2.8 With the dial indicator reading +0.015, scribe a second line on the flywheel opposite the pointer. (See Line 2 in previous sketch in Paragraph 2.7.) Now measure the distance between the two scribed lines and then scribe a third line on the flywheel exactly equidistant between the first two lines. This third line is the head end dead center (HEDC) point and should be labeled #l HEDC or #2 HEDC, depending on the cylinder that was checked.
2.7
2.9
2.10 To check the accuracy of the HEDC line, the process should be repeated using 2.10 through 2.14. Bar the unit over in the direction opposite normal rotation to align the third line (see 2.9), HEDC mark, with the pointer. Set the indicator to a zero reading. 2.11 Bar the unit over in the direction opposite normal rotation, continuing past Line 1 until the indictor reads +0.030".
2.12 Bar the unit over in the normal rotation to align 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 indicator again 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 2.12 within 0.002". 2.15 If a and b differ by more than 0.002", repeat Steps 2.4 through 2.14 until this level of accuracy 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 of 0.030 to 0.040 inches between the pickup tip and the pin or hole.
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ES 4010 Balanced Pressure Indicator Testing: Requirements, Procedure & Calculations

A. Scope
This standard outlines the requirements, procedures and calculations necessary to perform and properly report a balanced pressure indicator test on a compressor. Its use wi II provide consistent and accurate results, and conform to current industry-accepted practices. All indicator tests and reports issued should conform to this standard.
B . Requirements and Procedure

1. 2. Assemble the required test equipment shown on Table I, Page 11. Prior to test, all pressure gages should be calibrated using the dead weight tester and all thermometers should be checked for accuracy in an oil or water bath. When required, measure the clearance volume of the cylinders in question in accordance with ES 4008. Check all significant hardware (piston rings, packing and valves) and assure that it is in good working order. Replace parts as required. Set the proper head end and crank end end-clearances. Locate the head end dead center of Throw #2 and properly mark the flywheel in accordance with ES 4009 . Remove the crankshaft extension cover (C-910-812) from the auxiliary end and install the crankshaft extension seal (Y-900-461, 465) in its place. This exposes the crankshaft so that the Balanced Pressure Indicator (BPI) can be coupled to the compressor. Couple the BPI to the crankshaft extension using the Woods coupling assembly. Level the indicator and align it to the coupling to prevent binding and vibration and allow for smooth operation of fhe instrument. 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 as where the follower is just starting on the down slope of the cam lobe. )
3.
4.
5.
6.
7.
8.
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9.
Install all other test gear. All pressure and temperature measurements must be taken at the cylinder nozzles (flanges) and at the valve caps when connection taps are available. Start the unit, and when the normal operating speed is achieved, readjust the breaker point setting. By use of the timing light, adjust the points so that the #2 HEDC mark on the flywheel is exactly in line with the pointer. Check out all instrumentation to ascertain that it is functioning properly. Allow the unit to reach operating temperatures and then load the compressor. Adjust the suction and discharge conditions as close to design conditions as possible. Allow the unit to continue running until the operating conditions stabilize. Dismantle and clean the diaphragm pressure pick-ups. Reassemble using new diaphragms 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 to 3 - 5" of water. Use the adjustable spark plug-type pick-up for these low pressures. Install the pick-ups in the first cylinder and begin indicating. Use the spark plug pickup only in the first stage suction and only where pressures are less than 30 psig. Indicate the first stage cylinder(s) of a multistage unit first and progressively work to the higher stages, indicating the final stage cylinder(s) last. The pressure pick-ups will normally function accurately without having to be recalibrated when the cylinders are indicated in this sequence. Any pick-up must be recalibrated when it is moved from a higher stage to any one of the previous stages. For each set of test conditions, indicate the complete unit (all cylinders) twice. This is to assure that good data is achieved. The proper sequence is to indicate the unit starting with the first stage and proceeding to the last stage as described in Paragraph 15. When this first pass is completed, then indicate the second time using the same sequence. 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 used for each end so the cards can be accurately replotted. However, when time does not permit this, both ends may be superimposed on the same card, providing the cards are legible.
10.
11. 12.
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17.
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b. Each P-T card should be properly labeled and contain a suction line, a discharge line, the cylinder end line(s), a minimum of 4 reference pressure Ii nes, and the #2 HEDC line. Always check the timing before plotting each P-T card and again before plotting the $2 HEDC line on the card, The ea center line is of paramount importance d d to the card accuracy and it must be plotted correctly. One degree variation can mean several per cent error in results. c. Pressure, temperature, speed, and engine load data must be recorded with each indicator card and recorded on the ES 4010 data sheet, a sample of which is shown at the end of this standard. Pressures are to be recorded at the cylinder flanges (or preferably at the valve caps when connections are available) using the dead weight tester. For pressures 5 5 PSIG, a mercury or water filled manometer should be used in lieu of the dead weight tester* Temperatures are to be recorded at the same locations as the pressure data using the mercury-in glass or the Fisher Scientific Precision Thermometers inserted directly into the gas stream. Record the speed with 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 HEDC mark is aligned with the flywheel pointer. At this position, the stylus on the indicatir should be in line with the dead center line plotted on the card. If not, the timing has slipped. The data should be voided from this test run and the test repeated. Using the replotter, replot each P-T card into a pressure-volume (P-V) diagram. Each cylinder end should be plotted on a separate sheet. The total area of the P-V diagram can 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%. Each P-V diagram should contain all of the features as shown on the sample diagram found on Page 8. CAUTION: When replotting, be certain to properly phase the suction and discharge lines with the P-V diagram itself. This is extremely important when analyzing valve losses. Proper setting of dead center is imperative in this process. Once the P-V diagram has been replotted, the BHP, capacity, and valve losses (when required) can be calculated using the following method: a . Scale Factor of P-V diagram: SF = Pr1 - Pr2 d
19.
20.
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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: BHP = IHP EM
where BHP = brake horsepower IHP = indicated horsepower EM = mechanical efficiency (0.95)
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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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i.
Capacity pumped by applicable cylinder end: Qs = QA x Pt Psc x Tsc TS x 1 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 QS
where BHP = brake horsepower used by cylinder end QS = capacity pumped by cylinder end (MMSCFD) k. Valve losses in each cylinder end: SVL = ASVL A DVL = ADVL 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 of which is shown at the end of this standard. Prepare a written report to describe the test results and include all P-T cards, P-V diagrams, data sheets, and calculation summary sheets arranged in a logical sequence.
23.
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Balanced Pressure Indicator Test - Data Sheet

Customer Location Register No. Cyl. #1 Serial No. Cyl. #2 Serial No. Cyl. #3 Serial No. Cyl. #4 Serial No. Test Number Indicator Card No. Time Stage Cylinder No. (Throw) Cylinder Diameter (in.) DA/SAHE/SACE HE/CE VVP opening (in.) PS (PSIG - D. W. T.) PD (PSIG - D. W. T.) TS (F) TD (F) PB (PSIA) Tamb. (F) Speed (RPM) Eng. MNFLD ("HG) Governor Dial Frame Serial No. Cyl. #5 Serial No. Cyl. #6 Serial No. Cyl. #7 Serial No. Cyl. #8 Serial No. Date Test Data by
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Balanced Pressure Indicator Test - Calculation Summary

Customer - Location Register No. Test No. RPM Stage Cylinder Diameter (in.) Area C. E. (in.2) Area H. E. (in.2) Disp. C. E. (CFM) Disp. H. E. (CFM) MEP C. E. (PSIA) MEP H. E. (PSIA) BHP C. E. BHP H. E. BHP Total Pt C. E. PSIA Pt H. E. PSIA Barometric Press. (PSIA) Vol. Eff. C. E. (%) Vol. Eff. H. E. (%) Capacity MMCFD-Qa C.E. Capacity MMCFD-Qa H.E. Capacity MMSCFD - Qs C.E. Capacity MMSCFD - Qs H.E. Capacity MMSCFD QsCE + QsHE BHP/MMCFD @______PSIA, F BHP/MMSCFD @ 14.7 PSIA, 60F Date Test Data by
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Table 1
Item 1. Precision balanced pressure indicator pickups, and associated cables & hoses. 2. Pressure transducers, Type 4-317-0001; 0-100 psig; 0-500 psig; 0-1000 psig 3. Transformer, voltage stabilizing 1 KVA 4. Pressure gages, 0-1500 psig and 0-100 psig 5. Hand revolution counter 6. Timing light 7. Multi-purpose meter (VOM) 8. Dead weight tester 9. Thermometers, precision dial and mercury-in-glass 10. Replotter, indicator card Manufacturer N. L. Miller, Houston, Texas Consolidated Electrodynamics Corp. General Electric Seeger Hasler --Simson Ametak/Mansfield-Green Fisher Scientific N. L. Miller, Houston, Texas
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ES 4100 Compressor Field Performance Test Specification

1.0 Scope
This standard outlines the requirements, procedures and calculations necessary to perform, interpret and properly report field performance tests on Ajax, Superior or Joy reciprocating compressors and to ensure that results are valid.
2.0 Purpose
2.1 The requirements of this specification are mandatory where verification of guaranteed compressor capacity and/or power by field testing is required by the customer. 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 operating problems or discrepancies, such as valve plate or spring failures, pulsation-induced vibration, high discharge temperature, low capacity, low efficiency (BHP/MMSCFD) or driver overload. Supplemental specifications ES4101 and ES4102 provide general requirements for field performance test instrumentation and for analysis and interpretation of results.
2.2
2.4
3.0 Pre-Test Requirements

3.1 Preliminary Investigations
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3.1.1 Prior to undertaking a field performance test, it is important to review the units operating history and the process which the compressor supports. This can uncover errors that may invalidate the test. In the case where a test is to be conducted to evaluate an operating problem, this review may uncover the actual problem without expending the time and expense involved in a rigorous performance test. Preliminary investigations should focus on a number of areas as listed in paragraphs 3.1.2 through 3.1.9. Many of these investigations can be made by plant operations or maintenance personnel, with direction from AjaxSuperior technical representatives. 3.1.2 Process piping should be inspected for errors, faulty valves and improperly sized valves. 3.1.3 A recent gas sample should be analyzed to assess whether the compressor is working with a gas composition that is the same as, or at least similar to, the gas on which performance curves and or representations were based. 3.1.4 Recent plant operating log sheets should be reviewed and operating conditions compared with the performance curves. 3.1.5 Since performance is represented at the compressor flanges and based on suction flow, look for excessive system pressure drops before and after the individual compressor cylinders. Investigate whether the operators have checked and cleaned piping screens, and determine what the history of cleaning has been. 3.1.6 Verify whether the specified clearance plugs, valve spacers and other clearance devices are installed and adjusted according to the performance curves. 3.1.7 Investigate whether suction pressure is stable or varies with time, as compressor throughput is very sensitive to suction pressure. 3.1.8 Particularly in services other than gas transmission, investigate whether there are 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 that flow is accurately measured upstream of the compressor. 3.2 Verify Compressor Mechanical Condition 3.2.1 For design confirmation and performance guarantee demonstrations prior to conducting a performance test, it is important to confirm that the compressor and 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, deteriorated compressor valves or other wear that can adversely affect performance. Even new compressors should be checked, since it is possible that dirt or other foreign material, ingested at the time of process start-up, can cause rapid and premature deterioration of cylinder internal components. 3.2.2 The checks listed below in paragraphs 3.2.3 through 3.2.10 will require a significant amount of time and labor prior to the test. However, they will generally save time overall. a. These inspections shall be mandatory prior to conducting a performance test for the purpose of verifying a performance guarantee with standard three percent tolerance. b. These inspections are recommended prior to conducting a performance test for reasons other than verifying a performance guarantee. Failure to perform them may lead to costly repeat testing, after remedial mechanical corrections are completed. It is recognized that it may not be feasible to make every check in all cases; however, exceptions must be made with care and with consideration of the risk of invalidating the performance test results. c. Where previous maintenance analyzer records have been maintained, skilled technicians may be able to verify the condition of compressor cylinders through the use of a maintenance analyzer, rather than by physical checks. This approach may 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 seats or guards with flaws must be reconditioned, and new plates and springs installed where needed. Valve cap O-rings should be carefully checked and replaced if there is any sign of mechanical or chemical distress. 3.2.4 Inspect valve pocket bores in the cylinders for damage which might lead to external 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 one piston per stage must be removed so that the rings can be inspected to ensure that 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 cause leakage 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 and inspected similarly. Cylinder bore damage should be honed smooth, if minor. If
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cylinder bore damage is substantial, other reclamation procedures or cylinder replacement must be considered. 3.2.6 Packing ring condition must be checked to make sure that the rings, case and piston rod are in good condition and wont cause abnormal or excessive leakage. Check the packing drain/vent for leakage and the crosshead guide packing cavity for gas leakage and ring debris. Verify that the packing is receiving proper lubrication and is properly aligned. Worn or damaged components must be repaired or replaced as appropriate. 3.2.7 With the compressor operating, check the variable volume pocket (VVP) balance line for high temperature. If the temperature is high, the VVP piston ring may be broken or worn, requiring inspection and repair. The scale readings on each VVP should be verified. The VVP must be screwed all the way in and the position of the 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 using the procedure specified in ES4009 (contact Superior Marketing). Usually, this should 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 the procedure specified in ES4008 (contact Superior Marketing). 3.2.10 All unloading devices should be cycled to check for proper operation. In cases where oil or dirt may be trapped in an unloader, it should be drained or cleaned as 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 properly open 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-out during operation. If drop-out is evident, this will have to be measured during the actual 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 it measures, e.g., suction or discharge. Note that Ajax-Superior performance curves and 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 a performance guarantee, there should be agreement between Cooper and the customer as to the guarantee or design point(s). If the customer will not be able to run the guarantee or design condition, there should be prior agreement on the conditions 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 start of testing. Flow meters should meet AGA standards or equivalent. It is generally the customers responsibility to provide this verification. The method of calculating flow 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 be installed before and after each stage as close to the cylinders as possible. It may also be necessary to install pressure gauges at various points in the gas system to determine the magnitude and location of system pressure drops. a. The range of each gauge should be properly selected for the operating test conditions. See ES4101 (contact Superior Marketing) for specific recommendations. b. Each pressure and temperature gauge must be calibrated in the range for which it will be used in the test. See ES4101 for specific recommendations. c. An official record of each devices calibration should be documented for future reference. 3.4.4 Provision must be made for a gas sample during the test. This should be obtained in a pre-purged sample bottle and the composition analyzed as soon as possible in a lab. Preferably, gas samples should be obtained both upstream and downstream of the compressor if drop-out is suspected. In some cases where drop-out is substantial (more than one percent of mass flow) it is necessary to obtain samples after each scrubber, as well as at the first cylinder suction. Samples should be taken from locations that will prevent dirt and liquid contamination of the gas sample. a. Where available, station on-line gas analyzers can be used to take continuous samples. In such cases it is important that the analyzer samples the actual gas in the same condition as it passes through the compressor suction (i.e., not after mixing 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 will not be indicated. Visual observations of scrubber drains and inside the compressor intake (with the compressor shut down and depressurized) will need to be made to ascertain whether the gas is really dry or saturated. This information must be noted on the test log sheet and the gas composition will have to be adjusted for any water content prior to determining the final compressor performance from the test data. 3.4.5 Verify the presence of, and add as necessary, cylinder indicator passages and appropriate analyzer connections and valves per ES4101 (contact Superior Marketing). Most Ajax-Superior cylinder bodies have test ports at the suction and discharge flanges of the cylinder and on the horizontal center line of the cylinder to read internal pressures during the compression cycle. WARNING: Adding any drillings or weldments to, or otherwise modifying, compressor cylinders, piping or pressure-containing vessels or components must be done with proper consideration of the effects on mechanical strength and integrity, certification requirements and safety. Improper alteration of pressurized vessels or components can result in explosions, damage to equipment, and injury or death to personnel. a. Some forged steel cylinders do not have internal indicator test ports. Consult Ajax-Superior Engineering for recommendations if it is necessary to field test such cylinders. b. With the compressor shut down and cylinders de-pressurized, remove plugs from each indicator connection and insert a wire into the passage to ensure that it is actually present and clear. c. If a suction oil flushing system is present, the flange port may not be available for testing. If this is the case, the flushing system can be temporarily disconnected during the test, or a suction bottle port can be used instead if there is no restriction, such as an orifice, between the suction bottle port and the compressor suction flange. 3.4.6 Indicator test ports should also be installed in suction and discharge bottles and accompanying piping. These are used to measure pressure drops and to investigate any pressure pulsations that may be present during operation. For diagnostic 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 and pulsation levels across these restrictions can be measured. Obtain details of each internal 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 be installed at each test port. Full-ported ball valves are preferred and must have a pressure rating higher than the cylinder working pressures. Kiene valves and needle valves should not be used, as they have internal flow restrictions that tend to dampen the pressure signal causing inaccurate indicator results on most high speed compressors. 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 should be done with the compressor shut down and depressurized. 3.4.8 A drive coupling, connected to the end of the compressor crankshaft, must be provided for the rotary encoder. This must be a torsionally rigid coupling as explained 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 is particularly important for accurate performance assessment on compressors with suction pressures below 300 psi. This may require taking a barometer to the site. Barometric pressure readings reported by airports and radio stations are usually corrected to sea level and thus are not valid for use in calculating compressor performance, unless properly readjusted to site conditions. For compressors driven by Superior CleanBurn gas engines with CleanBurn II airfuel control panels, the barometric pressure read-out in the panel may be used if no other barometric pressure indication is available. 3.4.11 Prepare a set of log sheets. Generally, the standard log sheets provided in ES4102 should be used (contact Superior Marketing). 3.4.12 Identify the personnel who will be involved in performing the test. Determine each persons role and review the test procedure with them. Make a dry-run of all tasks before actually starting the test. Make sure that assignments are clearly understood so that testing time can be minimized and conditions can be held stable 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 customers, operators and owners safety procedures with cognizant site personnel. 3.5.2 Always make sure that the above safety procedures are followed during the actual testing. 3.5.3 Prior to testing, review equipment instruction manuals and become generally familiar 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 personnel to risk of injury or death, or plant machinery or other equipment to damage.
4.0 Indicator Test Measurement Standards, Instrumentation & Equipment

4.1 See supplemental standard ES 4101
5.0 Test Procedure & Requirements During The Test

5.1 Analyzer Set-Up 5.1.1 Transducers must be calibrated using a dead weight tester (See ES4101) before each test run and after each transducer change. Care should be taken to ensure that the transducer is calibrated across its range and that the range is appropriate for the pressure being measured. Also, the transducer must be a cooled type to reduce 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 doesnt have to be moved during testing. 5.2 Gas Samples 5.2.1 When testing with a suction flow meter, a gas sample should be taken just up stream 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 the suction line before the compressor (prior to any scrubbers or vessels) and in the
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discharge line just prior to the meter to determine if the gas compositions are the same. If they are not, then liquid has probably dropped out during the compression 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 are draining liquids, then liquid drop-out is occurring and must be measured or otherwise accounted for in the test results. 5.3.2 To measure the drop-out, the scrubber manual dump valves can be closed when starting the test. This will allow the drop-out to collect in the scrubber. For a measured period of time at constant operating conditions, by marking the starting position and ending position of the liquid levels, and by knowing the internal diameter of the scrubber (for cylindrical vessels), the liquid volume drop-out rate can be calculated. 5.4 Bypass Valves 5.4.1 Using a temperature sensing device, make sure that the system bypass is not leaking. If the bypass line temperature changes significantly from when the compressor is not running, then the bypass valve is probably leaking and the test results will be invalidated. An ultrasonic transducer can also be placed on the bypass valve during the test to check for leakage. 5.5 Stable Operating Conditions
Table 1
5.5.1 During the data collection phase ALLOWABLE DEVIATIONS described in section 5.7, the Variable Allowable operating conditions must not Deviations vary significantly for the duration Average suction pressure +/- 1% of the test. The data must be Average discharge pressure +/- 1% Suction temperature +/- 2F within the allowable deviations Speed +/- 0.5% listed in Table 1, which are based Cooling water inlet temperature +/- 2F on SGA-PCRC 84.10a. If conditions Cooling water flow rate +/- 3% Metering temperature +/- 3F vary more than this amount, the accuracy of the test will be compromised and it will have to be rerun.
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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 the stable 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 stage pressures, temperatures, etc. are known. This may require an extra person for recording this data. 5.7.2 Each cylinder should then be indicated, taking pressure-volume (P-V) cards as a minimum. a. When using the ENSPEC 3000 or 1400, the transducer is first attached to the suction line, then the discharge line and next the head end (HE). Then the transducer 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 discharge traces are located reasonably and the IHP is close to that expected. If any aspect of the card is suspect, the measurement equipment should be checked and the test rerun. 5.7.3 It is often advisable to take pressure-time (PT) cards in the HE and CE valve pockets to study valve opening and closing events. 5.7.4 PT cards should be taken on the suction and discharge if excessive pulsation is suspected. These traces will aid in determining the significance (frequency and amplitude) of the pulsation. 5.7.5 Additional PT cards can be obtained at various points, such as in pulsation vessels, before and after vessels, etc., to check for pulsations. 5.7.6 When investigating pulsations, indicator cards should be taken as close to the compressor valves as possible, i.e., in the cylinder body through the suction and discharge flanges and through the valve caps. 5.7.7 The distance from the measured pressure to the transducer should be as short as possible and the fittings should conform to the requirements shown in ES4101.
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6.0 Analysis & Interpretation of Results

6.1 See supplemental standard ES 4102
7.0 Reporting Of Results

7.1 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 documented observations. The report should include copies of important indicator cards, log sheets, calculated data and other pertinent information that will allow the reader to understand how the test was run and to interpret the results. 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.
7.2
7.3
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ES 4101 Ajax-Superior Compressor Field Performance Test Instrumentation

1.0 Scope
1.1 This standard defines the instrumentation required to accurately do field performance tests on Ajax, Superior, or Joy reciprocating compressors. Calibration procedures for the instrumentation are also listed. This standard is a supplement to ES4100, Ajax-Superior Compressor Field Performance Test Specification.
1.2
2.0 Purpose
2.1 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. Testing procedures are listed that will insure accurate performance data. Techniques for operating analyzers vary between analyzer manufacturers. Unless otherwise noted, the procedures listed are for the Entronics En-Spec 1400 and EnSpec 3000 analyzers. The required accuracies and calibrations apply, however, to indicating testing done with analyzers from any manufacturer.
2.2 2.3
3.0 Compressor Analyzers

3.1 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 then be saved and processed by a microprocessor which is part of the analyzer. The results can 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 a function of crank angle. Analyzers use the compressor dimensions to calculate the swept volume at each angle reading and then produce pressure-volume diagrams and calculate compressor horsepower. Pressure-crank angle plots are also made to determine system pressure drops and gas pulsations. The analyzer records the cylinder and nozzle pressures in relation to the crankshaft position and a starting point or out dead center is required.
3.3
4.0 Out Dead Center

4.1 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 in either the flywheel or coupling hub. The pin or hole should be located in the largest diameter available. With a large diameter, out dead center is easier to locate accurately and the higher velocity at this point will generate a stronger signal for the analyzer. Out dead center is established according to Superior Engineering Standard ES 4009. Out dead center must be accurately located. A one-degree error in out dead center will typically result in a three percent error in indicated horsepower. For a 12inch diameter coupling hub, one degree is only 0.1 inch of travel around the hub. It has been suggested that bearing clearance could cause the out dead center during running to be different than the out dead center found using ES 4009. Superior did laboratory testing to compare both methods and determined that out dead center did not change on either the Ajax or Superior units.
4.2
5.0 Encoder
5.1 The speed of a compressor changes throughout each revolution due to the torque change within each revolution. To obtain accurate pressure-volume cards, an encoder 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 equal time intervals cannot compensate for the speed change within each revolution. The encoder drive must be attached to the compressor crankshaft; friction drives can slip and cause errors. A torsionally rigid coupling is used to connect the encoder to the compressor crankshaft drive. Sections of rubber or plastic tubing will not allow accurate phasing. The encoder shaft must be parallel to the crankshaft to
5.2
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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 drive shaft is provided that permits driving an encoder on the free end of the shaft. The crankshaft to drive coupling must also be torsionally rigid. The Thomas Style CC, Size 62 flexible coupling supplied by Superior is recommended for the crankshaft to drive coupling. An adaptor must be used between the lubricator drive and the encoder coupling due to the different shaft sizes. The encoder drive assembly for an SW frame with a lubricator drive off the end of the crankshaft is shown for reference in Figure 1 and its bill of material in Table 1.
5.4
5.5
Table 1
Bill Of Materials
Item 1 2 3 4 5 6 Description Drive on crankshaft Thomas size 62 coupling Lubricator drive Drive adaptor Encoder coupling Encoder 1/2" to 1/4" Renbrant 1/4" x 1/4" 1440 pulses/rev. 1/2" lubricator shaft 5/8" lubricator shaft Comments Part Number ---B-909-524-00 B-909-524-002 ------C25C25S ----
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Compressor Cylinder Technical Data Book Figure 1
Encoder drive arrangement when lubricator is driven from the crankshaft.
6.0 Pressure Pickups

6.1 Pressure pickups must be accurate and stable. Accuracy and stability are affected by linearity, hysteresis, repeatability, resolution, thermal zero shift and thermal sensitivity shift. Non-linearity will cause inaccurate readings since the analyzers use a calibrated pressure at one point or an input of a known millivolts per psi. The analyzer then uses a linear fit to determine intermediate pressures. Pickups should be checked for non-linearity using a dead weight tester to pressurize the pickup and with output readings taken throughout the pickup pressure range. Hysteresis results in an output that is dependent upon the direction of pressure change. Due to the construction of the pickup, increasing pressures will read lower than actual and decreasing pressures will read higher than actual. Hysteresis and non-linearity are normally listed as a percent of the full scale reading of the pickup and combined, they should not be greater than 0.35% of the full scale reading.
6.2
6.3
6.4
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6.5
Repeatability is a measure of how accurately the pickup can duplicate an output and is 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. Resolution of strain gage pickups is infinite; however, the resolution of the digital analyzer is not. The analyzer resolution is discussed below. Thermal zero shift is the shift in the output voltage at zero pressure as the pickup temperature changes, and can be a source of error since the pickup will normally be used at a different temperature than the calibration temperature. Thermal zero shift should not be greater than 0.015 percent of the full scale reading per degree Fahrenheit of temperature change. Thermal gain shift is the shift in the sensitivity or gain of the pickup as the pickup temperature changes and is also a source of error due to the fluctuation in operating temperature. Thermal gain shift should not be greater than 0.0075 percent of the full scale reading per degree Fahrenheit of temperature change. Non-cooled pickups can be temperature compensated to reduce thermal gain shift and zero shift; however, for indicating, cooled pickups should always be used. Cooled pickups can be designed for either liquid coolant or air/inert gas cooling. Calibrations should be done with the coolant on.
6.6
6.7
6.8
6.9
6.10 Using pressure pickups with a range far greater than the pressures measured results in using only a small portion of the pickup and analyzer range. The analyzer is a data acquisition system and therefore uses the full range of the pickup being used and divides that range into increments depending on the design of the data acquisition system. A 12 bit D.A. system would divide the full scale voltage into 4096 steps. For a 2000 psi pickup, pressure can be measured in 2000/4096 or 0.49 psi steps. A 500 psi pickup can measure in 0.12 psi steps. 6.11 Precise Sensors Model 70222 pressure pickups for the En-Spec analyzers are available in the following ranges: 500, 1000, 1500, 2000, 3000 and 5000 psig. Precise Sensors model 141-1 pressure pickups are available for measuring low pressures. For maximum accuracy, always use the lowest pressure range pickup suitable for the measured pressure.
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6.12 Pickups should be calibrated using a dead weight tester. Several calibration techniques are available for the En-spec analyzers. The following calibration is recommended 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 than four 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 the maximum 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 obtained above. 6.12.4 With the analyzer in the pressure gage mode and using the dead weight tester, apply pressures in the range to be measured and check the transducer output. Approximately 5 pressures should be checked and any pressure error must not exceed the following: Max Transducer Range (psig) 50 200 500 1500 2000 3000 5000
Max Error (psig) 0.5 0.8 2 6 8 12 20
6.12.5 Provided the transducer error is within the above limits, the millivolts per psi value can be used for the quick calibration. 6.12.6 When the indicating tests are complete the transducer should again be calibrated to insure that the calibration has not changed.
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7.0 Indicator Valves

7.1 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 a quick-change adaptor to speed data taking. The adaptor is normally drilled and valved to permit zeroing the transducer. The adaptor, valving, cylinder drilling and connecting fittings make up the indicator passage. Any restriction in this indicator passage will distort the indicator traces. To keep the distortion to a minimum the connecting piping should be as short as possible and full ported ball valves should be used. The pipe and valve hole size should be as close to the cylinder indicator tube size as possible. Refer to Figure 2 for indicator tube components available from Superior.
Table 2 Bill Of Materials

Item 1 2 3 4 5 6 7 8 Description Drive on crankshaft Adaptor Vent valve Quick connect body Quick connect stem Ball valve Nipple (stainless sch. 80) Cylinder body Comments See Paragraph 6 1/4" NPT for vent valve 7/8"-18 UNS for transducer 1/2" NPT for quick connect 1/4" NPT 1/2" NPT 1/2" NPT 1/2" NPT 1/2" NPT ---Part Number ---A-904-015 A-061-680 A-061-678 A-061-679 A-903-707* A-904-016** 21TN0409SS# ----
* 0-3000 psig @ 100 F ** 3000-6000 psig @ 100 F # Rated for 6250 psig @ 300 F
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Figure 2
3
8 1 2 4 5 6 7
Transducer Piping Arrangement
7.2
The indicator tube valving must not be partially closed to reduce tube resonance and smooth the pressure traces. This restriction will distort the card and result in inaccurate data. 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 must be done with the compressor shut down and depressurized.
7.3
8.0 Indicator Tube Phase Delay

8.1 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 to 1500 rpm showing that if unrestricted indicator tubes are used, the most accurate data is obtained if the out dead center is not rotated. Comparisons were made using cards taken at the indicator tube to cards taken at the same time with a pickup buried in the cylinder. Data should not be rotated to compensate for indicator tube restrictions.
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9.0 Pressure Gages

9.1 Pressure gages are used to establish operating conditions and although performance will be based on pressures recorded by the analyzer, accurate gage pressures are required to set conditions and evaluate pressure drops in the system. Pressure gages should be calibrated using a dead weight tester with at least four pressures checked in the range that will be used during test. Calibration records should be maintained with the other test data.
10.0 Thermometers/Thermocouples
10.1 Thermocouples are available that are accurate to within one degree of the measured temperature and are the preferred method of measuring temperatures for performance testing. Glass thermometers, although fragile, can also be used. Metallic dial thermometers should not be used.
11.0 Barometric Pressure

11.1 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 for local barometric pressure. Barometric pressures that are listed by airports have been corrected to sea level to allow pilots to set their altimeters and must be corrected back to the job site elevation before using for performance tests. The following corrections must be subtracted from the sea level readings to obtain the barometric pressure at the job site:
Elevation (ft) 100 200 500 1,000 2,000 Correction (in. Hg) .108 .216 .537 1.066 2.100 Elevation (ft) 3,000 5,000 8,000 10,000 Correction (in. Hg) 3.105 5.025 7.696 9.344
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11.2
For indicating test where the compressor suction pressure is above 300 psig and therefore changes in atmospheric pressure are small in relation to the measured pressures, the barometric pressure can be estimated by subtracting the above altitude correction from 29.9 inches of mercury.
12.0 Gas Flow

12.1 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 the industry standard. The meter should be located on the suction side of the compressor with pressure taps and distance from valving and elbows as listed in AGA Report #3. The orifice plate should be removed, inspected and measured to an accuracy of .001 inch. The meter pipe diameter should also be measured to an accuracy of .001 inch. When reinstalling the orifice plate, insure that the sharp edge of the orifice is facing upstream. Flowing pressure and orifice differential pressure must be recorded using a calibrated pressure gage and manometer or calibrated transducers. Pressure pulsations at the orifice meter or in the pressure lines will cause the metered flow to be in error. Orifice delta pressure excursions in excess of 10 percent of the average delta pressure should be corrected before testing. This can be done by reducing the pulsation or by installing a smaller orifice plate to increase the average delta pressure across the orifice plate.
13.0 Summary
The accuracy of performance testing requires accurate equipment, careful calibration and diligent testing. It is the responsibility of the analyzer operator to insure that the testing is properly done and that the instrumentation is in good working condition. Any required maintenance should be completed before testing is started.
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ES 4101A Field Performance Test Specification

1.0 Scope
This standard lists the steps required to record compressor cylinder pressure volume cards using the EN-Spec 1400 analyzer. The specification is an addendum to ES 4100 and ES 4101.
2.0 Purpose
2.1 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 consistent method for taking field data that have the required accuracy to address field performance guarantees. Instructions for operating the En-Spec 3000 are included in the En-Spec 3000 operating manual.
2.2
3.0 Procedure
3.1 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 Setup

4.1 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.
Action POWER ON YES YES Display [0.0 % IDs used] [0.0 % Memory used] [10-10-94 8:30] [Mode?] Action EXIT
Display [Blank] [Clear all memory?] [Clear all memory?] [Are you SURE??]
KEYBOARD DATA ENTRY
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Enter the following data for up to 40 cylinder ends:

Display [Eng _ 1 /01C] [Enter Engine ID] [Eng _ 1 /01C] [Enter Cyl ID] [Eng _ 1 /01C] [New ID-Continue?] [Degs. Outer Dead] [Center _ 0.00] [Sample Size] [10 to Rpm]] [Comp. Bore] [XX.XXX Inches] Action XXX/XXC (or H) ENTER XXX/XXC (or H) ENTER YES X.XX ENTER 10 ENTER 10-10-94 8:32 XX.XXX ENTER Display [Comp. Rod Dia.] [X.XXX Inches] [Main Rod Length] [XXX.XXX Inches] [Radius] [XX.XXX Inches] [Do Valve Losses?] [YES/NO X] Action X.XXX ENTER XXX.XXX ENTER XX.XXX ENTER YES ENTER Repeat keyboard data entry until all cylinder ends are entered into the EN-Spec 1400
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5.0 Pickup Calibration

5.1 The following assumes that the identities have been loaded into the EN-Spec 1400 and that you are starting with the analyzer off:
Display Blank [Clear all memory?] [Clear memory by engine number?] [Clear memory by cylinder number?] [XX.X % IDs used] [XX.X % memory used] [10-10-94 8:34] [Mode?] [Apply 0 PSI] [Push Enter] [Remove pickup and push Enter] [Transducer Range] [PSI ? XXXX.]
Action POWER ON NO NO NO EXIT DEADWEIGHT CALIBRATE ENTER ENTER XXXX. ENTER
Display [Enter PSI you can supply XXXX.] [Apply XXXX PSI] [Push Enter] [Trans. Sens.] [X.XXX Push Exit] [10-10-94 8:36] [Mode?] [Remove and zero Transducer] [Remove pickup and push Enter] [Actual 0] [Lo 0 Hi 0]
Action XXX ENTER XXXX ENTER [EXIT] **Record sensitivity for future reference PRESSURE GAUGE ZERO TRANSDUCER ENTER
Using the dead weight tester, apply pressure to the pickup in the range the pickup will be used. Five pressures in this range should be checked. The pressure reading on the En-Spec should agree with the dead weight tester within the limits listed in 6.12.4 of ES 4101. If the pickup is acceptable, the millivolts per psi number that were determined during calibration may be used with the QUICK CALIBRATE feature of the analyzer. If this feature is used, the pickups should be deadweight calibrated at the end of the test to insure that the calibration has not changed.
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6.0 Taking Pressure-Volume Cards

If different pickups are being used, the calibration must be re-entered using QUICK CALIBRATE. 6.1 Calibration Action QUICK CALIBRATE XXXX ENTER X.XXX ENTER Display [Remove Transducer] [Push Enter] [Calibration] [Done. Push Exit.] Action ENTER EXIT
Display [12-12-94 8:40] [Mode?] [Transducer Range] [PSI? _XXXX] [Trans. Sens.] [MV/V?] 6.2
Begin taking cards (including nozzle traces). Action USE PRELOADED DATA START ZERO TRANSDUCER START Display [Working] [Remove and zero] [Transducer] [Connect Trans. to Cyl. Push Start] [Working] [Remove and wait for results] ZERO TRANSDUCER START 1HP = XX.XX SPEED = XXXX.XX ENTER ZERO START Action
Display [12-12-94 8:40] [Mode?] [Eng X /XXC] [Ready to start] [Remove and zero] [Transducer] [Connect Trans. to Suc. Push Start] [Working] [Remove and zero] [Transducer] [Connect Trans. to Disch. Push Start] 6.3
Using preloaded data, continue indicating the remaining cylinders.
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ES 4102 Analysis And Interpretation Of Compressor Field Performance Test Results

1.0 Scope
This standard provides guidelines for analyzing and interpreting the results of compressor field performance tests. Section 3.0, On-Site Review of Indicator Cards, is an in-process check 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-process check be performed so that data quality problems may be quickly resolved and repeat testing avoided. Section 4.0, Indicator Test Data Analysis and Troubleshooting, is a basic approach to interpretation of indicator cards. A step-by-step procedure is provided for preparing the measured indicator card for comparison to the ideal case and sample indicator cards illustrating more common problems.
2.0 Purpose
2.1 This standard is intended to be used with Engineering Standards 4100 and 4101, AjaxSuperior Compressor Field Performance Test Standard and Test Instrumentation. Section 3.0 shall be used during all compressor performance tests. Section 4.0 should be used for basic interpretation of indicator cards. If an unusual or special condition exists that is beyond the scope of this standard, the AjaxSuperior Engineering Department should be consulted.
2.2 2.3
3.0 On-site Review Of Indicator Cards

3.1 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 affect the quality and usefulness of the data can be easily corrected such that the tests may be 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 problems and the necessary corrections. Figure 3.1 is a data sheet that should be used to record pertinent information during each indicator test. Figure 3.2 is an example of a typical pressure volume (P-V) diagram that can be used to compare with abnormal P-V diagrams shown in this standard. 3.1.1 Measurement Channel Restriction - Excessive flow restriction in the pressure measurement channel produces indicator diagrams of marginal usefulness. Figure 3.3 is an example of a P-V diagram exhibiting excessive restriction in the measurement channel. As can be seen in this figure, the corners are rounded and very few, if any, pressure pulsations are evident. Channel restrictions may be present anywhere along the length of the passage, from the internal cylinder pressure port through the adapters, fittings and valves up to the transducer. Refer to Engineering Standard 4101 for more details on causes and corrections. 3.1.2 Measurement Channel Pulsation/Resonance - The gas dynamics between the interior of the cylinder pressure port and the measurement transducer can produce significant distortion of the apparent dynamic cylinder pressure. These dynamic effects range from quarter-wave acoustic resonance of the indicator passage to a time lag between the pressure in the cylinder and sensing of the pressure by the transducer. The recommendations provided in Engineering Standard 4101 are intended to minimize the effect of channel resonance. An example of a pressure time (P-T) curve with channel resonance is shown in Figure 3.4. A manual technique to filter-out the channel resonance is also shown in this figure. Channel resonance should not be confused with external piping and bottle pulsations which is covered 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 externally caused pulsations occurring in the cylinder and signs of abnormal valve action. If an abnormal condition is suspected that can not be explained as channel 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 reviewing the P-V diagram for evidence of a shift in cylinder suction and discharge
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pressures compared to the normally expected pressures in the suction and discharge flanges. Figure 3.5 shows a P-V diagram where the pressure transducer drifted upward. This causes the suction toe pressure to appear to be higher than the suction pressure trace and the discharge toe pressure higher than the discharge pressure trace. The discharge valve loss appears to be abnormally high. In this example the drift was found to be caused by improper cooling of the pressure transducer. It is very important to eliminate transducer drift to allow proper diagnosis of compressor performance. 3.1.4 Incorrect Pressure Transducer Range - Inaccurate or distorted pressure data can be caused by the use of a pressure transducer with a range inappropriate for the pressures to be measured. Figures 3.6 and 3.7 show pressure transducers whose ranges are too low and too high for the pressures being measured. Refer to Engineering Standard 4101 for specific recommendations for selecting pressure transducers of the correct range. 3.1.5 Incorrect Out Dead Center Reference - An incorrect Out Dead Center reference is a common problem. If the error is sufficiently large it can be detected by inspecting the indicator cards. Small errors may not be easily detected by inspection of the cards although they can create significant errors in the apparent performance of the compressor. It is very important to set the Out Dead Center reference accurately and in a manner that provides accurate dynamic reference signals. Refer to Engineering Standard 4101 for more 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 Troubleshooting

This section to be provided in a future revision
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Figure 3.1 Indicator Test Data Sheet

Customer Location Register No. Cyl. #1 Serial No. Cyl. #2 Serial No. Cyl. #3 Serial No. Cyl. #4 Serial No. Driver Model Serial # Test Data By Frame Serial No. Cyl. #5 Serial No. Cyl. #6 Serial No. Cyl. #7 Serial No. Cyl. #8 Serial No. Date
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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Figure 3.2 Typical PV Diagram
Clearance Volume (including pockets) Discharge Volume 2 Pd 3 Discharge valve closes Minimum cylinder volume Discharge valve opens
PRESSURE
Re-expansion
Compression
Suction Intake Volume Suction valve opens Ps 4 Piston displacement of swept volume Total cylinder volume (including pockets) Suction valve closes Maximum cylinder volume 1
VOLUME
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Figure 3.3 PV Diagram with rounded corners, indicating excessive channel restriction or pressure transducer with a slow response time
Clearance Volume (including pockets) Discharge Volume
The indicated horsepower is less than the actual
Pd Discharge valve closes Minimum cylinder volume PRESSURE
Discharge valve opens
Re-expansion Suction Intake Volume
Compression
Suction valve opens Ps
Suction valve closes Maximum cylinder volume
Piston displacement of swept volume Total cylinder volume (including pockets)
VOLUME
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Figure 3.4 PT Curve with channel pulsations/resonance manual correction shown by drawing envelope lines and finding average curve
1350
Envelope TDC Average curve P2 Actual P2 1134 psig Envelope Actual P1 610 psig P1
PRESSURE (PSI)
750
900
1050
1200
Envelope
600
Average curve Average curve

-150 -120 -60 0 60 120
450
150
TDC ANGLE (DEGREE)
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Figure 3.5 Typical P-V Diagram indicating pressure transducer drift
Pd Indicated Pd predicts excessive valve loss
Discharge valve closes Minimum cylinder volume
Re-expansion PRESSURE Suction Intake Volume Suction valve opens
Compression
Ps Indicated Ps predicts zero valve loss Piston displacement of swept volume Total cylinder volume (including pockets)
VOLUME
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Figure 3.6 P-V Diagram indicating a pressure transducer with a range too low for the pressures measured
Gap in pressures
Pd
PRESSURE
Re-expansion Suction Intake Volume Suction valve opens Ps Piston displacement of swept volume Total cylinder volume (including pockets)
Compression
VOLUME
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Figure 3.7 P-V Diagram indicating a pressure transducer with a range too high for the pressures measured
Valve losses indicated horsepower toe pressures erroneous
Pd
PRESSURE
Compression Re-expansion Suction Intake Volume Suction valve opens Ps Suction valve closes Maximum cylinder volume
Piston displacement of swept volume Total cylinder volume (including pockets)
VOLUME
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ES 5011 Hydrostatic and Helium Test of Compressor Cylinders, Cylinder Heads, and Valve Covers
1.0 Scope
This procedure outlines the necessary operations required for hydrostatic and helium testing compressor cylinders and other related pressure retaining components which, when secured to the cylinder, can be considered as part of the cylinder or part of an unfired pressure vessel.
2.0 Requirements
Compressor cylinders and pressure retaining auxiliary parts, which are secured to the cylinder, 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 Cylinder (gas wetted surfaces) (MAWP) Test Pressure 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) Bonnets and/or clearance pockets (MAWP) (gas wetted surfaces) (See Note) Cylinder (Water Jackets) Superior Cylinder (Water Jackets) Ajax Cylinder (Water Jackets) 1.5 times maximum allowable working pressure 1.5 times maximum allowable working pressure 115 PSIG minimum - 150 PSIG maximum 115 PSIG minimum - 150 PSIG maximum 100 PSIG minimum - 115 PSIG maximum
Note: For bonnets/unloaders, blueprints will designate if specific areas are to be hydro tested and any specific pressure requirements for these areas. The part number drawing denotes the required test pressure for each cylinder or component and should be reviewed before each test. Compressor Performance Data Sheet (Form 1041-4) can be consulted for maximum allowable working pressure (MAWP) and required hydrostatic test pressures on individual jobs. Engineering should be contacted for any discrepancies or questions on test pressures, or if data sheet pressures do not agree with the pressures indicated on the part number drawing.
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3.0 Hydrostatic Test Procedure

3.1 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 some instances, such as after rework and/or special request, the hold time and/or pressure may be increased (see ES5026 and ES5016). Note: For valve covers (caps) only, the test period is fifteen (15) minutes minimum. 3.2 3.3 3.4 The test pressure is specified in Section 2 and also on each component drawing. All surfaces to be inspected for leaks should be dry prior to inspection. Inspection is performed with a flashlight, mirrors, and/or fiberscope, and is a visual check for evidence of water leaks. No leakage is allowed. In the case of leaks around the quill (when a quill is used), the quill is re-tightened, the unit is blown clean, wiped dry, and retested. Any leakage into the bore, into the gas passages, into water jackets, or out of the body results in cause for rejection. When customer specifications do not prohibit impregnation, cylinders which leak within the limits established by Engineering Standard ES 5026 can be impregnated per ES 5026. Cylinder must be re-hydrotested and helium or air tested after impregnation per ES 5026. All testing data is to be recorded on Form SI 411. Joints are to be sealed, where possible, with gaskets as designed and specified on the Bill of Material. Common, readily available joint sealing compounds can be used in the event of joint leakage problems. Cylinder bodies are to be stamped TESTED to identify acceptance of hydrostatic testing. They should not be stamped if they leak. All cylinder bodies and all cast iron, nodular iron, and cast steel compressor heads/ unloaders, bonnets, valve caps, unloader bottles, and other pressure retaining components must be tested on all gas wetted surfaces. Therefore, the component is either tested in a cylinder or in a pot fixture which allows water pressure to reach all gas wetted surfaces. Compressor heads and all other pressure retaining components are to be stamped TESTED to identify acceptance of hydrostatic testing. They should not be stamped if they leak.
3.5
3.6
3.7
3.8
3.9
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3.10 Parts (other than cylinder bodies) machined from steel plate, bar, tubing, or forgings are exempt from hydrotesting, except those fabricated by welding, where a defective weld joint might leak directly to the atmosphere, or for those heavily machined parts that may have potential problems as deemed by Engineering. All cylinder bodies are to be hydrotested! 3.11 For hydrotesting and air or helium testing, electronic digital pressure sensing instruments (accuracy and capacity to 15,000 psi) are to be used, regardless of the test pressure up to the maximum capacity.
3.12 All pressure gages shall be certified per established frequency.
4.0 Helium Testing

4.1 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 an impregnated 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 blown dry with air. 4.1.2 The pressure test will be performed using helium at the cylinder maximum allowable 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 may occur 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 are stamped with a capital H right next to the tested stamp.
5.0 Air Testing

Air testing can be used in place of helium to air test an impregnated cylinder. The steps used should be the same as in Section 4 above. Impregnated cylinders designated for sour gas applications 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 and thoroughly dried. All unpainted surfaces of the parts will be sprayed with a light rust preventive oil (Tectyl 511-M or equal).
6.2
7.0 Documentation
7.1 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, and test results. All cylinders (rejected and accepted) are recorded in the log. A hydrostatic test data sheet (Form S.I. 411 - Rev. 4) must be completed (see attached) on each cylinder and filed with the register number in the Inspection office. Copies of these can then be provided to Marketing when requested by the Sales Release. When a helium test is performed, the appropriate section of the test sheets is to be filled out. If a unit is considered scrap, a scrap transaction is recorded and the part identified as scrap. If a unit is considered salvageable or meets the impregnation criteria (ES 5026), a Hold transaction is recorded, the part identified as held for salvage.
7.2 7.3
7.4
7.5
8.0 Repair Procedures

8.1 Hold transactions recorded on potentially salvageable rejects should contain the serial number, part number, date, and reason for rejection. These are reviewed by Quality Control and Engineering and the appropriate disposition made. ES 5026 controls the repair procedure for impregnated cylinders and need not have Engineering review. Impregnated cylinders must be hydrotested and helium or air tested per ES 5026 procedures. 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 working pressure of the cylinder body, cylinder head, or other component. In no case shall the water jacket test pressure exceed 200 psig. Retest results are to be recorded in the log and on the test data sheet.
8.2
8.3
8.4
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Ajax-Superior Division/Compressor Plant West Burgess Street Mount Vernon, Ohio 43050
Inspection Form S. I. 411 Date: 3/94 Revision: 3
Hydrostatic and Helium Test Sheet (Tested per ES 5011)

1. Hydrostatic Test Shop Order Number Cylinder Part Number Register Number Serial Number Inspected By Date 2. Hydrostatic Retest Reason for Retest Size Hydrostatic Test Pressure (Gas Passages) Water Jacket Test Pressure Tested By Date Lube Holes Drilled
Hydrostatic Test Pressure (Gas Passages) Inspected By Date 3. Helium Test Helium Test Pressure* (Gas Passages) Inspected By Date
Water Jacket Test Pressure Tested By Date
Tested By Date
* Helium Test Pressure is maximum allowable working pressure as stated on blueprint (unless otherwise agreed to by customer and Quality Assurance Manager, and stated on the Quality Plan).
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Contact Technical Publications Dept. for current version. (937) 327-4279

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5/8"-11 UNC Soc. Head 60-70 Grade 5

1-1/2"-20 UNFFlat Head 35-45 N/A

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