WG

WG Compressor Frame Instruction Manual
Operation,Maintenance, and Parts

Instruction Manual
WG COMPRESSOR SC
FRAME SERIAL NUMBER
WG 00G1
CYLINDER SIZE
XX" 00D
Customer: XX
Table of Contents WG-8/24/03
Cooper Energy Services n Superior Compressor Product Group Page a

WG Instruction Manual
Table of Contents
Section 1
Introduction................................................................................................. 1-1
About this manual ...................................................................................................................................... 1-1
Identifying your compressor frame and cylinder serial numbers............................................................... 1-2
Compressor Frame Overview .................................................................................................................... 1-2
Crankshaft Rotation ................................................................................................................................... 1-3
General Compressor Specifications ........................................................................................................... 1-5
Compressor System Vibration ................................................................................................................... 1-6
Balancing Compressor Frames .................................................................................................................. 1-7
Additional information-website ................................................................................................................. 1-7
Prerequisites ............................................................................................................................................... 1-8
How to use this manual .............................................................................................................................. 1-8
Related Publications................................................................................................................................... 1-9
Standards .................................................................................................................................................... 1-9
Our Quality Policy ..................................................................................................................................... 1-9
Warranty..................................................................................................................................................... 1-9
Section 2
Safety Precautions and Guidelines ............................................................ 2-1
Important safety information...................................................................................................................... 2-1
Note, caution, and danger symbols ............................................................................................................ 2-1
Warning signs and labels ........................................................................................................................... 2-2
Specified precautions ................................................................................................................................. 2-3
Temporary shipping plugs in compressor equipment ................................................................................ 2-3
Compressor frame crankcase rapid pressure relief valves ......................................................................... 2-3
General precautions.................................................................................................................................... 2-4
General maintenance precautions .............................................................................................................. 2-4
Compressor system maintenance precautions............................................................................................ 2-5
Pressurized air and water precautions ........................................................................................................ 2-5
Fluid precautions........................................................................................................................................ 2-5
Asbestos precautions.................................................................................................................................. 2-6
Pipes, connectors, fittings, lines, tubes and hoses...................................................................................... 2-6
Burn precautions ........................................................................................................................................ 2-7
Coolant Precautions ................................................................................................................................... 2-7
Oil precautions ........................................................................................................................................... 2-7
Fire and explosion precautions................................................................................................................... 2-7
Crushing or Cutting precautions ................................................................................................................ 2-8
Mounting and dismounting precautions..................................................................................................... 2-8
Section 3
Lubrication And Cooling ........................................................................... 3-1
Compressor frame lubrication specifications............................................................................................. 3-1
Cooper Energy Services n Superior Compressor Product Group Page c

General specifications.................................................................................................................................3-2
Lubrication system maintenance ................................................................................................................3-2
Compressor Cylinder and Packing Lubrication..........................................................................................3-3
Viscosity requirements ...............................................................................................................................3-4
Application requirements............................................................................................................................3-5
Lubrication Rate .........................................................................................................................................3-6
Force Feed Lubricator....................................................................................................................3-6
Synthetic Lubricants ...................................................................................................................................3-7
Multi-grade lubricants.................................................................................................................................3-7
Additional recommendations......................................................................................................................3-8
Pump per point system................................................................................................................................3-8
Operation of a typical lubrication system ...................................................................................................3-8
Maintenance..............................................................................................................................................3-10
Proportional lubrication system ................................................................................................................3-11
Lubricator Worm And Gear Drive .....................................................................................................3-11
Compressor Frame Lubrication Oil Cooling ............................................................................................3-12
Compressor Cylinder Cooling ..................................................................................................................3-12
Packing Cooling........................................................................................................................................3-13
Coolant Requirements...............................................................................................................................3-14
Corrosion............................................................................................................................................3-15
Scales and sludge ...............................................................................................................................3-15
Cooling system ...................................................................................................................................3-16
Section 4
Sour Gas Compressor Applications...........................................................4-1
General Information....................................................................................................................................4-1
Hazards of Hydrogen Sulfide or "Sour Gas" ..............................................................................................4-1
Concentration Levels ..................................................................................................................................4-2
Trim Requirements .....................................................................................................................................4-2
Hydrogen Sulfide (H2S) Concentrations Up To 2% By Volume ........................................................4-2
Level 1-11p Trim (H2S) Concentrations of 2% - 5% By Volume .......................................................4-3
Level 2-11 p Trim (H2S) Concentrations > 5% ...................................................................................4-3
Enhanced H2S Trim Requirements ......................................................................................................4-4
Section 5
Installation ...................................................................................................5-1
General........................................................................................................................................................5-1
Preparing The Foundation ..........................................................................................................................5-1
Foundation Bolts ..................................................................................................................................5-2
Placement And Leveling ......................................................................................................................5-3
Coupling Installation And Alignment.........................................................................................................5-5
Rexnord Flexible Coupling Torque Values .........................................................................................5-6
Crankshaft Web Deflection..................................................................................................................5-6
Cylinder Mounting......................................................................................................................................5-6
Sliding Rod Through Packings ............................................................................................................5-7
Setting Piston End Clearance ...............................................................................................................5-7
Piston Rod Runout ...............................................................................................................................5-8
Vertical runout tolerances ....................................................................................................................5-9
Page d Cooper Energy Services n Superior Compressor Product Group

Section 6
OperationStart-up ......................................................................................6-1
Startup ........................................................................................................................................................ 6-1
Preparation for Initial Startup .............................................................................................................. 6-1
Initial Startup ....................................................................................................................................... 6-3
Normal Startup .................................................................................................................................... 6-4
Shutdown.................................................................................................................................................... 6-4
Normal Shutdown................................................................................................................................ 6-4
Emergency Shutdown.......................................................................................................................... 6-5
Recommended Operating Conditions ........................................................................................................ 6-5
Section 7
Maintenance ................................................................................................ 7-1
General ....................................................................................................................................................... 7-1
Acceptable Tolerance Clearance Values.................................................................................................... 7-1
Torque Recommendations ......................................................................................................................... 7-2
Critical Bolt Torques ........................................................................................................................... 7-3
Precautions........................................................................................................................................... 7-3
Component Maintenance ........................................................................................................................... 7-4
Base (Crankcase) ................................................................................................................................. 7-4
Crankshaft, Thrust And Main Bearings............................................................................................... 7-5
Connecting Rod And Bearings ............................................................................................................ 7-6
Crosshead Guide .................................................................................................................................. 7-7
Crosshead removal and installation..................................................................................................... 7-7
Auxiliary End Cover............................................................................................................................ 7-8
Drive End Cover .................................................................................................................................. 7-8
Lube Oil Supply (Sump)...................................................................................................................... 7-9
Drive Coupling Hub ............................................................................................................................ 7-9
Flexible Drive Coupling .................................................................................................................... 7-10
Troubleshooting Rexnord Couplings................................................................................................. 7-11
Elongated Bolt Hole.................................................................................................................... 7-11
Scored Body on Bolt ................................................................................................................... 7-11
Misalignment Failure .................................................................................................................. 7-11
Fatigue Failure ............................................................................................................................ 7-12
Compression................................................................................................................................ 7-12
Elongation ................................................................................................................................... 7-12
Torque Overload (Visible only with strobe light while running) ............................................... 7-12
Cylinder Body.................................................................................................................................... 7-13
Cylinder Head.................................................................................................................................... 7-13
Piston, Piston Rings And Piston Rod ................................................................................................ 7-13
Piston Rod Packing ........................................................................................................................... 7-14
Valves ................................................................................................................................................ 7-17
Valve Installation ........................................................................................................................ 7-17
Valve Replacement ..................................................................................................................... 7-18
Special Tools ............................................................................................................................................ 7-20
Alarms And Shutdowns ........................................................................................................................... 7-20
Recommended Maintenance Schedule .................................................................................................... 7-21
Cooper Energy Services n Superior Compressor Product Group Page e

Troubleshooting ........................................................................................................................................7-22
Section 8
Frame "as built" Bills of Materials ...........................................................8-1
Section 9
Cylinder "as built" Bills of Materials .......................................................9-1
Page f Cooper Energy Services n Superior Compressor Product Group

WG Series Compressor Frame Instruction Manual
Section 1
Introduction to the WG Series Compressor and
Specifications
About This Manual
Thank you, for purchasing Cooper Energy Services equipment! This Instruction Manual
contains safety, operating and basic maintenance instructions for the Superior® WG series
compressor frames.
Cooper Energy Services is committed to continuous improvements and design advancements.

Because of this commitment, changes may occur in your compressor frame that may not
appear in this instruction manual. Some photographs or illustrations in this manual show
details or options that may not appear on your compressor frame. Guards, covers or other
protective mechanisms may have been removed for demonstrative or illustrative purposes.
Any time a question arises concerning your compressor or this instruction manual, please
contact an authorized Cooper Energy Services Distributor for the latest available information.
Figure 1-1 WG Compressor
It is very important that per-
Durable Frame:
sonnel associated with Enhanced structural strength,
operation maintenance of Up to 9000 one-piece construction
Horsepower
the WG series compressor @ 1200 RPM
read this manual and sup-
port documentation. Keep O’Ring Seals
this manual with related lit-
Digital
erature and compressor No-Flow
information. Store it so it is Meter
easily found by mainte-

nance or service personnel.
It is also important that Easy to service
Oil Supply
users carefully study the 48” cylinder System
Lower Center of
safety information provided Spacing Gravity for less
in Section 2. Always use Vibration
6” and 7” Extra Robust
good safety practices at all Stroke Capability Support
times to prevent injury to
personnel or damage to equipment.
This manual contains confidential and proprietary information from the Superior
Compressor Products Group of Cooper Energy Services, a division of Cooper Cameron
Corporation. This manual is given to users for the limited purpose of providing
Section 1: Introduction to Servicing the WG Series Compressor WG-4/3/03
Cooper Energy Services n Superior Compressor Product Group Page 1-1

information to facilitate use and maintenance of WG series compressor frames purchased
from Cooper Energy Services. By receiving this document, you agree not to use such
confidential information for any purpose other than limited purpose stated herein and
further agree not to disclose such information to others except in accordance with the
limited purpose stated herein.
All specifications and ratings are subject to change without notice. Superior® is a trademark
of Cooper Cameron Corporation.
Identifying Your Compressor Frame and Cylinder
Figure 1-2 Frame Nameplate

Correspondence concerning your
compressor frame must include the
Cooper Energy Services compressor
frame serial number. The compressor
frame serial number applies to the
frame and running gear parts. It is lo-
cated on the frame nameplate which
is attached to the top cover. Each Figure 1-3 Cylinder Nameplate
compressor frame and cylinder has its Correspondence concerning your cylinder
own serial number. must include the Cooper Energy Services
cylinder serial number.
Compressor Frame Overview

All Cooper Energy Services compressor frames are engineered for reliable, continuous, heavy
duty and trouble free operation. These ruggedly constructed, balanced-opposed type com-
pressor frames are built with high speed, high precision, high quality and field proven stan-
dards of CES’s Superior® compressors. Easy access to all wearing parts means simplified
Page 1-2 Cooper Energy Services n Superior Compressor Product Group

maintenance and dependable service. The balance-opposed design, with two crank throws
separated by a crank cheek, is a modern standard for reciprocating compressor frames. This
manual describes the WG series compressor frame. These compressor frames are designed
for oil and gas production, gas transmission, process, cogeneration and power generation
applications.
Precision designed main and connecting rod bearings are thick walled, steel backed and split.
The crankshaft is removed through the top of the base without disturbing the cylinders. The
lube oil pump and the force feed lubricator are gear or shaft driven and mounted on the
auxiliary end cover. Either may be maintained independently.
Lube Oil is drawn from the sump through a strainer that protects the lube oil pump. A full-
flow lube oil filter with a differential pressure indicator capable of identifying a plugged filter,
protects all compressor frame running parts.
Although piston and rod lengths may vary according to the stroke and model, all cylinders
will fit interchangeably on the standard crosshead guide. Careful attention is given to the
cooling of cylinders designed for a 1.5:1 to 5:1 pressure ratio.
Vt Figure 1-4 WG Cylinder Head Options

a Pneumatically
r
Operated Pocket
i
a Typical Variable Pocket
b Cylinder Head Plug
l
e
V
o
l
u
m 00748
00749
e
Pockets are furnished as standard equipment on all cylinder classes, except the model #602
through #605 forged steel cylinders. On these cylinders, other methods of adding clearance,
such as fixed heads, fixed volume heads, or valves spacers can be furnished when required.
Crankshaft Rotation
When facing the oil pump end of the frame, the crankshaft rotates in a counterclockwise
direction.

Figure 1-5 WG Stroke Options
Figures 1-6 and 1-7 show the general configuration of the WG compressor
Figure 1-6 WG Compressor
Breather
Connecting Rod
Crankshaft
Frame

t Figure 1-7 General WG Series Compressor Specifications
Table 1-8 Compressor Specifications

Specification Type Of Unit
WG6 WG7
Connecting Rod Length Center to Center-inches (mm) 17 (432) 17 (432)
Crosshead Guide Bore Diameter - inches (mm) 13.75 (349) 13.75 (349)
Crosshead Pin Diameter - inches (mm) 4.625 (117.5) 4.625 (117.5)
Crosshead Shoe - Oiling Method External Internal
Lube Oil Filter Differential Pressure - Normal >5 psi --
Lube Oil Filter Differential Pressure - Alarm Point 15 psi --
Lube Oil Filter Differential pressure - Shutdown 25 psi --
Maximum Limit for Reciprocating Weights 539 lbs 539 lbs
* Subject to change without notice.

Compressor System Vibration
Due to the nature of the horizontal compressor design, the reciprocating weights generate
some vibrational forces. Proper balance of reciprocating weights on the opposing throws will
minimize this effect.
Compressor systems (including skids, bottles, piping, valves, and other components) are sub-
ject to vibration. The design goal is to have a system free of vibrations in a normal operating
speed range.
Operators and maintenance personnel should be alert for excessive system vibration that can
cause damage to equipment. Normally, clamping or adding additional support to a vibrating
component will raise natural frequency and eliminate the vibration problem.
Compressor cylinder mounting can be stiffened, if necessary, by attaching additional supports
directly to the cylinder from the skid or foundation. Most cylinders now have a machined
boss with drilled and tapped holes for attaching an outboard cylinder vibration suppression
device. This is the preferred method of attachment.
t Figure 1-9 WG Transverse Cross Section
Suction
Valve
Piston Piston Rod Crosshead
Variable
Volume
Pocket
Discharge Valve Packing Connecting Rod

Location

Balancing Compressor Frames

Cooper Energy Services manufactures balanced opposed reciprocating compressor having one to six
cylinders. The cylinders range in size from 3 to 26.5 inches (76 mm to 673 mm) in diameter and may
be mounted on the frames in various combinations.
I CAUTION N DANGER
Since the goal is to produce a balanced opposed
compressor, it is necessary to make the
Balancing of the unit is accom- reciprocating weight on each pair of opposing
plished by using both an Failure to verify and correct
throws approximately the same.This is quite a
appropriate weight crosshead compressor balance can
assembly and piston rod jam task, in view of the large number of cylinder result in excessive mechani-
nut (balance nut) The maxi- sizes and throw location combinations that are cal vibration, frame crack-
mum allowable variation is possible, and because each piston and rod ing, piping vibration,
two pounds (0.90 kg) on the
reciprocating weights and one assembly (piston, rings, piston rod and cap foundation cracking and
pound (0.45 kg) on the con- screws) has a certain combined weight which other damage to the com-
necting rod weights, but not to will probably be different from the weight of the pressor. It also creates a
exceed one pound net, for each potentially unsafe operating
piston assembly that it will oppose.
pair of opposing throws. condition for the operator.
I CAUTION
The crosshead assembly consists of a pair of
shoes, the bolts and nuts to attach the shoes, and the crosshead. There are
When replacing crossheads,
connecting rods, pistons, or
two different weight crossheads available.
changing piston ring material,
Also available are balance nuts in 2.5 and 5-pound increments. Consult an
the new parts should be
Authorized Unit Distributor for details concerning the use of the special
weighed, in order to reaffirm
the actual unit balance. weight nuts. In addition to the above mentioned balance parts, the
connecting rod weight is also involved in the balance. Connecting rods
vary in weight and when the units are assembled at the factory, care is taken to select the connecting
rods so that the weight variation for opposing throws does not exceed 1 pound (0.45 kg).Every effort
should be made to achieve as near equal balance between opposite throws as possible.This does not
apply to adjacent throw pairs, which sometimes vary by 100 pounds (45 kg) or more, depending on
cylinder sizes.
Figure 1-10 Balance Sheet Example

t
The estimated balance for the original assembly

of a compressor is recorded on the Compressor
Vent Fill Plug Torsional and Balance Data Sheet. A copy of the
data sheet for each compressor is included in the
Upper Operation Manual, and should be referred to in
Plug the event
. a change which would affect the bal-
ance is contemplated.The actual weight of parts
. from the estimated weights. Also, when
can vary
replacing crossheads, connecting rods, pistons, or
changing piston ring material, the new parts
Drain Plugshould be weighed, in order to reaffirm the actual
00752 unit balance.

Additional Information
Please visit the Cooper Energy Services web site: http://www.cooperenergy.com
Unrestricted copies of Service Bulletins are available at the Cooper Energy Services web site.
You must have Adobe® Acrobat® Reader version 3.0 or later in order to view the bulletins:
http://www.cooperenergy.net
Prerequisites
Personnel using this guide should be familiar with compressor systems, standard mechanical service
tools, and compressor terminology. Service personnel should have adequate experience in good
maintenance and troubleshooting techniques. Cooper Energy Services recommends that all personnel
using this manual should complete CES Superior Reciprocating Compressor Training. Training
includes the following:
• Frame, crosshead guide, and lubrication systems
• Compressor details including: rings, rider bands, pressure packings, valves, and unloaders
• Support systems to include: Coolers, water pumps, and control systems
• Description of installation, inspection, and set up procedures for rod run out, web deflection, cou-
pling alignment
• Description of recommended operational procedures include: startup, normal & emergency shut-
down and compressor performance control
• Description and application of recommended maintenance: maintenance, critical repairs, and trou-
bleshooting
If training is needed, contact the CES Learning Center by calling (713) 354-4062.
How to Use This Manual

Manual Organization
To make finding information as easy as possible, the Superior WG Instruction Manual is organized
into the following sections:
• Table of Content.
• Section 1: Introduction To WG series compressor and frame specifications. This section
describes the purpose of the manual and prerequisites. It includes information on how to use the
manual, related publications and important product information.
• Section 2: Safety Precautions and Guidelines. This section explains basic equipment maintenance
safety policies and practices. regarding compressor frame operation and maintenance.
• Section 3: Lubrication and Cooling Specifications. This section is a comprehensive reference
regarding, lubricating and cooling the WG series compressor frame.
• Section 4: Specifications for sour gas applications.

• Section 5: Installation. This section provides an in-depth functional description guidelines for the
foundation, coupling installation, crankshaft web deflection, cylinder mounting, setting piston end
clearance, piston rod run out.
• Section 6: Operation Start-up. This section provides procedure for startup, recommended operat-
ing conditions, and form to request for performance curves.
• Section 7: Maintenance. This section contain precautions, tolerance limits, and recommended
torque values.
• Section 8: Frame "as built" Bills of Materials unique to your compressor. Included are exploded
views of the assemblies.
• Section 9: Cylinder "as built" Bills of Materials unique to your compressor. Included are
exploded views of the assemblies.
Related Publications
The following related publications contain more information about the Superior WG Series Compres-
sor:
•Superior MH, WH, W7, & WG Compressor Frame Technical Data Book.
•Superior Compressor Cylinders Technical Data Book
Standards
Cooper Energy Services has developed several standards for our compressor addressing cooling
water quality, lubrication, and packaging. CES recommends that users of Superior compressor
understand and follow these standards to get the best performance possible from the equipment. CES
also recommends that oil and gas production service packagers follow the guidelines for prime mov-
ers described in the American Petroleum Institute’s Specification for Packaged Reciprocating Com-
pressors for Oil and Gas Production Services (API Specification 11P). American Petroleum
Institute http://www.api.org will default you to http://www.global.ihs.com 1-800-854-7179 ext.
7969 for a copy of API 11P.
Our Quality Policy

All Cooper Energy Services employees will work to understand and to meet or exceed our customer's
expectations. Customers include purchasers of goods and services, co-workers, other departments
and suppliers. All employees will correctly and efficiently perform their respective functions in
accordance with established requirements, and identify needed changes. Providing goods, services
and communications with ever-increasing quality and value for our customers is a continuous busi-
ness process in our company.
Warranty
The Seller warrants to the Buyer that the equipment to be delivered hereunder will be free from
defects in material, workmanship and title and will be of the kind described in the contract. THE
FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES

WHETHER WRITTEN, ORAL OR IMPLIED (INCLUDING ANY WARRANTY OF MER-
CHANTABILITY OR FITNESS FOR PURPOSE). If it appears within one year from the date the
equipment is placed in service but no later than eighteen (18) months from the date of delivery to the
Buyer, whichever first occurs, that the equipment does not meet the warranty specified above and the
Buyer notifies the Seller promptly, the Seller shall correct any defect, at the Seller's option, either by
repairing any defective part or parts or by making available, at the Seller's factory, a repaired or
replacement part.
The liability of the Seller to the Buyer (except as to title) arising out of the supplying of the equip-
ment, or its use, whether on warranty, contract or negligence, shall not in any case exceed the cost of
correcting defects in the equipment or part thereof and upon expiration of the warranty period all such
liability shall terminate. The foregoing shall constitute the sole remedy of the Buyer and the sole lia-
bility of the Seller.
The preceding paragraph shall not apply and the Seller assumes no liability whatsoever for breach of
warranty when there is evidence that the defect arose as the result of (a) abuse or negligence in the
operation of the equipment, (b) failure to maintain the equipment properly, (c) overloading or over-
speeding, or (d) use of repair parts not approved by Seller.
The warranty given to the Seller by its supplier of special equipment, including but not limited to gen-
erators, is hereby assigned without recourse by the Seller to the Buyer. AS TO THIS SPECIAL
EQUIPMENT, WHICH GENERALLY BEARS THE NAMEPLATE OF THE SELLERS SUP-
PLIER, THE SELLER ASSUMES NO LIABILITY WHATSOEVER FOR BREACH OF WAR-
RANTY, WHETHER WRITTEN, ORAL OR IMPLIED (INCLUDING ANY WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PURPOSE).
Copyright© 2002 Cooper Cameron Corporation. All rights reserved.
Copyright© 2002 Adobe Systems Incorporated. All rights reserved.

Section 2
Safety Precautions and Guidelines
Important Safety Information
DO NOT OPERATE OR ATTEMPT TO REPAIR THIS EQUIPMENT UNLESS YOU
HAVE HAD THE PROPER TRAINING APPROVED BY SUPERIOR. FOR TRAINING
INFORMATION, CONTACT THE COOPER ENERGY SERVICES TRAINING
DEPARTMENT IN HOUSTON, TEXAS, PHONE (713) 354-4062.
Do not operate, work, or perform any lubrication, maintenance or repair on this equipment
unless you have read and understand the operation, lubrication, maintenance and repair
instructions and warnings in this Operations Manual. Failure to follow the instructions or
heed the warnings could result in injury or death. Contact your authorized Cooper Energy
Services Distributor for replacement manuals. Proper care is your responsibility.
Most accidents involving equipment operation, maintenance and repair are caused by failure
to observe basic safety rules or precautions. An accident can often be avoided by recognizing
potentially hazardous situations before an accident occurs. A person must always be alert to
potential hazards. Equipment operators should also have the necessary training, skills and
tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this equipment can be dangerous

and could result in injury or death.
Safety precautions and warnings are provided in this manual and on the equipment. If these
hazard warnings are not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by a safety alert symbol and followed by a signal word such as
"DANGER!" as shown in the Note, Caution and Danger Symbols portion of this section.
Note, Caution, and Danger Symbols

These safety instructions and procedures are intended to prevent injury in the operation and
maintenance of Cooper Energy Services compressors and auxiliary equipment. These safety
procedures should not be considered as the only precautions to be taken. Good judgement and
careful safety practices should always be used.
Section 2: Safety Precations and Guidelines WG-4/3/03

The following safety alert symbols and signal words are used
throughout this manual and are intended to highlight items or advise
you of special circumstances.
i When changing the
frame lubricating
The NOTE symbol is an alert indicating an essential operating oil, change the oil filter.
procedure or condition. The following is an example of a NOTE:
The CAUTION symbol indicates that if the specified precaution is

not heeded, damage to equipment and/or personal injury may result.
The following is an example of a CAUTION:
I CAUTION
The DANGER symbol indicates that if the specified warning is not
heeded, there is a substantial risk of serious equipment damage,
personal injury or even death. The following is an example of a NDANGER
DANGER:
Cooper Energy Services cannot anticipate every possible circumstance that might involve a
potential hazard. The warnings in this publication and on the equipment are therefore not all
inclusive. If a tool, procedure, work method or operating technique not specifically
recommended by Cooper Energy Services is used, you must satisfy yourself that it is safe for
you and others. You should also ensure that the equipment will not be damaged or made
unsafe by the operation, lubrication, and maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are presented on the basis
of information available at the time it was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These
changes can affect the service given to the equipment. Obtain the complete and most current
information before starting any job. Authorized Cooper Energy Services Distributors have the
most current information available.
Warning Signs and Labels

There may be several specific safety signs on your equipment. Please take the time to
familiarize yourself with the safety signs.
Make sure that you can read all safety signs. Clean or replace these if you cannot read the
words or see the pictures. When cleaning the labels use a cloth, water and soap. Do not use
solvents, gasoline, etc., to clean safety signs. The use of solvents, gasoline, etc., could loosen
the sign's adhesive and cause the sign to fall off.
You must replace a label if it is damaged, missing or cannot be read. If a label is attached to a
part, and that part is replaced, make sure a new label is installed on the replaced part. See your
Authorized Cooper Energy Services Distributor for new labels.

Specified Precautions
It is important that these precautions be read and clearly understood. All of the precautions
that follow are interpreted as having a CAUTION or DANGER status.
Temporary Shipping Plugs in Compressor Equipment 1
Small diameter threaded connections located on compressor frames,

cylinders are components are often sealed at the factory with
temporary plastic plugs. These temporary plugs protect the
equipment from dirt, water and other contaminants during shipping
NDANGER
Stainless steel plugs are rec-
and storage. The type of plug used is usually a “push-in” insert that ommended. Always verify
can be easily identified, even when painted. A threaded plastic pipe that all temporary plastic
plug may occasionally be found on older compressor cylinders. plugs are replaced before
using the compressor equip-
Painted threaded plastic pipe plugs may look like painted steel pipe ment.
plugs. Any Plastic plugs found must be replaced. The equipment
installer must determine the purpose of all empty ports (i.e. vent,
lubricator oil connection, cooling water connection, etc.) and insure each port is properly
connected to its specific application or plugged.
Ports that are not used must be filled with a properly installed steel plug. If the existing plugs
are painted, scrape off enough paint to verify that the plug is made of steel and not plastic. If
any plug is in question, replace it.
Pressurizing the compressor equipment while temporary plugs are in place may result in
serious injury or death and may damage the equipment.
Compressor Frame Crankcase Rapid Pressure Relief Valves2
Cooper Energy Services recommends the installation of Bicera crankcase rapid pressure
relief valve. These valves protect the compressor frame from excessive pressure.
The Bicera valve has a 120 o exhaust port opening through which pressure is vented. Due to
the content and high temperature of the vented gas, proper orientation of the exhaust port is
critical for a safe operating environment. Vented gas could be dangerous to both operator and
equipment. The 120o exhaust port must always be directed towards the drive end of the
compressor frame. It must never be directed toward an area where the vented gases could
come into contact with operators or other personnel.
1.Per CES Engineering Service Bulletin SB282

2.Per CES Engineering Service Bulletin SB290

General Precautions
Attach a DO NOT OPERATE or similar warning tag to the start
button or controls before performing maintenance or repairing the
equipment. When appropriate, attach tags at the equipment and at
NDANGER
each operator's position and disconnect starting controls.
Be absolutely sure the remote starting system is disabled and/or If Poisonous or suffocating
disconnect the starting system on the equipment being serviced. gases are being com-
pressed, follow all plant
safety procedures prior to
Use caution when removing cover plates. Gradually loosen (do not and during maintenance on
any gas equipment or pip-
remove) the last two bolts or nuts located at opposite ends of the ing to avoid injury or death
cover or device. Pry cover loose to relieve any spring or other due to inhalation of such
pressure, before removing the last bolts or nuts. substances.
It is in the best interest of everyone involved in operation and

maintenance of the equipment to observe these additional precautions:
•Always wear safety glasses or goggles, steel-toe safety shoes, hearing protection and protec-
tive head gear. Additional equipment may be required by the job conditions.
•Do not wear loose clothing, neckties, or jewelry that can catch on controls or other parts of
the moving equipment. Keep long hair tied back.
•Make certain all protective guards and covers are secured in place.
•Use only non-flammable, non-toxic cleaning solvents. Never use gasoline or other flamma-
ble products for cleaning purposes.
•Use fans, blowers, etc. during maintenance and clean-up work in enclosed areas to remove
fumes released by cleaning solvents and vented gases.
•Never put maintenance fluids into glass containers; since glass containers break.
•Report all needed repairs.
•When operating this equipment in an enclosed area, vent the exhaust to the outside.
•Keep the area around the unit clean and orderly with ample space to walk safely around the
unit. Clean up spills and leaks quickly to prevent accidents caused by slipping and falling.
General Maintenance Precautions

Unless instructed differently, perform all maintenance as follows:
•Follow all safety and operating procedures put in place by the company that owns and oper-
ates the equipment.
•STOP the equipment. Do not attempt any repairs or adjustments to the equipment while it is
running. Ensure the protective locks or controls are in the applied position. Make sure all
protective guards and covers are installed, if equipment must be started to make adjustments

or checks. To help prevent an accident caused by parts in rotation, work carefully around
them.
•Make sure all nearby personnel are aware of the start-up and do not allow unauthorized per-
sonnel on or around the equipment when maintenance or repair is being performed.
• Do not disable or bypass automatic alarm/shutoff circuits. They are provided to prevent per-
sonal injury and equipment damage.
•Before replacing any studs, measure the stud's height from the machined surface and install
the replacement stud to the identical height.
Compressor System Maintenance Precautions

•Suction and discharge block valves must be closed to prevent gas from flowing into the
compressor system during maintenance.
•Vent all gas pressure from the compressor system and know the piping system associated
with the compressor. Open discharge blowdown and/or bypass valves to vent into the atmo-
sphere.
•Be sure to allow the compressor system to cool for at least 15 minutes before opening suc-
tion or interstage vents. Air may be drawn into the system if a vacuum exists. This can
create an explosive mixture.
•Check local or panel pressure gauges for a zero reading before removing any gas pressure
components such as valves, valve caps, or cylinder heads.
•Unloader control pressure is typically not shown on gauges. Carefully vent unloader con-
trol pressure lines by loosening the control line tubing fitting.
•Remove manual barring devices if used during maintenance before starting the equipment.
•Lock out starting devices and controls
Pressurized Air and Water Precautions

Pressurized air and water can cause debris and/or hot water to be blown and could result in
personal injury. When using pressurized air or water for cleaning, always wear eye/face
protection and protective clothing and shoes. Cooper Energy Services recommends that the
maximum air pressure applied in this type of application must be below 200 kPa (30 psi) for
cleaning purposes.
Fluid Precautions
Always use a board or cardboard when checking for a leak. Escaping fluid under pressure
(even a pinhole size leak) can penetrate body tissue, causing serious injury or possible death.
If fluid is injected into your skin, a doctor familiar with this type of injury must treat it
immediately.

Asbestos Precautions
Cooper Energy Services equipment and replacement parts shipped from the factory are
asbestos free. Cooper Energy Services recommends the use of ONLY genuine Superior®
parts. If any replacement parts containing asbestos are used, the following guidelines should
be used in handling these parts and asbestos debris.
Caution should be used to avoid breathing dust when handling components containing
asbestos fibers. If this dust is inhaled, it can be hazardous to your health. The asbestos used in
components is usually bound in a resin or sealed in some way. Normal handling is not
hazardous as long as airborne asbestos dust is not generated.
If dust, which may contain asbestos, is present, there are several common sense guidelines
that should be followed.
•Never use compressed air for cleaning. Avoid areas where airborne asbestos particles may be
present.
•Avoid brushing or grinding of asbestos containing materials.
•For clean up, use wet methods or a vacuum equipped with a high efficiency particulate air
(HEPA) filter.
•Use exhaust ventilation on permanent machining jobs.
•Wear an approved respirator.
•Comply with applicable rules and regulations for the work place. (i.e. U.S.A. OSHA require-
ments 29 CFR 1910.1001).
•Follow environmental rules and regulations for disposal of asbestos.
Pipes, Connectors, Fittings, Lines, Tubes and Hoses

Do not bend or strike any high-pressure connection (i.e. pipes, fittings, connectors, lines,
tubes or hoses). Do not install bent or damaged pipes, connectors, lines, tubes or hoses.
Repair any loose or damaged fuel and oil pipes, fittings, connectors, lines, tubes or hoses.
Leaks can cause fires.
Inspect all pipes, fittings, connectors, lines, tubes and hoses carefully. Do not use your bare
hands to check for leaks. Tighten all connections to the recommended torque (Section 5).
Check for the following:

•End fittings damaged, leaking or displaced.
•Outer coverings chafed or cut and wire reinforcing exposed.
•Outer covering ballooning locally.

•Evidence of kinking or crushing.

•Armoring embedded in the outer cover.
Burn Precautions
Do not touch any part of operating equipment. Allow the equipment to cool before any repair
or maintenance is performed on the equipment.
Make sure that all clamps, guards and heat shields are installed correctly to prevent vibration,
rubbing against other parts and excessive heat during operation.
Relieve all pressure in air, oil, fuel or cooling systems before any lines, fittings or related
items are disconnected or removed.
Coolant Precautions
Remove the cooling system filler cap slowly to relieve pressure. Use caution when removing
vent release valve, grease fittings, pressure taps, breathers or drain plugs. Hold a cloth over
the cap or plug to prevent being sprayed or splashed by liquids under pressure.
At operating conditions, the equipment coolant is hot and under pressure. The cooling system
and all lines to heaters or the equipment contain hot water. When pressure is relieved rapidly,
this hot water can turn into steam.
Allow cooling system components to cool before draining. Any contact with hot water or
steam can cause severe burns. Check the coolant level only after the equipment has been
stopped and the filler cap is cool enough to remove with your bare hand.
Cooling system additive (conditioner) contains alkali. To prevent personal injury, avoid
contact with the skin and eyes and do not drink. (Remember: Antifreeze/glycol solutions, as
well as most lubricants, are flammable.)
Oil Precautions
Hot oil and components can cause personal injury. Do not allow hot oil or components to
contact the skin.
Fire and Explosion Precautions

A flash fire may result in personal injury if crankcase covers are removed within 15 minutes
after an emergency shutdown.

Fire may result from lubricating oil or fuel sprayed on hot surfaces causing personal injury
and property damage. Inspect all lines and tubes for wear or deterioration. They must be
routed, supported or clamped securely. Tighten all connections to the recommended torque
(Section 7). Leaks can cause fires.
Crushing or Cutting Precautions

Wear protective glasses when striking objects to avoid injury to your eyes.
Chips or other debris can fly off objects when struck. Take care to insure no one can be
injured by flying debris before striking any object.
Mounting and Dismounting Precautions

Do not climb on, or jump off, the equipment or stand on components that cannot support your
weight. When possible use platform steps and hand holds (if equipped) when mounting and
dismounting. Clean steps, hand holds and platform areas of the equipment you will be
working on or around. Always wear protective head gear when working on the compressor
package.

Section 3
Lubrication And Cooling
The complete lubrication system of the compressor is divided into two parts, of equal
importance:
1.) The system that provides lubrication to the frame running parts ( see the compressor Frame
Technical Data Book).
2.) The system that provides lubrication for the cylinders and packing.
Both systems can use oil from the frame sump. However; if required, the cylinder system may
use oil from an external tank. (This is especially done when the oil for cylinder and packing
system is different type compared to the frame oil).
Compressor Frame Lubrication:
A gear driven lubricating pump is mounted on the auxiliary end of the frame. The pump
delivers the oil from the frame sump to the bearings, connecting rods and the crosshead
guides. An adjustable pressure relief valve is installed in the delivery cavity of the frame for
cold start protection. An off-mounted shell and tube type oil cooler is provided with
connections for water inlet and outlet. Other features include a connection port for low oil
pressure shutdown switch. An oil level sight gage with low oil indicator is installed on the
frame.
Frame Lubrication Specifications:

A good mineral oil of recommended viscosity, which provides resistance to oxidation, and
corrosion is generally suitable for frame lubrication. A detergent oil if readily available may
also be used. To assure oil suitably, always use a reliable and known brand.
Cooper Energy Services does not endorse particular brands of oils and does not guarantee the
quality or performance of lubricating oils. Satisfactory oil quality is the responsibility of the
refiner, blender or re-brander. The responsibility for selecting the proper lubricant falls on the
user. Use only products with field proven reliability and merit. Using known and reputed
products will provide the best assurance for achieving effective lubrication. Use of such prod-
ucts should always follow the manufacturer’s recommendation. Do not permit your compres-
sor to be used as an experimental unit for trying out new or questionable lubricants.
Compressor design, operating conditions, and the gases being handled all have a significant
effect on how well a lubricant performs in the given application. The following will assist
users in selecting the proper lubricant for each application.
The lubrication of Superior® Compressors requires the use of premium quality, lubricating
oils designed for heavy duty compressor service.
In addition to the above requirement, the frame lubricant must be capable of operating with
the type of gas being handled by the compressor cylinders. For most sweet natural gases and
allied gas services, a lubricating oil with the minimum quantities specified in ES1002 (see
Section 3: Lubrication and Cooling 4/3/03

Table 3-1 & 3-2) will be suitable. In applications where the compressor cylinders are handling
corrosive gases such as H2 S or CO2 , a lubricant with a higher TBN or method for adequate
retention of the original TBN is recommended for service in the frame.
General Specifications
The general specification for lubricating oil for use in Superior® compressor frames is as
follows:
Table 3-1 General Specifications

Specification Range Test Procedure
Viscosity: cSt @ 100oC 12.5 to 16.3 ASTM D 445
Viscosity: cSt @ 40 o C 204 Maximum ASTM D 445
Viscosity Index 70 Minimum ASTM D 2270
Flash Point 400 o F (204oC) Minimum ASTM D 92
Pour Point 15oF (-9o C) Maximum ASTM D 97
Table 3-2 Viscosity Information-this information is equivalent to the ranges above and provid-
ed for information only
Specification Range Test Procedure
Viscosity: SUS @ 210oF 75 to 85 ASTM D 88
Viscosity: SUS @ 100oF 1100 Maximum ASTM D 88
Lubrication System Maintenance

I CAUTION
The compressor oil and filters should be changed after the first 500
hours on a new or overhauled compressor. After the first oil change, Low lube oil pressure alarm
and shut down device(s)
the oil and filters should be changed every 2000 hours. Cooper must monitor compressor
Energy Services strongly recommends that customers use a frame’s lube oil pressure
down stream of the com-
laboratory analysis program to ensure proper lubricant performance. pressor frame’s lube oil fil-
An experienced, reputable lab should be used and results should be ter, recommended location
is at driver end of lube oil
carefully analyzed and trended. Regular monitoring of the crankcase header when possible.
oil condition can help establish oil change out periods for a specific
unit. Oil condition and trace metal element trends can be effective
diagnostic and preventive maintenance tools.

t
Figure 3-3 The
compressor frame
lubrication system
consists of a gear
driven pump,
pressure relief valve,
check valves, oil
cooler and oil filter.
This Figure
illustrates the
lubrication oil system
flow.
Compressor Cylinder and Packing Lubrication:

The cylinder lubrication system consists of a forced-feed lubricator and distribution block system
that provides lubrication for cylinder walls and piston rod packing.
Compressor design, operating conditions, and the gases being handled all have a significant
affect on how well a lubricant performs in the given application. Because of a variety of gases
and operating conditions encountered by Superior compressor cylinders, the lubricant must be
selected with the proper characteristics suitable for the application involved. In all applica-
tions, the oil used for compressor cylinders should have the following qualities:
•Good wetting ability
•High film strength
•Good chemical stability
•Clean and refined
•Unless the service uses Hydrogen Sulfide, oxidation and corrosion prohibitors are not
required, but may be beneficial.
•Pour point must be equal to gas suction pressure minus15oF-20o F (8oC-11o C).
•Good resistance to carbon deposits and sludge formation. If any carbon is formed, it should
be the soft, loose and flaky type.
•Minimum flash point is 400o F (204oC).

Viscosity Requirements
The viscosity of the oil should be selected on the basis of 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 3-4 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.
Table 3-4 Minimum viscosity and specifications for Superior® cylinder lubri-
cants
Table 3-4A
Discharge Oil Viscosity Viscosity SUS
Pressure Specification @ 210 F Remarks
0-499 psi ISO 100 (SAE 30) 55-70 Crank Case Oil
500-1199 psi ISO 150 (SAE 40) 70-85 Crank Case Oil
1200-1999 psi ISO 220 (SAE 50) 85-110 External Oil
4000-up psi ISO 460 (SAE 70) 125-150 External Oil
METHANE WITHOUT H2 S, METHANE CONTAINING ANY COMBINATION OF HEAVY

HYDROCARBONS (EXCLUDING ETHANE),CO2 AND H 2 0 THAT TOTALS TO <5% (BY MOLE WT.)
Note: (External Cylinder Lubrication Supply Required above 1200 psi
Table 3-4-B
Discharge Oil Viscosity Viscosity Remarks
Pressure Specification SUS @ 210 F
METHANE WITH H2S, METHANE CONTAINING ANY COMBINATION OF HEAVY

HYDROCARBONS (EXCLUDING ETHANE), CO2 AND H2O THAT TOTAL TO 5-20% (BY MOLE WT.)
Note: (External Cylinder Lubrication Supply Required)

Table 3-4-C
Discharge Oil Viscosity Viscosity Remarks
Pressure Specification SUS @ 210 F
0-499 psi ISO 220 (SAE 50) 85-110 External OIl
CO2, HEAVY HYDROCARBONS,METHANE CONTAINING ANY COMBINATION OF HEAVY HYDROCARBONS

(EXCLUDING ETHANE), CO2 AND H2 O THAT TOTALS TO >20% BY MOLE WEIGHT.
Note: (External Cylinder Lubrication Supply Required)
Application Requirements
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 provide basic guidelines in
selecting the proper lubricant for these special applications. Final selection should be made
only after consultation with an Authorized Unit Distributor and the desired oil supplier:
Table 3-5 Minimum Qualities of a Compressor Cylinder Lubrication
Service Recommendations
Requires compounding with 3% to 5% acid less tallow or other suitable

Wet Air
fatty oils. Increase supply over normal.
Use minimum viscosity listed in Table 3-4, plus 3% to 5% compounding

High Pressure (PSIG)
with tallow if gas is “wet”.
High Discharge Temperatures(350 o -375o) Contact A CES Authorized Unit Distributor.
Use viscosity data in Table 3-4 and 3% to 5% compounding with tallow

Natural Gases, Methane, Ethane
if the gas is “wet” and/or saturated.
Natural Gases Saturated With Water and/or Requires compounding with 3% to 5% acid less tallow or other suitable
“Wet” With Higher Ended Hydrocarbons fatty oils. Increase supply over normal.
These gases are dilutents of oil. Use the next higher viscosity over
Butane, Propane, Ethylene, Carbon Dioxide Table 3-4 recommendations. Increase supply quantities over normal.
Lubricant must be dry.
Hydrogen, Nitrogen, Helium, Carbon Mon- There are inert gases relative to lubricating oils. Use the recommenda-
oxide, Exhaust Gas, Ammonia Synthesis tions in Table 3-4.
Ammonia Use a mixed base or napthentic straight mineral oil.
Use dry, compounded, straight mineral oil. 3% to 8% compounding with

Hydrogen Sulfide acid less tallow and addition of corrosion and oxidation inhibitors is
required. Viscosity as recommended in Table 3-4.

Lubrication Rate
I CAUTION
IT IS IMPORTANT that during start up safe and ample lubrication The lubrication rate
should be provided. This is accomplished by properly adjusting the for break-in should be
force feed lubricator pump(s). Observe the detailed instructions, double that for nor-
given in Section 6, when first starting up the compressor. With all mal operation.
lubricator pumps set at full stroke, bring the cylinder pressure up
slowly until the unit is running at full rated speed and load. Watch for any signs of
malfunction. After the first 48 hours at full load, the lubrication rate should be gradually
reduced to the amount necessary for correct lubrication. Adjustment should be made slowly,
a little each day, and should take several days to accomplish.
Experience has shown that the quantity of the oil required to properly lubricate compressor
cylinders is dependent upon bore diameter, stroke, and speed. For the Superior® compressors
1/5 (0.2) pint per day for each inch of cylinder bore diameter has normally proven to be an
adequate quantity.
The piston rod and packing is considered as Figure 3-6 Force Feed Lubricator
a separate cylinder but with double the
lubrication rate required. Packings then
require 2/5 (0.4) pints per day for each inch
of rod diameter. Minimum should be 0.45
pints per day per packing.
See Figure 3-6 for an example of a force

feed lubricator. A quantity of 1/5 (0.2) pint
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. See section 6-2 thru 6-3 for
information on the sight glass oil level.
The gas being compressed, its cleanliness and tendencies to act as an oil dilutent, and the type
of the 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.

Table 3-7 is an example of the calculations for determining the

i The regulator is not
lubrication rate for a 2-throw compressor frame with one (1) 10” designed to make large
bore diameter cylinder and one (1) 20” bore diameter cylinder quantities of oil in a
short time period, such as refill-
operating at 1200 RPMs: ing the crankcase after oil or fil-
Over-lubrication can be just as harmful as under-lubrication. ter changes.Its function is to
Excess lubrication can cause valve deposits, valve failures, compensate for small losses that
occur during normal operation.
contamination of the gas stream, and other down-stream
equipment.
Figure 3-7 Example of Calculating Lubrication Rates for Cylinders and Packing
Lubrication Rate For the 10” Cylinder…

1 packing X 2.75” X 0.4 pints/day = 1.1 pints/day or 11 drops/minute
PLUS 10” X 0.2 pints/day = 2 pints/day or 20 drops/minute
EQUALS 3.1 pints/day or 25 drop/minute
Lubrication Rate For the 20” Cylinder…
1 packing X 2.75” X 0.4 pints/day = 1.1 pints/day or 11 drops/minute
PLUS 20” X 0.2 pints/day = 4 pints/day or 40 drops/minute
EQUALS 5.1 pints/day or 50 drop/minute
Total Lubrication Rate…
3.1 pints/day or 25 drops/minute for the 10” bore diameter cylinder
PLUS 5.1 pints/day or 50 drops/minute for the 20” bore diameter cylinder
EQUALS 8.2 pints/day or 75 drops/minute
Synthetic Lubricants
Synthetic lubricants have higher flash points than conventional lubricants. 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 have low viscosity indexes.
For these reasons, when synthetics are considered for use in compressor cylinders or frames,
consult an Authorized Unit Distributor.
Multi-Grade Lubricants
Multi-grade oils provide the same protection as heavier single grade oils and do not put 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 oils is being considered for use a
a cylinder lubricant, consult an Authorized Unit Distributor.

Additional Recommendations
For wet and saturated gas conditions and 0-1000 PSIG, use a minimum viscosity of 85 SUS at
210oF with 3% to 8% compounding with acid less tallow, or two grades heavier than normally
used for the pressure conditions involved.
For heavy hydrocarbon and sour gases, use the next higher viscosity as shown in Table 3-4,
with a minimum of 85 SUS at 210oF.
For refrigeration service, use the highest possible viscosity that should be used and still retain
the pour point 15 oF below gas suction temperature.
For chemically active gases, consult an Authorized Unit Distributor.
Whenever there is any question as to viscosity selection, always use the heavier oil.
For oil viscosities over 100 SUS at 210oF, take measures to maintain lubrication pump inlet
temperatures at or above 120 oF.
Pump Per Point System
If a cylinder has more than one feed point, and more than one pump, the requirements for
lubrication must be split evenly. On a normal force feed lubricator (Figure 3-6), the proper
proportioning of oil to cylinders and packings should, as a first approximation, be adjusted by
the drops per minute method. To validate the lubrication rate, it must be measured using
actual oil consumption for a 24 hour period. A visual inspection of the lubrication rate is
required for this type of system. This is done by removing a valve at each end of the cylinder
after 48 hours of continuous operation at the final lubrication settings. There should be a film
of oil over the entire circumference of the ring travel section of the cylinder bore.
As a result of the inspection, individual pumps may be adjusted “up” or “down” in the same
proportion as the size of the cylinders being fed to improve the lubrication rate.
Operation
The cylinder lubrication system consists of a force-feed lubricator and distribution block
system that provides lubrication for the cylinder walls and piston rod packing (see Fig 3-8 for
a typical setup).
The lubricator is directly driven off the compressor shaft through a right-angle-drive worm
and spur gear set mounted on the lubricator box. Lubricator pump(s) fed directly from the

crankcase lube system or from an external tank are used to provide oil to the cylinders.
(Note that oil from the lubricator box is not used.) A packager-supplied external tank is
used when the requirements of the cylinder oil are different from those of the crankcase. A
shutoff valve is supplied to isolate the external tank and the lubricator box. The oil flows to
the pumps and then pumped to a common manifold feeding the automatic divisioning
system. The automatic divisioning system consists of a rupture indicator (set for the job),
a 10-micron strainer, a digital no-flow and counter, divider blocks and optional pin
indicators (shows which points are over-pressurized and sets accordingly). Each
lubrication point (cylinder and packing case) has a double ball check valve.
The lubricator box uses the same oil as in the frame or external tank to lubricate its cams
and bearings. The right-angle-drive gear on the lubricator box requires a gear oil that meets
ISO 680 AGMA-8 (Exxon TK-680 Cylesstic is acceptable).
If a blockage or other anomaly occurs, and the system pressure continues to build up, the
safety rupture relief in the collector manifold bursts, relieving pressure throughout the
entire system and causing the no-flow shutdown to activate and stop the compressor. The
protruding pin in the indicator on the distribution block gives a visual indication of the point
where the blockage occurred. Before restarting, new rupture discs of the same color and
thickness as originally installed must be replaced at the location where rupture occurred. It
is the thickness of the “color coded” discs that determine the rupture pressure. Refer to
rupture disc data sheet in Auxiliary Equipment section of this manual.
Figure 3-8 General Cylinder Lubrication Logic

Maintenance
In order to operate properly, the lubrication system must be completely purged of air. This is
done by LOOSENING, BUT NOT REMOVING the nuts of the lube lines at the point of
injection to permit purging of oil and air. The nut at the entry to the distribution block, all pin
indicators and 1/8-inch pipe plugs in the face of the block must be loosened also, for the same
reason.
! Caution
High pressure oil streams may puncture skin. Use proper wrench and keep hands away from the
immediate point where the system is purging air.
Loosen the vent screws in the top section of the distribution block. Continue to operate the
lubricator pump manually until clear, air-free oil appears at either of the two loosened vent
screws. Retighten this vent screw and continue pumping until air-free oil emerges at the other
vent screw. When this occurs, retighten second vent screw. Continue to operate the pump
manually until air-free oil has emerged from tubing nuts at every injection point. Then, and
only then, tighten the nuts on the tubing lines, the pin indicators, and pipe plugs.
Note
If distribution block must be disassembled for cleaning, observe the following:
a. Record order of manifold sections and outlet positions in order to facilitate reassembly.
b. Have a clean work area.
c. Avoid vise marks; protect ground surfaces, and NEVER grip the ground mating surfaces
in a vise.
d. Pistons are not interchangeable - - each piston is match-honed

to its cylinder. I CAUTION
e. Pistons are removed by hand-punching with a brass rod (either If the distribution block is
disassembled, carefully
way). observe the torque used
when reassembling mani-
f. Clean all sections with an approved solvent. folds:
•Distribution Block Tie
g. Do not disassemble check valves - - clean with compressed air. Rod Nuts = 20-25ft.
lbs. (27-34Nm)
Replace defective parts, as required. •Check Valves = 15-20
ft. lbs. (20-27 Nm)
•End Plugs = 15-20
h. Use all new gaskets when reassembling manifolds. ft.lbs. (20-27 Nm)
•Alternate Outlets and
Pin indicators = 10-15
ft. lbs. (14-20Nm)

Proportional Lubrication System
The distribution block type lubrication system is a metered, positive, displacement method of
lubricating the compressor cylinders and packing.
The force feed lubricator pumps oil into a single main line leading to a proportional
distribution block. Hydraulically balanced pistons in the block divide the oil into accurate
metered amounts for each lubrication point it serves. Selection and make-up of the
distribution block allows for accurately measured “shot” sizes, and precise proportioning to
meet different or equal oil requirements.
Because of the positive, metered operation, central warning equipment can sense trouble
anywhere in the system.
Safety equipment includes pin fault indicators, in each outlet from the distribution block, a
pneumatic or electric shutdown switch in the event of lubricant flow failures, and a rupture
disk in the lubricator collector manifold.
Since the system operates on a proportional basis, a single adjustment at the force feed
lubricator pump increases or decreases the flow to every lubrication point.
Oil flow rates given in percent of lubricator pump stroke accompany each compressor. These
settings must be followed and checked to provide adequate lubrication for both “break-in” and
normal operation.
Lubricator Worm And Gear Drive
When starting a compressor for the first time, or after servicing, be sure that the gear box is
filled with Exxon TK-680 Cylesstic Worm Gear Oil (ISO680 AGMA-8). It is advisable to
check periodically to be certain that the supply of gear oil is maintained. New units are filled
with oil at the factory, and should not need filling. See Figure 3-9.
t
Figure 3-9 Gear Box Filling
Vent Fill Plug Filling Instructions
Upper 1. Remove vent/fill plug.

Plug 2. Loosen
. upper plug.
3. Fill with Exxon TK-680 Cylessic oil
.
(ISO680 Agma-8) until it begins to leak at
upper plug.
4. Tighten upper plug. Install vent/fill plug.
Drain Plug
00752

Compressor Frame Lubrication Oil Cooling
The compressor frame is lubricated by the pressurized lubrication system. The oil must be cooled
by the shell and tube cooler provided with the compressor (shipped separate for mounting by the
packager). Oil should be circulated through the shell side and coolant through the tube side of the
cooler.
The maximum recommended oil temperature for oil returning to the frame is 175 oF (79o C). To
insure this oil temperature, coolant temperature and flow must be selected to remove heat
according to Table 3-10.
Table 3-10 WG Compressor Frame Heat Rejection Data

Compressor Heat Rejection
Model WG6 WG7
2-throw 66,672 BTU/hr (70,339 kj/hr) 46,300 BTU/hr (48,847 kj/hr)
Compressor Cylinder Cooling
Some Superior compressor cylinders are built with cooling water jackets. These cylinder jackets
can be cooled by one of three ways: (1) dry jacket, (2) standpipe, or (3) circulated water cooling.
1. Dry jacket cooling is generally used where the gas discharge temperature is less than 140 oF
(60o C) and gas inlet temperature is greater than 60o F (16oC). In this form of cooling, the
air present inside the cylinder water jacket is the medium which transfers heat out of the
cylinder. The cylinder jackets must be vented when this form of cooling is used.
2. In standpipe cooling, a water with corrosion inhibitor and/or antifreeze solution is used as
the medium for heat transfer. The cylinder jackets are filled with the coolant and then
vented to the atmosphere at their highest point. The vent (or standpipe) should be a 6-inch
(15 cm) long vertical section of pipe which will contain the coolant when it expands. The
pipe must be topped with a vented cap to prevent dirt from entering the coolant. This form
of cooling may be used when the gas discharge temperature is less than 250°F (121°C). and
the rise between gas suction and discharge temperature is less than 170°F (77°C). The
temperature of the liquid coolant will reach a mean temperature somewhere between the
suction and discharge gas temperatures. Accordingly, a coolant must be chosen whose
boiling point is at least 25°F (14°C) greater than the mean temperature and whose freezing

point is at least 25°F (14°C) less than the suction gas temperature (or ambient, whichever
is lower).
3. The third form of cooling is by coolant circulation through the cylinder jackets. This form
of cooling must be used on compressor cylinders having gas discharge temperatures greater
than 250°F (121°C) or a gas temperature rise greater than 170°F (77°C).
For maximum performance, it is recommended that the cylinder coolant temperature be

maintained 10oF to 15°F (6o C to 8°C) higher than the suction gas temperature. At lower
coolant temperatures, condensation forms on the cylinder walls. This condensation must be
avoided as it has a tendency to wash the oil film from the cylinder bore, promote corrosion
(especially in non-lubricated cylinders), and cause internal damage by excessive wear on rods,
rings, valves, and the cylinder bore due to lack of lubrication. Also, condensates are
incompressible fluids which can cause damage to any cylinder part by creating forces well
beyond the capability of the machine.
To control condensates and still maintain optimum cylinder

performance, the coolant must be monitored and regulated. This is
accomplished by monitoring the coolant in and out temperatures for
i Applications that
require low suc-
tion tempera-
each cylinder with thermometers and sight flow indicators. From
tures below 40o F (4 oC)
these readings, the operator may regulate the water flow to each must contact an Autho-
cylinder by using a water regulating valve until a coolant temperature rized Unit Distributor for
differential of 10°F (6°C) (15°F (8°C) maximum) is obtained. assistance.
Packing Cooling
In the majority of applications, rod packings will perform satisfactorily without a coolant
being circulated through the packing case and therefore don’t have coolant passages. Some
applications, however, do require that the packing cases be cooled in order to achieve
adequate packing ring life. These applications usually involve high pressures and
temperatures, marginal lubrication (characteristically encountered with wet and sour gases),
and unclean gases. On these units, the packing cases are provided with internal coolant
passages. (Figure 3-11 & 3-12).
Adequate cooling flow through the packing cases at a satisfactory temperature is required to
properly conduct the heat out of the packing. Inlet coolant temperatures should be as cool as
possible, but no higher than 90°F (32°C) is recommended to achieve optimal cooling. The
coolant flow required is normally 1 GPM (4 lpm) for each inch of rod diameter with a
minimum of 2 GPM (8 lpm). A pressure drop with water coolant of approximately 30 to 50
psig (207-345 kPag) should be expected across each packing case at the required flows.

t Figure 3-11 Crosshead Guide and Distance Piece - Lube and Liquid Cooled Package
t Figure 3-12 Crosshead Guide and Distance Piece - Lube and Non-Liquid Cooled
Coolant Requirements
I CAUTION
The primary purpose of any water treatment is to protect the surfaces Cleanliness is critical.
of the cooling system from cavitation, corrosion, scaling, or sludge protect cooling water
deposits that would reduce the transfer of heat to the coolant. from impurities and
always use clean tools.
It is the responsibility of the operators/users to consult with reliable

vendors of cooling system treatments in order to adequately protect
the equipment from damage caused by cavitation, corrosion, scale and sludge formation and
other water treatment related problems.

Corrosion
Corrosion is a chemical reaction in a metal such that the surface of the metal exposed to cooling
water is changed into one or more of its various compounds, especially iron to iron oxide (rust).
As the depth of the corrosion increases iron oxide particles will flake off, exposing more new
surface material to attack. Where it will occur in the cooling system and to what degree it will
progress depend on factors such as quality of water, metals in the cooling system, surface
temperature, and mechanical conditions of surfaces. The types of corrosion commonly found in
cooling systems can be crevice, cavitation and erosion, fretting or galvanic.
Scales and Sludge

Minerals dissolved in water form scales and sludge. The dissolved minerals tend to come out of
solution when the water is heated. In doing so, the scale is formed on the hot metal surfaces
and impedes good heat transfer. The scales and sludge also interfere with the ability of
corrosion inhibitors to form their protective films.
The most important consideration for the cooling system is good water quality. Table 3-13
shows the range of maximum limits for raw cooling water quality. If raw water is tested and is
found to have higher concentrations than those shown on the chart, the water will require
treatment or deionizing. If concentrations are below those shown, the water is suitable for use
with inhibitors added.
Table 3-13 Raw Cooling Water Specifications
Category Standard System Steam System

pH Level 7.5 MIN / 9.5 MAX 7.5 MIN / 9.5 MAX
Total Hardness PPM 100.0-170.0 MAX 5.0 MAX
Chlorides PPM 25.0 MAX 25.0 MAx
Sulfates PPM 20.0-100.0 MAX 20.0-100.0 MAX
Total Dissolved Solids PPM 300.0-400.0 MAX 300.0-400.0 MAX
Silica PPM ----- 50.0 MAX
An inhibitor is a chemical part of coolant treatment that reduces corrosion by forming a

protective film on the metallic surfaces of the cooling system. These protective films can be of
anti foam or coating nature. The anti foam nature reduces the formation of air bubbles in the
coolant. The coating effect gives a protective layer between the metal surfaces and the coolant.
During cavitation, the violent collapse of the vapor bubble literally blasts small holes in the film.
The job of the inhibitor is to recoat these areas. Because the inhibitor is recoating the metal
surfaces, its concentration levels must be maintained to continue adequate protection. Therefore,
the coolant inhibitor concentration must be checked periodically, and added when needed.

Good industrial grade antifreeze should be used in all closed-type cooling systems. All
industrial grade antifreezes have some corrosive inhibitors. When exposed to heat, these
inhibitors break down. This characteristic requires periodic adjustments to maintain the
corrosion protective qualities of the coolant.
Corrosion inhibitors vary in the chemical make-up and concentrations depending upon the
manufacturer. Most of the products will do an adequate job when quality water (deionized and
demineralized) is used. Corrosion inhibitors are ineffective in hard or sub-quality water. The
key to adequate cooling water is to begin with clean water and use a reliable water treatment
specialist.
Chemical treatment of a closed water system is simplified by the use of proprietary inhibitor
compounds. The low make-up water requirements of closed systems and, therefore, minimum
compound additions place a minimum burden on the user for materials and maintenance.
Periodic testing of the coolant, whether by the user or the vendor of the treatment system, is
absolutely necessary in order to assure that a proper level of protection is maintained. The
equipment user must obtain the specific instructions for the use and testing requirements of
the inhibitor compounds from the supplier or manufacturer.
A clean system is a prerequisite for establishing protection of any cooling system. Adequately
protected closed cooling systems seldom, if ever, present problems caused by scaling,
corrosion, deposits or cavitation.
Cooling System
There are three types of cooling systems used for stationary equipment: open, closed and
combination.
Open systems involve cooling towers, spray ponds, etc., and cool the water by evaporation.
Closed systems involve heat rejection through or shell and tube-type or radiator-type heat
exchangers.
Combination systems have the engine and compressor jacket water in a closed system using
shell and tube-type heat exchangers to transfer the heat to an open system using cooling
towers, etc, as above.
Closed type systems are commonly used and approved cooling methods; however, because
open-type systems involve not only large volumes of make-up water, but also the ease of
airborne contamination, Cooper Energy Services do not recommend using these for this
equipment.

Section 4
N DANGER
Sour Gas Compressor Sour gas or hydrogen sul-
fide (H2S) is a highly cor-
Applications rosive and extremely toxic
gas. Every precaution
reguarding life and equip-
This section defines additional compressor hardware and special ment must be taken in a
materials for use when the compressor is applied in sour gas or hydrogen sulfide applica-
corrosive gas service. The requirements listed are based on tion. Read and understand
American Petroleum Institute (API) Production Equipment the United States Depart-
ment of Labor’s Occupa-
Standard 11P, National Association of Corrosion Engineers’ tional Safety and Health
(NACE) Standard MR0175, and Cooper Energy Services Administration (OSHA)
experience. Additional specifications may apply to pulsation regulations for Air Con-
dampers, piping and other equipment used in conjunction with this taminants (standard
compressor. Copies of API 11P and NACE MR0175 can be 1915.1000) and the Con-
purchased on line: fined Space Pre-Entry
Check List (standard
American Petroleum Institute http://www.api.org will default 1910.146 App D). These
you to http://www.global.ihs.com 1-800-854-7179 ext. 7969 for a regulations are available
copy of API 11P. online at the OSHA web-
site:www.osha-slcgov.com
National Association of Corrosion Engineers-A copy of specifi- Cooper Energy Services
cation MR0175 can be purchased online at www.nace.org or by recommends that Superior
calling (281) 228-6200. equipment users and oil
and gas service equipment
These specifications apply to equipment only! Follow safe packagers follow the
operating and maintenance procedures associated with personnel guidelines set forth by the
National Association of
around sour gas machinery as dictated by your company Corrosion Engineers in
procedures. Sour gas is poisonous and attacks the nervous system specification MR0175:
and can cause paralysis, permanent injury or death! Sulfide Stress Cracking
Resistant Metallic Materi-
als for Oilfield Equipment.
Hazards of Hydrogen Sulfide or “Sour Gas”
Caution should be taken when working in or around hydrogen sulfide (H 2S). This chemical is
dangerous and can cause harm to personnel. H2S is colorless and smells like rotten eggs. In
higher concentrations it will kill your sense of smell and impede your ability to detect it. DO
NOT relay on your sense of smell as a detection method.
Table 4-1 gives some general information on the concentrations levels of H2 S and its effect on
the body. This should be thoroughly read and understood before working in an H2S
environment.

Table 4-1 Effects of H 2S on the Human Body at Various Concentrations
H2 S Concentration Effects
1 ppm (0.0001%) Detectable “rotten eggs” odor.
Protective Equipment Is Recommended For Any Concentrations Over 10 ppm (0.001%)
100 ppm (0.01%) Kills sense of smell in 3 to 5 minutes. May burn eyes and throat.
200 ppm (0.02%) Kills sense of smell rapidly. Burns eyes and throat.
500 ppm (0.05%) Loss of reasoning ability and sense of balance. Respiratory distur-
bances will occur within 12 to 15 minutes of exposure. Requires
prompt artificial respiration.
700 ppm (0.07%) Rapid loss of consciousness and breathing. Death will result if not re-
moved quickly. Immediate artificial respiration is required.
1,000 ppm (0.10%) Immediate unconsciousness. Permanent brain damage may result if
not rescued immediately.
The equipment specifications are based on three levels of sour gas plus additional National
Association of Corrosion Engineers’ (NACE) requirements as defined by the following
percentages of H2 S:
Level I Less than 2% H2S (by volume)

Level 1-11P 2% to 5% H2S (by volume)
Level 2-11P Greater than 5% H2 S (by volume)
Enhanced Trim Follow NACE MR0175 Guidelines
Trim Requirements
For Hydrogen Sulfide (H 2S) Concentrations Up To 2% By Volume:
•For any concentration of H2S up to 2% by volume in lubricated service, special trim will not
be required. Standard material is acceptable and special lubrication practices are recom-
mended.
•The frame lubricant used must have a total base number (TBN) of 15 or higher to help pre-
vent the lubricant from turning acid and damaging bearings and bushings. This alkalinity
must be maintained during operation in the machine at no less than approximately 30% of
the original TBN number by appropriate timely make-up or complete oil changes.
•The frame lubricant must meet or exceed the requirements of MIL-L-2104B, Supplement
No1.

•A complete oil analysis program on the frame lubricant is required to determine proper oil
change intervals as well as to monitor the condition of the lubricant and the unit.
•Compressor cylinder lubricants must adhere to the requirements of Superior Engineering
Standard ES1002. Viscosities are to be on the high side of the pressure conditions normally
required and a 3% to 5% compounding (similar to steam cylinder oils) is also required.
•The compressor cylinder lubricant rate is to be double the normal rate for equivalent non-sour
gas applications.
•All brass, bronze, copper and other copper alloys are to be avoided on hardware for all gas
wetted parts.
•The distance piece is to be properly vented in accordance with local safety standards to pro-
vide maximum safety to personnel.
•Soft iron or aluminum gaskets are to be used between the valve and valve seat.
•The O-ring material used for standard equipment is Viton (Spec. 473) and this is also accept
able for H2S service. For lower temperature operations (< 27°F (<-3°C) Neoprene (Spec.
479) can be specified as an option.
Level 1-11P trim (H2 S Concentrations of 2% - 5% By Volume) include all of the

requirements applicable to concentrations of less than 2% apply plus the following additional
requirements:
•A suitable corrosion inhibitor should be added to the cylinder lubricating oil.
•Cylinders are to be equipped with a suction flushing system (injection of cylinder lubricating
oil into the suction nozzle of each cylinder). This is in addition to the regular cylinder lubri-
cation. This helps to resist the natural solvent action of the sour gas and insures a thorough
distribution of oil for better lubrication. It also helps to better form a barrier to corrosion by
coating all the valve surfaces with an oil film.
•Oil slingers are to be used on each compressor rod in the distance piece compartment to
insure that none of the H2S contaminated cylinder or packing lubricant works its way back
into the crankcase and contaminates the frame lubricating system.
•Packing and piston ring material shall either be non-metallic or contain no copper bearing
metals.
•Compressor valves will be standard construction and hardness.
•All carbon steel, alloy steel, or 12CR steel parts which are gas wetted (come into contact with
the process gas stream) are to have a maximum hardness of 22 HRC. This is to include all
internal fasteners and V.V. pocket screws as a minimum, but excludes valve fasteners.
•The piston rods are 17-4 pH stainless steel with a hardness of 28 - 33 HRC (Heat Treat Spec
ZA).
•Forged steel cylinder bodies made of AISI 4142 are to have a maximum hardness of 235 HB.
Engineering will evaluate these applications on an individual basis as some cylinder pres-
sure ratings may have to be reduced because of the mechanical properties restrictions.

Level 2-11p Trim (H 2S Concentrations > 5%) All of the requirements for H2 S
concentrations of 2%-5% apply plus the following:
•Valve components made of carbon steel or AISI 4140 alloy steel shall have a maximum hard-
ness of 22 HRC (Heat Treat Spec. H2S). This reduces the pressure differential capability of
any specific valve design and thus the pressure differential capability of the cylinders. Engi-
neering will evaluate these on an individual basis and select appropriate alternative designs
to meet the application requirements.
•This reduced hardness requirement also includes steel valve cages (retainers) when they are
used.
•Compressor valve components may also be made of AISI 416 stainless steel with a maximum
hardness of 22 HRC.
•Valve plates wherever possible are to be plastic to better prevent seat wear against the softer
valves seats.
•When metallic plates are required, 410 stainless steel with a hardness of 17 to 22 HRC will
be used.
•Nimonic 90 valve spring material will be used.
•Two compartment configuration of distance pieces is required. The outer compartment must
be purged with inert gas to a pressure of 3 to 5 inches (7.6 to 12.7 cm) H2 O.
•All compressor cylinder and distance piece critical bolting, capscrew, studs, and nuts which
come in contact with the process gas stream shall conform to ASTM A913-B7M (bolts and
studs) and ASTM A194-2HM (nuts).
•All instrumentation that comes into contact with the process stream (liquid level controls,
shutdowns, bourdon tubes, process valving, relief valves, etc.) shall meet the full require-
ments of NACE MRO175 except stainless steel tubing fittings. This requirement is the
packager’s responsibility.
•The distance piece shall be purged with inert gas. The packager is responsible for purging
per these requirements. If other venting or purging systems are desired the details are to be
negotiated between the purchaser and the packager (i.e., vacuum systems or sweet natural
gas purge). The final detailed system should provide for the safety of persons around the
equipment and should prevent contamination of the frame oil with sour gas. Packing cases
will not be purged unless required by the customers.
Enhanced H2S Trim Requirements

Enhanced H2S Trim Requirements are based on guidelines established by NACE MR0175.
That standard specifies more rigid H2S trim levels than required for standard API 11P trim.

The following requirements should be followed when H2 S trim in excess of API 11P
requirements is needed to meet NACE. This enhanced level of trim can also be used for any
concentration of H2S as required by the customer.
The requirements are as follows:

•A suitable corrosion inhibitor should be added to the cylinder lubricating oil.
•The cylinders are to be equipped with a suction flushing system (injection of cylinder lubri-
cating oil into the suction nozzle of each cylinder).
•Two compartment distance pieces are required. The outer compartment must be purged with
inert gas to a pressure of 3 to 5 inches (7.6 to 12.7 cm) H2 O. The inner compartment can
either be separately vented as described previously or purged with inert gas to a pressure of
3 to 5 inches (7.6 to 12.7 cm) H2 O.
•Oil slingers are to be used on each compressor rod in the distance piece compartment to
insure that none of the H2S contaminated cylinder or packing lubricant works its way back
into the crankcase and contaminates the frame lubricating system.
•Compressor valve springs are to be Nimonic 90.
•Packing garter springs are to be Inconel.
•The piston rods are stainless steel with a hardness of 28 - 33 HRC (Heat Treat Spec. ZA).
•Tungsten carbide coating is required in the packing travel area of the piston rods.
•The valve components are to be made of carbon steel or AISI 4140 alloy steel with a hardness
of 22 HRC maximum (Heat Treat Spec H2S). This reduces the pressure differential capabil-
ity of any specific valve design and thus the pressure differential capability of the cylinders.
Engineering will evaluate these on an individual basis and select appropriate alternative
valve designs to meet the application requirements. Compressor valve 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.
•Forged steel cylinder bodies are to be made of AISI 4142 with a maximum hardness of 235
HB. Engineering will evaluate these applications on an individual basis as some cylinder
pressure ratings may have to be reduced.
•All steel gas wetted parts are to have a maximum hardness of 22 HRC. This is to include all
internal fasteners and V.V. pocket screws as a minimum.
•Valve plates wherever possible are to be plastic to better prevent seat wear against the softer
valve seats.
•When metal plates are required, 410 stainless steel with a hardness of 17 to 22 HRC shall be
used.
•All compressor cylinder and distance piece critical bolting, capscrews, studs, or nuts which
come into contact with the process gas stream shall conform to ASTM A193-B7M (bolts
and studs) and ASTM A194-2HM (nuts).

Section 5
Installation
General
Installation of the compressor will be determined by the fabricator and the end customer.
Since the method employed will vary due to application, the following is offered as a guide to
aid in the installation. These instructions are based on previous installations that have proven
satisfactory.
There are two basic compressor mountings: the baseframe or skid mount and the direct to
block mount. (See Figures 5-1 and 5-2.) The baseframe/skid mount is most commonly used
whereby the fabricator sets up the complete installation as a package. This package is then
moved to location and placed on a foundation. With the block mounting, there is no
intermediate (baseframe) between the compressor and foundation, thus the compressor is
mounted direct to the foundation (block). This type installation is of a more permanent nature.
If you have a choice as to the location of the compressor, select a site where the ground under
and around the unit will be firm and dry at all times. Filled ground, wet clay, unconfined sand
and gravel, or similar soils provide poor support. Be sure that sufficient space is available for
necessary maintenance. For instance, there should be ample space to permit removing the
piston and rod assembly out the outboard end of the cylinder. See that provisions can be made
for an overhead hoist, or that a portable crane can be moved into position as necessary for
removal or installation of major parts or assemblies. Electrical outlets, lighting and cleanliness
are other important factors. Adequate ventilation is essential to safety and the welfare of the
operating personnel.
Preparing the Foundation
The responsibility for an adequate foundation is that of the customer. Thus, it is suggested that
a foundation engineer be called in where soil conditions are questionable or where the
location of the compressor is such that transmitted vibration would have detrimental effects
not only to the compressor installation, but on surrounding machinery, buildings, or
personnel. Often times, a neighboring installation on similar soil will serve as a clue to the soil
conditions.
However, unless the nature of the ground is well known, it is advisable to dig several test pits
at the proposed site. CES will gladly furnish data on weights and unbalanced forces required
for calculations by a foundation engineer. In any case where increasing the size of the
standard minimum foundation is necessary, the area of the base should be increased to
Section 5: Installation 4/3/03
Cooper Energy Services n Superior Compressors Page 5-1

decrease the soil loading and the possibility of rocking. When freezing temperatures are likely
to occur, the foundation must be carried well below the lowest expected frostline as
determined by the foundation engineer.
Figure 5-2 Block (Concrete) Mounting
Figure 5-1 Base Frame/Skid Mounting
00757
00758
Foundation Bolts
To locate the foundation bolts, make a wooden template to temporarily position the bolts
according to the dimensions given on the foundation plan. Set up the template in the exact
position to be occupied by the compressor, allowing space for the grout as indicated. (Figure
5-3). Fasten the template firmly in position.
The next step is to attach the bolts to the template so that they will extend into the foundation.
There are two important items which should be considered at this point:
a. Make sure the bolts project far enough through the frame hole to allow two full threads
beyond the nut. Allow for thickness of grout, frame, nut, etc.
b. Provide allowance for misalignment. A piece of 2-1/2 to 3-inch (6 to 8 cm) pipe or metal
tube positioned around each bolt (Figure 5-3) will prevent the bolts from being cemented
into a fixed position and thus allow slight movement of the bolts for alignment with the
holes in the frame. Stuff paper or rags around the bolts at the top of the pipe to prevent
cement from entering when the foundation is poured. The length that the bolts extend into
the foundation is indicated on the foundation plans.
WG-4/3/03

Placement and Leveling t Figure 5-3 Foundation Bolt Positioning
After the foundation has been

completed and the concrete has had
ample time to thoroughly set, the
unit is ready to be placed upon the
foundation.
First, remove the template and chip

off the top layer of pure cement and
sand so that the grout will have a
good solid surface for bonding.
Then, clean the top surface of the
foundation thoroughly. Soak the
surface for several hours before
pouring grout, but make sure there is
no standing water. Remove the
stuffing from around the foundation
bolts, but place a dam around the top 00759
of the bolt and extending into the
can, to avoid grout contact with any
part of the bolt. Next, screw each jackscrew through the frame (Figure 5-3) in a manner
which would support the frame approximately 1 to 1.5 inch (2.5 to 3.8 cm) above the
foundation. This provides for leveling, aligning and grouting. (There should be a jackscrew at
each holddown bolt.)
With the compressor resting on the jackscrews, check to see that it is

level. Place level on top side of frame as required to level in both
directions all around. Bring frame to level by adjusting jackscrews.
I CAUTION
Keep all jackscrews snug. After levelling, foundation bolt nuts Responsibility for the grout
belongs with the customer
should be secure but NOT TIGHTENED. It is very important the unit or their contractor. Grouting
is aligned as accurately as possible so that after grouting or shimming material instructions should
has been completed, the foundation bolts may be pulled down be carefully followed. Fail-
ure to comply with this
without any resulting stresses. warning may result in dam-
age to your unit.
When the grout has completely hardened, LOOSEN THE
JACKSCREWS and tighten down all the foundation bolt nuts
evenly. Make sure that no stresses are set up when pulling down the nuts by checking
alignment with a dial indicator.

Coupling Installation and Alignment
i Laminated rings
must be re-assem-
The success of a compressor installation depends greatly upon the bled in the coupling
exactly as received.
construction of the foundation and upon the care used to align the
compressor with its driver. The standard flexible coupling used to
drive the Superior compressor is shown in Figure 5-4. Installation is as follows dial indicator
method:
Figure 5-4 Flexible Coupling Assembly

a. Disassemble the flexible
coupling. Note the
arrangement of bolts,
washer, and nuts. They must
be replaced in their original
position. Tie a string or wire
through one bolt hole of the
laminated rings (A) to retain
the dialed position of
individual discs.
. b. Mount flange (B) on

engine flywheel. Torque
flange screws per Table 7-2
and lockwire together.
Mount hub (C) on
compressor crankshaft. (See
instructions given in Drive
Coupling Hub Page 7-9.)
c. With engine and compressor moved into position, as shown on the outline drawing,
reassemble coupling. Dimension (D) must be maintained during the following alignment
procedure.
t Figure 5-5 Dial Indicator Method of Alignment
00761
WG-4/3/03

The recommended procedure for establishing final alignment is called the “indicator method.”
Proper lining up may take a little time, but it is absolutely essential. Flexible couplings should
not be required to compensate for any misalignment that can be eliminated. The closer the
initial alignment, the greater the capacity of the coupling to take care of subsequent
operational misalignment.
d. Attach dial indicator as shown in Figure 5-5 (view B). Rotate coupling 360 degrees to
locate point of minimum reading on dial; adjust indicator to zero.
e. Rotate coupling 360 degrees. Observe misalignment reading.
f. Move engine or compressor, or both, until dial indicator reading

does not exceed 0.0003 inch for each inch of diameter at indicator
stem (0.0003 cm per each cm of diameter at indicator stem). This
i Bolt heads
should be held
and locknuts
is approximately 0.006 inch (0.015 cm) at outside diameter of only turned, when tight-
flange B. This corrects angular misalignment. ening coupling bolts.
g. Reset indicator to zero and repeat steps (d), (e), and (f); if either, the engine or
compressor is moved during aligning trials.
h. The coupling should be turned several revolutions to make sure no “end-wise creep” in
the crankshaft is measured.
i. Mount dial indicator (Figure 5-5 (view C)) to check for parallel misalignment. Set
indicator stem on outer diameter surface of flange B and adjust to zero.
j. Rotate coupling 360 degrees. Move and/or shim the units until
the indicator reading comes within the maximum allowable
variation of 0.004 inch (0.010 cm).
i Coupling bolts
are tightened at
the factory for
shipping purposes only.
k. Torque all bolts. See Table 7-2 for recommended torque values. When installing cou-
After several hours of operation, recheck both alignment and bolt pling, the below values
apply to bolts and lock-
torque.
nuts as they are received
from the factory. If any
l. When proper alignment is attained within the previously additional lubricant is
specified limits, the laminated rings A must appear vertical and used or if the threads are
wiped dry, these values
undistorted. There must be no end thrust due to poor initial must be modified.
assembly of the coupling.
n. Alignment should be checked periodically. Realign unit when parallel misalignment

exceeds 0.014 inch (0.036 cm) T.I.R. and/or angular misalignment exceeds 0.020 inch
(0.051 cm) T.I.R.

Table 5-6 Rexnord Flexible Coupling Torque Values
Coupling Size Bolt Size Threads/Inch Torque -- Foot- Dimension D--
in inches Lbs. (N-m) inches (mm) *on
Fig 5-4
500 3/4 16 260 (353) 8-3/4 (222)
550 7/8 14 350 (475) 9-7/8 (2480
600 1 14 490 (529) 10-7/8 (2760
700 1-1/8 12 630 (855) 12-7/16 (316)
750 1-1/4 12 830 (1125) 13-1/2 (343)
800 1-3/8 12 1100 (1492) 14-3/4 (375)
850 1-1/2 12 1400 (1898) 15-3/4 (400)
925 -- -- 1800 (2440) 17-1/4 (438)
Crankshaft Web Deflection Figure 5-7 Crankshaft Web Deflection Mea-

surement
The compressor should be aligned to the
driver according to the instructions given
above. During the alignment procedure, the
crankshaft web deflection should be measured
on the number one throw. (Figure 5-7) The
deflection should not be greater than 0.001
inch (0.025 mm). The deflection should be
periodically checked and should not exceed
0.002 inch (0.051 mm). Note: The deflection
can be measured with #1 connecting rod
removed.
Cylinder Mounting
Cylinders are normally mounted on the

compressor frame when shipped to a location. Sometimes, because of shipping and packaging
restrictions, cylinders may be shipped separately. If that is your case, the cylinder head and the
piston and rod assembly maybe installed prior to shipment.
When reassembling the cylinder to the crosshead guide, use a criss-cross pattern nut
tightening sequence. See Table 7-2 for recommended torque values.
Outer end cylinder supports, if supplied, are intended to support the weight of the cylinder
only. Do not use them to force the cylinder into alignment. If a cylinder cannot be aligned,
check for dirt, burrs, or other irregularities at the mounting surfaces.
WG-4/3/03

Sliding Rod Through Packings
Obtain a piston rod starter tool before attempting to slide the rod through packing. This tool
consists of a split sleeve cone and capscrew. The piston rod should be coated with grease
before and after installing it on the rod. This tool is designed to protect the packing rings from
damage during removal and installation of the rod from the cylinder.
Setting Piston End Clearance Figure 5-8 Piston End Clearance

Check
Piston end clearance is set by screwing the piston and
rod assembly further into or out of the crosshead. With
a cold compressor, the total clearance should be
distributed with two-thirds on the head end and one-
third on the crank end of the cylinder. This allows for
thermal growth of the reciprocating assemblies during
normal operation.
Measure end clearance as follows:
a. Remove a valve from each end of the cylinder.
b. Bar over the compressor, at least one revolution in Figure 5-9 Measuring the Piston
the normal operating direction, to insure all parts are End Clearance
working freely.
c. While barring the compressor over again, head end

clearance is taken by inserting a 1-inch (2.5 cm)
length of soft solder between the approaching piston
and cylinder head. Pistons 10 inches (25 cm) and
larger should use solder inserted from both sides to
keep the piston from cocking and giving a false
reading (Figure 5-8). Measure the crushed solder
wire (Figure 5-9). The head end clearance should be
0.070 to 0.090 inch (1.78 to 2.29 mm) for a cold compressor.
d. Check the crank end using the same method. For a cold compressor, the crank end
clearance should be 0.030 to 0.050 inch (0.76 to 1.27 mm).
e. If any adjustment is needed, loosen the balance nut and screw the piston and rod assembly
in or out of the crosshead. The WG piston rods are threaded with 12 threads per inch. Thus
one complete turn of the piston and rod assembly moves it 0.083 inch (2.11 mm).

f. After adjusting the piston and rod assembly, recheck the head end and crank end clearances.
g. After setting the piston end clearance, re-torque (Table 7-2 torque values) the balance nut.
Piston Rod Runout
Once the piston and rod assembly and cylinder head are assembled, and the piston end
clearances are set, a check can be made for the piston rod runout. Proceed as follows:
a. Bar over the compressor until reaching the crank end dead center position.
b. Place two dial indicators as Figure 5-10 Dial Indicators

close to the packing as
possible. Zero the two dial
indicators. (Figure 5-10).
c. Bar over the compressor

until reaching the head end
dead center position.
Record indicator
movement.
d. The horizontal runout must

not exceed +/- 0.0010 inch
(0.025 mm) for 6" stroke, or +/- 0.0012 inch (0.029 mm) for 7" stroke. Allowable vertical
runout tolerances are in Table 5-11.
e. If the horizontal run out exceeds acceptable limits, loosen the packing and re-torque. If the
crisscross pattern of torquing is not followed, this may cause the packing case to seat at an
angle, causing the rod to deflect to one side. A second technique would be to loosen the rod-
to-crosshead nut, and rotate the piston one quarter turn before re-torquing. If the runout still
exceeds limitations, contact your Cooper Energy Services Aftermarket facility for
assistance.
f. If the vertical runout exceeds acceptable limits, check the packing case as explained for
horizontal runout. Also, check the piping and bottles attached to the cylinder to see if they are
distorting the cylinders. If runout still exceeds limits, loosen the cylinder to crosshead guide
nuts and re-tighten them. If the runout is still beyond acceptable limits, contact your Cooper
Energy Services Aftermarket facility for assistance.
WG-4/3/03

Section 6
Operation Start-up
Complete Superior® Compressor Start-Up Checklist and Report
Control Procedures Engineering Standard ES30 and forward to the
address included in procedure.
Preparation For Initial Startup
Prior to startup, the frame lubrication system should be primed by

I CAUTION
using the lube oil hand priming pump or automatic priming pump. Read this manual and famil-
iarize yourself with the
Use of this pump will prevent oil starvation in the bearings during compressor, auxiliary
startup, prolonging compressor life. Compressor design, operating equipment, and your com-
conditions, and the gases being handled all have a significant effect pany’s safety procedures
before attempting to start
on how well a lubricant performs in the given application. the equipment.
The following procedure is suggested before starting the unit for the first time, after an
overhaul of the frame or cylinders, or after an extended (over 6 months) shutdown.
a. Check the alignment between the driver and the compressor.
b. Verify the proper torquing of the foundation bolts.
c. Remove the top cover of the base and the covers for the
crossheads and distance pieces on each crosshead guide.
NDANGER
Thoroughly wipe the interior of the compressor with a lint free cloth
to remove any water or foreign material that may have accumulated Vent the compressor and the pro-
cess system to the atmosphere
during shipment or storage. before removing any gas-con-
taining part of the compressor or
d. Check the crankshaft for web deflection. its associated piping.
NDANGER
e. Check the piston rod runout.
f. Remove a valve from each end of every compressor cylinder.

High pressure oil stream may
puncture skin. Use proper
g. Check the piston end clearances on all cylinders, and then replace wrench and keep hands away
the valves. from the immediate point
where connection is purging
air.
h. Add lubricating oil, which meets the proper specifications, to the
base and to the lube oil filter.
Section 6: Installation WG-4/3/03

i. Check the force feed lubricator for cleanliness and fill to the proper level with oil.
j. Adjust all force feed lubricator pumps to full stroke for cylinder and packing break-in.
k. Disconnect ends of force feed lubricator lines as close as possible to cylinders and
crosshead guides. Hand pump the lubricators to fill lines and eliminate air.
l. Connect the force feed lubricator lines and operate pumps ten more strokes to force oil
into cylinders and rod packing.
m. Prime the frame oil system with the lube oil priming pump. Operate the pump a
minimum of 100 strokes or run automatic pre-lube pump. This should fill all empty oil
lines.
n. Hand lubricate the piston rod next to the packing. (This does not
apply to non-lubricated applications.) i Oil level in frame
should be filled to
the level in the Kenco level
o. Replace all covers with their respective gaskets and tighten regulator NOT the level in
the frame bull’s-eye.
screws according to Table 7-2. Distance piece covers may be left
off to check for packing leaks on start up if not using sour gas. For
sour gas applications, see warnings in sour gas trim Section 4.
p. Check to see that all crosshead guides or distance pieces and packings are individually
vented with the proper size of vent lines. Refer to Engineering Standard ES3 for the most
up-to-date recommendations.
q. Verify that all safety switches, shutdown devices, and relief valves are properly set and
operational. See Table 7-16 for normal operation, alarm, and shutdown settings.
r. Visually verify that all guards are in place.
s. Unload the compressor for startup by placing the bypass line between the first stage
suction and last stage discharge lines.
t. Verify that suction and discharge block valves are open.
The frame lubricant must be capable of operating with the type of gas being handled by the
compressor cylinders. For viscosity requirements see page 3-3 and Table 3-2 & 3-2.
Lube oil header pressure should be 50 psi (345 kPa) and is maintained at this level by the
pressure relief valve. If adjustment is required, it can be done by removing the cap which
provides access to the spring loaded adjusting screw. This should be adjusted while at normal
operating speed and temperature.
WG-4/3/03

When starting the compressor, verify a lube oil header pressure of 20 psi (138Kpa) or greater
occurs within 5 seconds of compressor startup. To prevent damage to the crankshaft and other
lubricated parts, all compressors are equipped with low oil pressure shutdowns. This is
triggered when the oil pressure falls below 20 psi (138 kPa).
The oil level in the frame is normally at the center of the sight glass. An alarm should sound if
the oil level rises 1 inch during compressor operation, this will submerge the gaskets on the
bottom of the front and rear covers. A shutdown should occur if the oil level rises an
additional 1.5 inch (3.8 cm) or if the oil level falls 1 inch (2.5 cm) from normal level.
The oil level in the frame sump should be checked while the compressor is running. The
correct level is shown by the round sight gauge on the auxiliary end of the compressor. Oil
level (while running) should be no higher than the top and no lower than the bottom of the
sight gauge. Oil may be manually added through the breather cap hole in the top cover. The
breather cap is designed to be threaded into its bushing by hand and no wrenches should be
used. Make up oil may also be continuously added through an optional, frame mounted oil
level controller connected to an oil supply tank.
Initial Startup
1. Open the valves supplying water to the compressor cooling I CAUTION
system (when required). Running compressor at
speeds less than 600 RPM
2. Start up and operate the unit under no-load conditions at for longer than 12 minutes
may result in unusual wear
reduced speed where possible (600 RPM for engine driven units). of the piston rings.
Check the oil pressure. When the compressor is started, an oil
pressure of 20 psi (138 kPa) must be experienced within 5 seconds or the compressor must
be immediately shut down. Do not restart until adequate oil pressure can be assured. The
oil level in the frame is normally at the center of the sight glass.
3. Run compressor for 2 to 5 minutes at 600 RPM. If driver is a constant speed electric
motor run compressor for only 1 to 2 minutes.
4. Shut system down and check all bearings and packings for high temperatures.
5. Remove crosshead guide covers and check all lubricated surfaces for high temperatures.
6. Check piping for oil or water leaks.
7. Start system and compressor up again and run for approximately 20 to 30 minutes. Add
oil to the crankcase to bring the oil level (while running) up to the middle of the sight glass.
Shut down and recheck as above.

NDANGER
8. Start unit. Bring unit up to full rated speed. Apply load to
compressor by closing the bypass line between the first stage
Do
suction and last stage discharge lines.
not immediately remove
9. During the initial period of operation, pay close attention to the equipment covers after
the machine for any unusual high temperature, pressure, or the compressor has been
stopped. Allow the unit to
vibration. In the event of equipment malfunction where
cool down to prevent possi-
excessive vibration, noise, high temperature, or any other ble explosion due to in rush
dangerous condition exists, the compressor should be stopped of air or injury caused by
immediately. contact with hot surfaces.
Normal Startup
Not all of the instructions provided for initial startups are required for routine starting. The
following notes comprise the normal starting procedure:
1. Set all clearance devices at positions suited for the planned operating conditions. Unload
the fixed volume pockets or suction valve unloaders.
NDANGER
2. Operate the force feed lubricator pumps, by hand, for ten
strokes. (Be sure the lubricator tank is kept full.)
3. Hand prime the frame lube oil system by priming 40 strokes Improper setting of variable vol-
with the lube oil hand priming pump or automatic priming pump ume pockets, fixed volume pock-
ets, valve unloaders, or other
(to prevent oil starvation in the bearings for compressor life). unloading devices can result in
damage and/or injury to equip-
ment and/or personnel.Operating
4. Turn on cooling water supply. the system without clearance and
loading information can result in
5. Start the unit. Check frame lube oil pressure. equipment failure due to overload,
excessive rod loads, and high tem-
peratures.
6. Operate at low speed (600 RPM where possible) and no load
for several minutes. Check force feed lubricator sight glasses for
feed (Figure 3-6). Check lube oil for proper level, at sight gauge.
7. Bring up to rated speed and apply load.
Normal Shutdown
1. Decrease speed to 600 RPM (engine driven units only).
2. Unload the compressor by opening the bypass line between the first stage suction and the
last stage discharge lines.
3. Shutdown the compressor driver.
WG-4/3/03

4. Close suction and discharge block valves.
5. Turn off water supply.
6. Relieve pressure by venting compressor cylinders, suction piping, and discharge piping
to remove any remaining gas.
Emergency Shutdown
In an emergency situation, the shutdown devices will shut down the system. In such as case,
the cause of the shutdown must be identified and corrected before restarting the compressor.
Refer to the Troubleshooting Page 7-23 thru 7-31 to troubleshoot compressor.
Recommended Operating Conditions
The compressor should only be operated at speeds, pressures, and temperatures listed on the
data sheets or performance curves. The unit should never be operated at conditions other than
those specified on the data sheets without contacting the manufacture.
Note
Superior attempts to furnish performance curves and/or computer printouts to assist you with com-
pressor operation. If they have been omitted please fill out the following form and new curves will
be provided to you. If compressor operating conditions change, contact your Cooper Energy Ser-
vices Aftermarket Sales Office.

WG-4/3/03

Fill Out and Return To: Cooper Energy Services

20110 GH Circle
P.O. Box 947
Waller, Tx 77484
Fax:713-890-1399
Unit Serial Number
Model
Compressor Cylinder Sizes
Elevation
Ambient Temperature (°F or °C)
Suction Gas Temperature ( °F or °C)
Specific Gravity
“N” Value
Design Suction Pressure
Anticipated Suction Pressure
Design Discharge Pressure
Alternate Discharge Pressure
A complete gas analysis must also be supplied.
Send Performance Curves To:

WG-4/3/03

Section 7
Maintenance
General
The diligent observation of the inspection and maintenance procedure, given in this section,
will go a long way toward insuring satisfactory operation of the compressor. Superior®
recommends planned periodic inspections of equipment. Regardless of the gas compressors,
malfunctions can occur. Faithful preventive maintenance and the use of genuine Superior®
parts will help prevent costly down time, repairs, and replacement costs. Planned shutdowns
for doing preventive maintenance will result in minimum maintenance costs and maximum
mechanical efficiency of your equipment. Good preventive maintenance practice includes a
periodic check of critical bolt torques, such as compressor main and connecting rod bolts and
drive coupling bolts.
Acceptable Clearance Values

Table 7-1 shows clearance values for some critical components when new. When a part is
first installed, the clearance should be within the range shown in Table 7-1. If not, the part is
defective or has been incorrectly installed. During inspections, clearances found exceeding
the clearance range indicate worn parts that should be replaced.
Table 7-1 Acceptable Tolerance Clearance Values

Assemblies Clearance range in inches (mm)
Crankshaft - Main Bearing 0.0040 - 0.0094 (0.102 - 0.239)
Connecting Rod Bearing 0.0040 - 0.0094 (0.102 - 0.239)
Crosshead Pin to Connecting Rod Bushing 0.003 - 0.006 (0.08 - 0.15)
Crankshaft End Play - Thrust Bearing 0.012 - 0.017 (0.31 - 0.43)
Crankshaft Web Deflection 0.000 - 0.001 (0.000 - 0.025)
Connecting Rod Thrust 0.016 - 0.031 (0.41 - 0.79)
Gear Backlash-Aux End Lube Oil Pump (WG) 0.003-0.007 (0.08 - 0.18)
Crosshead To Guide 0.010 - 0.018 (0.25 - 0.45)
Lube Oil Pump Drive Gear Backlash 0.010 - 0.014 (0.25 - 0.36)
Section 7: Maintenance 4/3/03

Table 7-2 Recommended Torques * American measurement (metric measurements)
Fastener (S.A.E.) Grade 5 or Better) SIZE TORQUE Ft.-Lbs. (N-m)*

SPECIFIC TORQUE VALUES
Main Bearing Cap 1-1/8" - 12 UNF 430 - 460 (583 - 624)
Connecting Rod Cap 1-1/8" - 12 UNF 570 - 630 (773 - 854)
Base Spacer Bar 1-1/4" - 12 UNF 640 - 700 (868 - 949)
Crosshead Guide to Frame 1" - 8 UNC 260 - 290 (353 - 393)
Cylinder to Crosshead Guide 7/8" - 9 UNC 200 - 220 (271 - 298)
Shoe to Crosshead 1/2" - 20 UNF 35 - 45 (47 - 61)
Balance Nut 2-3/4" - 12 UNR 3090 - 3790 (4192 - 5140)
Piston to Piston Rod Nut 2" - 8 UNF (for through rod) 1180 - 1265 (1598 - 1713)
GENERAL TORQUE VALUES
All Fasteners Size in Inches Torque Ft.-Lbs. (N-m)*
1/4 4-6 (5-8)
3/8 12-18 (16-24)
1/2 35-45 (47-61)
5/8 60-70 (81-95)
3/4 120-140 (163-190)
7/8 200-220 (271-298)
1 260-290 (353-393)
1-1/8 370-410 (502-556)
1-1/4 520-570 (705-773)
1-3/8 700-770 (949-1044)
1-3/4 930-1030 (1261-1397)
SPECIAL TORQUE VALUES
Cylinder Number Cylinder Diameter in inches Valve Cap Nut Torque Ft.-Lbs. (N-m)*
615 6.00 370 (502)
616 6.25 370 (502)
617 6.75 370 (502)
618 5.75 300 (407)
619 6.25 300 (407)
620 6.75 300 (407)
621 7.25 300 (407)
683 7.00 370 (502)
Page 7-2 Cooper Energy Services n Superior Compressors

Torque Recommendations
I CAUTION
To insure satisfactory compressor performance and to minimize When tightening nuts and
costly failures, it is extremely important to tighten all nuts and bolts bolts on compressor valve
to the recommended torque values specified in Table 7-2. caps, bottles, and flanges
care must be taken to avoid
Additional information is given in Service Bulletins SB168 and excessive tightening. Over-
SB175. Follow the following general recommendations. tightening can result in
unnecessary stress in the
•Torque wrenches should not be used to “break loose” fasteners. Use cylinder body and, in the
an appropriate wrench or breaker bar. case of valve caps, can
result in valve seat distor-
•Hand position is critical. Only pull from the hand hold to assure tion.
accuracy.
•Occasionally clean and lubricate the ratcheting head with light oil, NOT GREASE.
•Periodic calibration is essential to ensure accuracy.
Critical Bolt Torques

It is critical that the following preventative maintenance schedule be followed to prevent
major damage to your compressor. Check all critical bolt torques on components as follows:
•One month after unit is placed in service.
•Six months after unit is placed in service.
•Every twelve months thereafter.
Repeat this schedule when the compressor is rebuilt, overhauled, or has major repairs.
All torque values shown in Table 7-2 are based on threads which are clean, free of burrs,
paint, etc. and lubricated with engine oil or similar petroleum base lubricants. Unless
specified, DO NOT USE any compounds containing molybdenum disulfide as a thread
lubricant. Due to its high lubricity, excessive stresses will result if used with the torque values
given in Table 7-2.
Precautions
Follow the precautions listed below when any maintenance is performed. Damage to the
equipment, personal injury or death may result if these precautions are not followed.
a. Block the flywheel to prevent rotation of the compressor and driver.
b. Remove all gas by unloading, venting, and then “blinding” the compressor. Blinding
means to shut off all block valves so there can be no process gas flow to the compressor.

NDANGER
c. Eliminate all internal pressures by removing cylinder indicator
plugs or vent through indicator cocks, if provided.
d. Prevent clogged oil lines or filters by using only lint free cloths.
e. Ensure all tools and work areas are clean and free of oil, water,
When work is being done on
dirt, dust or grit. the compressor, the driving
unit must be blocked in such
f. Never file, grind or scrape any lubricated parts (i.e. bearing a way that the compressor
cannot turn over. Block
shells or saddles). valves must be closed on the
suction and discharge lines.
g. Never distort or mark the piston rod with any tool or device. Air or gas must be bled off
from the cylinders. Precau-
Rods that are bent or have burrs will damage the packing or tion must be taken to prevent
prevent it from sealing. In severe cases, the rod could break. the opening of any valve
which would release pressure
against a piston, causing it to
h. Never torque or tighten any nut, cap screw or stud if threads or rotate the unit at a critical
moment.
mating threads are covered with paint or other materials that are
not specified by Superior® for use on threads.
i. Genuine Superior® parts must replace any components which are changed.
j. Do not refinish worn valve plates.
k. When reassembling parts during maintenance, replace all worn or damaged gaskets and
seals.
l. Always install new cotter pins or lock wire.
m. Check and clean all lubricating oil passages when the unit is down for repair or normal
maintenance.
n. After a long period of shutdown or a major overhaul, frequently check the unit during
the first 300 hours of operation.
o. After completing maintenance, remove any locking or blocking devices before

attempting to rotate the equipment.
Component Maintenance
Base (Crankcase)
The base is made of high strength alloy iron and is heavily ribbed and reinforced for maximum
rigidity. Large spacer bars provide further stability and ease reassembly. The top and end covers
are individually removable to provide easy access to moving parts. Our open-top design allows

the crankshaft to be easily removed. An oil sump is provided in the lower portion of the base.
The line-bored main bearing supports have caps which are match-marked and numbered and
must be assembled accordingly.
Crankshaft, Thrust And Main Bearings
The complete crankshaft assembly includes the drive end oil slinger and the auxiliary end
drive gear. Both of these are shrunk onto the crankshaft, eliminating the need for keyways
and keys. The crankshaft is drilled to carry lubrication from the main bearings to the
connecting rod bearings.
The thrust bearing is a “half washer” type. It fits into a groove machined in the main bearing
saddle and is held captive by the crankshaft, the main bearing saddle and the main bearing
cap.
The upper and lower main bearing shells are interchangeable. After
the compressor has been run, it is preferable that the shells be placed
back in their original position. Therefore, upon removal of the
I CAUTION
bearing shells, they should be so marked. Only use a pencil for mark-
ing on the parting line faces
or in the groove of the bear-
After removing the main bearing cap and the upper bearing shell, the ing shells.
lower bearing shell can be rolled out from underneath the crankshaft
with the help of the main bearing removal tool. This is done by inserting the neck of the tool
into the oil passage hole in the crankshaft journal. When the compressor is barred over, the
tool will push the bearing shell out from underneath the journal and around to the top where it
can be removed. A new bearing shell can be installed using the same procedure.
Carefully clean the crankshaft, bearing shells and saddles before attempting to replace the
bearing shells. Under no circumstances should any filing, scraping, or other fitting be done on
either bearing shells or saddles. The bearing cap nuts should be tightened uniformly (using a
crisscross pattern) to the proper torque given in Table 7-2.
The main bearing clearance (tolerance value) can be checked by using a dial indicator and a
hydraulic jack. Proceed as follows:
a. Remove the top cover to gain access to the crankshaft.
b. Attach the dial indicator to the bearing cap via a magnetic base. Mount the indicator so
the button comes in contact with the crankshaft at its highest point. Depress the button until
the dial makes one complete revolution and set the pointer top to zero.
c. Use a hydraulic jack that will fit between the crankshaft and frame bottom. Position it as
close as possible to the bearing being checked.

d. Support the jack with a piece of wood and jack the crankshaft up and down to get a
clearance reading on the dial indicator.
e. Compare the clearance reading with the tolerance value given in Table 7-1. If the
clearance reading exceeds the maximum limit, the bearing needs to be replaced.
Connecting Rod And Bearings
NDANGER
The connecting rod is a steel forging, rifle-drilled to provide
lubrication to the crosshead pin bushings. The crankpin end of the rod
is split and retains the precision type bearing shells by means of four
Take extreme caution to ade-
alloy steel bolts and nuts clamping the cap and rod together. The cap is quately support the rod. If care
aligned to the rod by dowels and both parts are precision machined as is not taken during the bearing
an assembly. A complete assembly must be ordered, if replacement is removal process, personal
injury and equipment damage
necessary. could result.
The upper end of the connecting rod carries one pressed in bushing. When the bushing is
replaced in the field, extreme care should be used in shrinking the new bushing in place.
To change the connecting rod bearings (crankpin end), bar the compressor over until the
connecting rod cap rises to its highest point. This will offer easy access to the cap bolts.
Support the connecting rod so it will not drop after the cap has been removed.
With the connecting rod supported, remove the rod cap and its bearing half. In order to get
access to the other bearing half, bar the compressor over so the crankshaft moves slightly
away from the connecting rod.
NDANGER
Install a new bearing half against the back wall of the connecting rod.
The tang recess within the rod should support the bearing until the
crankshaft can be moved back into position. Complete the assembly
Always support the connect-
process by putting the other bearing half and rod cap in position and ing rod so it can not drop and
tighten the bolts (using a crisscross pattern) per the torque values given damage equipment or cause
in Table 7-2. injuries.
The rod cap and crosshead pin must be removed to remove a

connecting rod. The crosshead pin can only be removed when the i The caps and rods are
numbered by throw
crosshead is in the outermost position. Remove the crosshead pin and have their weights
assembly. Push the pin through the crosshead far enough to release the stamped on them. Always
install rods with this infor-
connecting rod. The connecting rod can be eased out of its position mation displayed up.
when the crankshaft throw is slightly below the innermost position.
A connecting rod can be installed by reversing the above procedure.

Crosshead Guide
The fasteners holding the crosshead guide to the base must be torqued uniformly (using a
crisscross pattern) to prevent cocking of the guide relative to the base and crankshaft. (See
Table 7-2 for torque values). Large side covers on the crosshead guide allow easy access to
the crosshead, connecting rod, and rod packing. The crosshead can be removed through these
openings without disturbing the cylinder mounting.
Crosshead Removal And Installation
The crosshead is made of ductile iron and has removable top and bottom shoes which have
durable bearing material on the sliding surface. Screws and locknuts hold the shoes firmly in
place. These must be torqued uniformly to the figure specified in Table 7-2. Like all bearing
maintenance, cleanliness is an important factor during the assembly of shoes to the crosshead
and placing the crosshead in to the guide.
To remove a crosshead proceed as follows:
a. Vent compressor clearance bottles, unloaders and all associated gas piping to
atmospheric pressure.
b. Bar over the compressor so piston is in the outer most position.
c. Remove the cylinder head and crosshead guide covers.
d. Loosen the balance nut with the crosshead nut wrench.
e. Use the piston puller to turn the piston and rod assembly out of the crosshead. Do not
use directly on the piston rod.
f. After the piston rod is free of the crosshead, remove the balance nut from the rod.
g. Prepare the piston rod for moving through the packing. (Section 6.) Pull the piston and
rod assembly out far enough to allow the crosshead to be removed.
h. Remove the crosshead pin assembly by loosening the center bolt, nut, and retainer plates,
switching them from end to end, and torquing the nut to pull the pin free.
i. Support the connecting rod and carefully remove the crosshead pin.
j. With the pin removed, slowly bar over the compressor to innermost position. Be careful
to support the small end of the connecting rod so it cannot score or dent the bottom slide.
k. Support the crosshead weight, roll the crosshead the rest of the way over and lift it out.
Care should be used to prevent damage to the shoes or slides.

To install a crosshead, reverse the above sequence. When using the crosshead installation
handles, more care and feel is required. DO NOT USE FORCE as this is the first indication
that the job is being done incorrectly and damaged crosshead shoes may result. The correct
procedure is to stand to one side of the crosshead guide and feed the crosshead across,
attempting to roll it in at short intervals. From the proper position, the crosshead will roll in
easily without damage to the shoes.
During the reassembly procedure, the machined face of the balance Crossheads and
nut must be toward the crosshead. Check piston end clearances and i balance nuts are
stamped with throw
then make sure that the balance nut is torqued properly (Table 7-2) numbers and must
against the crosshead. be replaced accordingly.
Auxiliary End Cover
The auxiliary end cover is aligned to the base and located by a dowel. Additional dowels in
the auxiliary end cover provide proper location for attaching the lube oil pump drive carrier
and the force feed lubricator drive carrier.
Drive End Cover

i This procedure
applies to the old style
The drive end cover is aligned with the base by two dowel pins. An cover part #620-093-001.
The new cover is machined
additional dowel pin is used in the end cover to locate the seal cover. and does not contain the
(The oil drain hole must be down.) The seal cover has a close pilot fit same number of components.
in the end cover.
If it is desirable to remove the crankshaft from the base without removing the drive coupling
hub, this can be done. First, remove the screws holding the drive end cover. Then support the
drive end cover in place on the crankshaft, while lifting out the crank. Remove the screws
holding the seal cover. The drive end cover can now be snaked off the crankshaft toward the
auxiliary end - leaving the seal cover on the slinger hub. It must be supported to prevent it
from moving.
Lube Oil Supply (Sump)
The oil circulating system is of the pressure, wet sump type, where the lubricating oil supply
is carried in the compressor frame and circulated by means of a gear type pump - gear driven
from the crankshaft.
The pump takes oil from the frame sump, through a suction strainer and delivers it into the
lubricating oil header, or manifold on the compressor - the oil first passing through an oil
cooler and full flow filter.

The precision built, gear type lube oil pump provides full pressure lubrication for all moving
parts in the frame. The pump, with its drive gear, can be removed from the base end cover -
independent of the cover or other gear drives. When installing the pump, observe the
following:
a. Clean the pump mounting face thoroughly.
b. Assemble key, drive gear and lock plate. Tighten screws holding the lock plate to the
gear, and fasten with lock wire. Add a slotted nut to the rotor shaft and lock in place with a
cotter pin.
c. Add gasket for carrier assembly. Slide carrier assembly into place on the end cover, using
the dowel to locate.
d. Proper gear backlash is given in Table 7-1.
Drive Coupling Hub
The main drive coupling hub has a shrink taper fit on the compressor crankshaft.
Additionally, the hub is held in place by a round locknut which threads onto the end of the
crankshaft and is locked in place by “Nylock” setscrews.
The coupling hub is removed as Figure 7-3 Removing Crankshaft Coupling Hub
follows (Figure 7-3):
a. Loosen lock nut (E), after
first unlocking its setscrews,
until there is 1/8 inch (3mm)
of space at dimension (X).
b. Mount steel bar (G) in the

manner illustrated. Putting a
1-1/2-6 UNC tapped hole at
its midpoint will permit a
standard 1-1/2 UNC cap
screw to be used as a
jackscrew.
c. Tighten nuts on cap screws

(H) per torque values given
in Table 7-2.
d. Torque jackscrew (J) up against the crankshaft per torque values given in Table 7-2.
e. Connect a 10,000 psi hand hydraulic pump to the 3/8-inch pipe tap (F) in the hub.

f. Operate the hand pump until the hub becomes loose and slides against the lock nut (E).
g. Remove the jackscrew and bar arrangement.
h. Remove nut (E); the hub can then be lifted off by crane or by hand.
If the proper equipment is not available, the most practical method of removing the coupling
hub from the crankshaft is by first removing the crankshaft from the base. The crankshaft and
drive end cover plate may now be taken to a suitable work area where the locknut is removed,
the hub heated and pressed off the crankshaft.
Install the coupling hub onto the crankshaft as follows:
a. When at room temperature, push the hub on the crankshaft taper as far as possible.
b. Push the crankshaft all the way to one side to take up any thrust clearance that may be
present.
c. Use gage blocks and shims to fill the space between the coupling and the compressor
end cover.
d. Remove the amount of shims needed to provide an advance of the hub on shaft of 0.050
inch (1.27 mm).
e. Heat the coupling hub and slide it on the shaft until it engages the gage block (with the
reduced amount of shims as defined in item d above).
f. Hold hub in position until it is cool enough to engage the crankshaft.
g. When hub has cooled to room temperature, install lock nuts and Nylock setscrews.
Flexible Drive Coupling
Obtain the most recent version of Service Bulletin SB149 for detailed information on flexible
drive couplings. The flexible drive coupling will give you relatively trouble-free service and
long life if installed and maintained properly. The coupling was selected based on known
loads and operating conditions of the driver and driven equipment.
Initial alignment is one of the most critical factors affecting coupling performance. It should
be remembered that the couplings are basically in-line devices which are intended to
compensate for small amounts of shaft misalignment caused by bearing wear, foundation
settling, thermal growth, etc.
The more attention paid to initial alignment, the larger the reserve margin that will exist for
accomplishing the intended purpose of the coupling. See page 5-4 to 5-5 for the
recommended limits. These limits represent about one-third of the total misalignment capacity

of the coupling and are generally adequate for most installations. It should be kept in mind
that there are definite advantages to be gained from aligning the equipment to more precise
values than those shown. The primary advantage is that the reserve margin for accepting
misalignment during the life of the machinery is thereby increased. Exceeding the Table 5-6
values for alignment will reduce the service life of the coupling.
Another factor to be considered, and one of the most important to good performance is
adherence to the bolt torquing recommendations Table 5-6. Loose bolts can induce fretting
corrosion, hammering, and pounding which will eventually destroy the bolts and coupling
discs.
Troubleshooting Rexnord Couplings
The Rexnord disc coupling is easily inspected. A visual analysis may point to possible drive
system problems. Proper evaluation of the disc packs and connecting parts may save
considerable maintenance costs and down time. Here are some of the more evident visual
inspection criteria and recommended corrective procedures. Consult Superior® or your
nearest Cooper Energy Services Aftermarket facility for further assistance.
Figure 7-4 Elongated Bolt Hole-Disc had broken

t
through bolt hole. Indicates loose coupling bolts. Replace

disc pack and tighten bolts to specified torque value.
00767
Figure 7-5 Scored Body Bolt-Discs embedded into

t
bolt body. Usually a result of a loose bolt. This may also

be caused by turning the bolt during installation. Replace
00768 the bolt and tighten locknut to proper torque. Do not turn
the bolt during locknut tightening process.
t
Figure 7-6 Misalignment failure- Disc is broken adja-

cent to washer face. Usually indicates excessive shaft mis-
alignment during operation. This type of disc failure usu-
00769 ally starts in the outer discs in the pack and progresses
through the disc pack. Realign equipment and replace disc
pack. Make HOT check of alignment to assure it is within
coupling misalignment capacity.

Figure 7-7 Fatigue Failure- Disc is broken adjacent to the washer
face with heavy corrosion along area of break. This failure is typical
of discs that have been in service for years or have been operating in
00770 an offshore environment. Breaks will first appear in the outer discs
and will progress into the disc pack. If excessive corrosion exists, they
should be replaced with stainless steel plating
Figure 7-8 Compression-Disc pack is wavy and dimension between

flange faces is smaller that indicated on installation instructions. This
means that the coupling was installed in a compressed condition or
equipment has shifted axially during operation. Check for thermal
growth. If the application is a bearing motor, verify that the operating
center line of the motor rotor is properly positioned.
t Figure 7-9 Elongation-Disc pack is wavy and dimension between

o flange faces is larger than specified on installation instructions or appli-
r cable assembly drawing. The coupling has been installed in an elongated
q position or equipment has shifted axially during operation. Realign posi-
u tion of equipment so coupling operates with a neutral flat disc pack. If
e sleeve bearing motor, make sure operating centering on motor rotor is in
proper position.
O
v
Torque Overload (Visible only with strobe light while running)
The disc pack has a bulge near the center or is bowed toward one flange in every other chord
position Figure 7-10. This condition is a result of a large torque overload induced into the
system above the peak overload capacity of the coupling. The remaining disc pack chordal
t
! Caution
Figure 7-10 Torque Overload If bulged or bowed condition
only appears in one chordal section there may be a loose bolt on
one side of the distortion. Loosen coupling locknuts and turn bolt
slightly to remove friction. Bulge should flatten out. Re-torque
locknuts. If distortion does not disappear, replace disc pack.

sections will be very straight and tight. Check the driven equipment loading. If not
correctable, contact the Cooper Energy Service facility immediately.
Cylinder Body
A wide range of cylinder sizes is available. Each cylinder is conservatively designed for very
low stress at rated working pressures.
Some cylinder bodies are provided with drilled water passages, top and bottom, which
connect the water inlet and outlet with the cooling muff, which surrounds the ring travel area
of the bore. Whenever the water jacket covers on the cylinder sides are removed to clean out
deposits, the drilled passages should also be cleaned out. If the pipe plugs in the crank end of
the drilled passages are removed, they should be coated with good waterproof sealer and
replaced. This will prevent water seepage into the atmospheric vent space.
Lube oil, from the force feed lubricator tubing system, passes through a check valve and into a
fitting on the outside should be cleaned out and all steel tubing checked for soundness and
tightness. This paragraph does not apply to non-lube operation.
Plugs are provided, on all size of cylinders, which can be removed and indicator cocks
inserted to take pressure readings, if desired.
Cylinder Head
After removing a cylinder head, examine the o-ring which provides

I CAUTION a seal between the cylinder head and the cylinder body for nicks,
tears and compression set. Replace as required. The water seal
The cylinder head must be grommets should also be checked. It is recommended that a
properly indexed on the complete set of o-rings and grommets, for all cylinder sizes used, be
mounting studs so that the
valve cut-outs in the head kept in stock at all times.
align with valve locations in
the cylinder body.
Piston, Piston Rings And Piston Rod
The piston is attached to the piston rod with six capscrews (for most piston sizes) and with
four capscrews on remaining sizes. Some pistons have a through rod and nut while others
have a one piece piston and rod. See Table 7-2 for proper torque values.
Prior to passing the piston rod through the piston rod packing, prepare the rod as described in
Section 5.
The piston end clearances are adjusted as specified in Section 6 and should be checked with
the balance nut torqued to its proper value.

In order to reduce cylinder bore wear, Superior® designed every piston to operate with rider
compression rings or rider rings. The rider compression rings and rider rings are not
collapsible in the piston groove, thus supporting the piston in the cylinder bore.
In non-lubricated applications, the rider compression rings, rider rings and the piston rod
packing will wear with time. Replacing these elements before they wear beyond allowable
limits will contribute to the successful operation of a non-lubricated cylinder. Contact the
Superior ® Engineering Department for wear limits for your specific cylinder size and
application.
Piston Rod Packing
Piston rod packing comes in

many different arrangements Figure 7-11 Typical Lubricated Wiper Packing Case
and designs. This manual will
not explain each individual
design, but should contain
enough detail to allow you to
successfully remove, maintain
and install the piston rod
packing on your compressor.
Piston rod packing can be

divided into two different
groups based on packing
function -- wiper packing and
pressure packing. (See Figure
7-11 and Figure 7-12). As the
piston rod moves through a
wiper packing, oil is stripped
off the rod and prevented
from migrating in to another
part of the compressor.
The purpose of pressure

packing is to prevent the loss
of gases from the cylinder along the piston rod. During initial operation, a packing may leak
or tend to overheat. This temporary condition occurs while the packing rings are adjusting to
the piston rod and packing case.
Definite lubrication rates and time intervals for packing “wear in” are difficult to prescribe.
Experience has indicated that these factors may vary widely on different applications. If there
is concern about proper lubrication rate, contact the nearest Cooper Energy Service
Aftermarket office.

Ordinarily, packing cases

t Figure 7-12 Typical Low Pressure Packing Case
(cups and glands) are not
severely worn. Therefore, it is
possible to repair piston rod
packings by replacing the
packing rings only. It is good
practice to keep a complete
set of packing rings on hand
for the packing assemblies of
all your cylinders.
In order to remove a packing

case from a crosshead guide
or cylinder, the piston rod
must be pulled out through the
assembly and cylinder.
Before disassembling a
packing case, note all
identification marks to ensure
components are reassembled properly. If components are not marked, identify each cup’s
position relative to the adjacent cup or flange by numbering or marking them together. While
disassembling a packing, record the position of each ring and the direction each ring faces for
proper reassembly.
Refer to Figure 7-13 for aid in identifying packing rings. Knowing your packing rings is very
helpful when ordering new ones.

t Figure 7-13 Typical Packing Configurations
00776

The packing cups and glands that are not being replaced by new ones
must be soaked and thoroughly cleaned in a non-acid solvent. They
should then be blown dry and examined closely for unusual nicks or
I CAUTION
burrs which might interfere with the rings free floating or contact As a general guide,
with the rod. Particular care must be taken with rings made of soft temperatures not
metals and it is very important that wiper rings be handled and tolerated by resting
installed carefully to prevent damage to the scraping edges. your hand on the
packing case flange,
Before installing new packing assemblies, it is important that the after the unit is shut
piston rod be carefully checked. If the rod is worn, rough, pitted or down, indicate to
has a taper, it must be replaced. fast of a wear rate.
For a lubricated
The bore for the pressure packing nose cup must be cleaned and packing, check to
examined for burrs. If found, burrs should be removed. Also, replace see if the lubrication
the o-ring in the outside diameter of the wiper packing flange with a rate is set properly
new one. per Section 3.
A new metallic gasket should be placed in the groove of the pressure

packing nose cup. Remove the old metallic gasket with a sharp tool; i The rings must
be placed in the
take care not to damage the groove. Clean the groove thoroughly and packing cups in the
install a new gasket. Tap the gasket into the groove with a hard rubber same position (facing
mallet. Do not use a steel hammer as this may damage the sealing original direction) as
surface of the new gasket. the original set.
After installing the packing cases and before connecting the oil tubing to the packing flange
(for lubricated packing), hand pump the force feed lubricator (when supplied) until oil runs
from one of the disconnected tubes. Connect this tube to the respective hole in the packing
flange and continue to pump the lubricator 12 to 15 more strokes.
After the piston and rod assembly has been reinstalled, the piston end clearance must be set
and the piston rod runout must be checked per Section 5.
Valves
Valve Installation
Suction and discharge valves must be installed in the proper direction. This can be determined
by first inspecting the valve to see which direction the valve plates move while opening or
compressing the springs. Gas will flow in that same direction (Figure 7-14).

Valve Replacement Figure 7-14 Valve Installation
Refer to Figure 7-14. Proceed

with valve removal in the
following manner:
a. Loosen bolts or nuts holding
valve cap. DO NOT remove
completely until after cap is
pulled out far enough to vent
any pressure trapped under
cap.
b. Remove valve cap, inspect

o-ring, place o-ring if
defective.
c. Loosen set screw in valve

retainer (bottom valves only). Insert threaded puller into valve
retainer and remove.
i Before removing
any gas containing
part of the compressor or
associated gas piping sys-
d. Using threaded valve puller, remove valve from seat in cylinder. tem, vent compressor and
system to atmospheric
pressure.
e. Remove, inspect and replace gaskets as needed.
f. Clean all gasket surfaces on valve and in valve pocket, and on

valve retainer and on valve cap. i The valve cap
flange must not
g. Install new gasket in valve pocket. Place valve in pocket contact the cylinder
body. Clearance must
FACING PROPER DIRECTION. exist at this point to
insure that pressure is
h. Install the retainer on top of the valve. Install new gasket in place applied to the valve and
on retainer, as applicable. retainer gaskets when
the relief cap bolts or
nuts are tightened.
i. Grease or oil the o-ring on the valve cap. Force the valve cap
into place by torquing the nuts or screws evenly to the values listed
in Table 7-2.
To replace a valve in a bottom port (assume that this is a discharge port), proceed as follows:
j. Invert retainer. Place valve on top of retainer with valve guard facing out (away from the
cylinder). Slip gasket on valve.

k. Lift the valve, retainer, and gasket up into the bottom port, making sure that the valve
seat enters first.
l. Tighten the retainer lock screw just enough to hold retainer and other parts in place.
t Figure 7-15 Valve Replacement
00778

m. Grease or oil the o-ring on the valve cap. Place new gasket in place on valve cap, as
applicable. Force the cap into place by torquing the nuts or screws evenly to the values
listed in Table 7-2.
Special Tools
Refer to the section 9 and 10 of this manual for information on special tools.
Alarms and Shutdowns
Each unit is equipped with a specified complement of electrically or pneumatically operated

alarm and/or shutdown devices. These devices are designed to protect the unit in the event of any
abnormal operation or any malfunction which may occur. Each device should be checked and
reset after each shutdown, or at least once every six months - whichever is sooner, to assure that
they are operative. All questionable devices should be replaced.
Several safety devices may be employed on compressor units. The most common ones and their
recommended set points are listed in Table 7-16. Questions regarding these and other devices and
their set points may be referred to the Cooper Energy Services Aftermarket office.
Table 7-16 Recommended Alarm Set point
Alarm/Shutdown Normal Condition Alarm Point Shutdown Point
Oil Pressure in Header 45-55 psig (310-380 kPag) 25 psig (173 kPag) 20 psig (138 kPag)
Oil Temperature out of 160-180°F (71-82°C) Out 185°F (85°C) Out 190°F (88°C) Out
the Frame
Vibration Nominal 1/4-3/8 turn from normal 3/8 - 1/2 turn from normal
condition condition
Gas Temperature Suction (TS) or Discharge 20°F (11°C) above TS or 25°F (14°C) above TS or
(TD) TD TD
Water Temperature Tin or Tout 20°F (11°C) above Tout or 25°F (14°C) above Tout or
Tin Tin
Gas Pressure Suction (PS) or Discharge 5% below PS 10% below PS

(PD) 5% above PD 10% above PD

System Recommended Maintenance Schedule
Adhering to Table 7-17 will result in less equipment

down time and less operating costs.
Table 7-17 SYSTEM Recommended Maintenance Schedule
CONTROLS Daily Weekly Monthly Semi-Annually Annually
or as
Needed
Perform safety shutdown system tests. X
Note and record panel gauge readings. X
Check calibration of all themometers and pressure gauges. X
LUBRICATION SYSTEM
Check oil levels, oil level regulator, and oil sight level. X
Check lubricator line connections for leakage. X
Inspect frame, lubricator, and packing cases for leakage. X
Clean and/or replace crankcase breather(s). X
Check compressor force feed lubricator pump(s) for proper output rate. X
Collect a compressor oil sample for analysis. X
Change compressor oil and filters elements after the first 400 hours of compressor operation. Oil and filter change periods can then
be extended out to 2000 hours of operation. Change lube oil filters when differential pressure reaches 12 to 15 psi.
Replace O-rings. X
MECHANICAL/OPERATING SYSTEM - CYLINDERS
Note and record inlet temperatures. X
Check for loose cylinder fasteners. X
Note and record cylinder discharge temperatures. X
Hand check suction valve covers from coolness. X
Listen for unusual noises. X
Check temperatures of coolant to and from cylinders, lube oil cooler, and X
packings.
Check one compressor valve on each stage. Inspect for broken plates, bro- X
ken springs, and trapped solids or liquids.
Remove the distance piece cover from the crosshead guide and inspect the X
packing area on each piston rod.
Remove head and piston of the first stage cylinder. Check cylinder bore, X
piston rings, packing rings, piston, and rod bearing.
MECHANICAL /OPERATING SYSTEM - FRAME
Check crosshead clearances. X
Check crosshead guide for wear metals. X
Check foundation bolt torques.
Check compressor coupling for proper alignment. X
Visually inspect frame interior for bearing material in frame, gear tooth X
condition, crosshead shoe and guide condition.
Roll out compressor thrust main lower shell for inspection. X
Check compressor accessory drive gear lash and general condition. X

Troubleshooting
Troubleshooting is the process of finding operational problems. This section describes the
difficulties which may arise during operation of a compressor, the typical origins or sources of
these problems and suggestions on how to repair the trouble. The following steps should be
followed in all troubleshooting activities:
a. Determine what general area is affected - frame, cylinders, lubricating system, etc.
b. Analyze the symptoms (clues) to pinpoint the exact location of the problem valves,
bearings, etc.
c. Replace all defective or damaged parts.
d. Return the unit to service and verify that normal operation is resumed.
Tables 7-18 through 7-22 list many typical symptoms, causes and corrective measures. It may
be necessary to refer to more than one symptom to locate the entire difficulty. The suggested
corrective actions are supposed to direct you to those areas most likely to be at fault.
However, do not limit your analysis only to those areas found in the table. If symptoms
persist, contact your nearest Cooper Energy Services Aftermarket office for possible field
assistance.
Table 7-18 Compressor Frame Troubleshooting
Symptom Possible Cause Potential Damage Corrective Measure
Compressor Mechanical Seized crosshead, rods, main Replace all defective parts. Check compressor for proper
will not turn
seizure of bearings. crankshaft alignment, piston rod runout, and lube oil
over compressor. system operation.
Tripped Defective shutdown device. Check the control system and device for proper operation.
shutdown
device.
Foreign material Cylinder scoring, valve Replace damaged parts and take measures to prevent
(water, non-lube damage, possible bent piston future foreign material entrapment in the compressor
packing, etc.) in or connecting rods. cylinders.
cylinders.
Improper piston- Possible piston or rod damage. Replace any damaged parts and properly set the piston-
to-cylinder end to-cylinder end clearances.
clearance.
Compressor Opposing Foundation cracking, weld Total weight of crosshead, balance nuts, piston rods,
vibration cylinders are out cracking, or foundation bolt connecting rods, and rings must be within 3 lbs. (1.4 kg) of
of balance. failure. same components on opposite throw. Replace balance
nuts or crossheads to obtain this balance.
Worn bearings. Possible broken frame, Verify crankshaft alignment, piston rod runout, and
connecting rods, crankshaft, or bearing clearances. Replace bearings as needed.
piston rods. Reverify alignment and runout.
Improper Foundation damage, Realign the compressor per Section 5.
compressor foundation bolt failure, grout
installation and cracking, or broken frame and
alignment. crankshaft.
Gas pulsation. Excessive vibration causing Analyze compressor with a vibration or indicator analyzer.
cracked welds, foundations, Install orifices at the cylinder flange, change piping,
grout, and parts. Also possible change cylinder operating configuration, or change
foundation bolt breakage. operating speed.

Table 7-18 Compressor Frame Troubleshooting

Loose valves. Valve seat damage, broken Remove valve and retainer. Replace broken parts. Dye
valve bodies, or broken valve check the cylinder valve seat for cracks. Install new valves
retainers. and tighten to proper torque.
Table7-19 Oil System Troubleshooting

No lube oil Lack of oil Scored bearings, crankshaft, Check all lubricated surfaces and replace parts as
pressure crosshead shoes and pins. required. Fill with oil to the proper level.
Possible seizure of
compressor.
Clogged strainer or Same as above. Check all lubricated surfaces and replace parts as
filters. needed. Replace filter element and/or strainer.
Lube oil pump or drive Same as above. Check mating gears and replace if needed. Check
gear. pump end clearances.
Air leak in suction piping. Same as above. Repair leaks as needed.
Low lube oil Low oil level. Scored bearings, crankshaft, Check all lubricated surfaces. Fill with oil to the
pressure crosshead shoes, and pins. proper level.
Seizure of compressor is
possible.
Clogged or dirty filters. Same as above. Check all lubricated surfaces and replace parts as
needed. Replace filter element and/or strainer.
Air leak on suction side Same as above. Find and stop leak.
of pump.
Sticking or maladjusted Same as above. Free or adjust valve.
pressure relief valve.
Excessive main and Same as above. Replace defective bearings.
connecting rod bearing
clearance.
High lube oil Lube oil cooler clogged Reduce viscosity resulting in Clean cooler.
temperature or dirty. lower lubrication and filtration.
.
Insufficient warm cooling Same as above. Correct water flow problem or temperature.
water through cooler.
Table 7-20 Cylinder Area Troubleshooting

Failure to deliver gas Restricted Clogged suction screens Clean suction line and screen, if
suction line or dirty.
filter screens
Defective or Cylinder damage through broken valve parts Replace defective plates, springs,
missing valves in the cylinder bore. High or low discharge or any other worn, broken, and
pressure between stages with insufficient rod defective parts.
reversal, resulting in pin failure
Deposits on Possible broken plate valves or springs. Clean and replace any defective
valves valve parts. Review type and
quantity of lube oil used.
Open or Possible insufficiencies on rod load reversal If open, load compressor. If
defective and head mechanism damage damaged, replace defective parts.
clearance pocket
Defective piston High discharge temperatures Replace rings
rings
Low compressor cylinder Worn piston Piston, ring, and bore overheating Replace with new rings
discharge pressure rings

Table 7-20 Cylinder Area Troubleshooting (Continued)
Defective or Insufficient rod load reversal. This can cause Replace plates, springs, or any
missing valves damage to the crankshaft from excessive other worn, broken or missing
heating, seizure of the crosshead pin, as well parts
as damage to the piston rods, crossheads,
crosshead guides, and connecting rods.
Collateral damage from broken parts
entering the cylinder bore
Open or Same as above If damaged, repair or replace
defective fixed/ defective parts
variable pocket
head
Low compressor cylinder Loose valve(s) Same as above. Also, check for valve seat Remove valve and retainer;
discharge pressure damage, broken valve bodies and retainers replace any broken parts. Dye
(Continued) check the cylinder valve seat.
Install new valves and properly
torque down valve caps
High compressor Improper setting High rod loads, insufficient rod load reversal, Increase setting of variable
cylinder discharge of volume or discharge temperatures exceeding the volume pocket(s) or open fixed
pressure. pockets. maximum working pressure. volume pocket(s) until discharge
pressure decrease to a proper
level. Unload the crank ends if this
does not reduce pressure. Open
all pockets before starting. Always
follow performance curves
provided with your compressor.
Improper Same as above. Open valve.
positioning in
piping
downstream of
the compressor.
Clogged cooler. Same as above. Clean coolers.
Insufficient capacity Dirty suction Possible cylinder heat buildup. Clean scrubber.
scrubber.
Worn piston Piston, rings, and bore overheating. Replace rings.
rings.
Restricted Clogged suction screens. Clean suction line and screen, if
suction line or dirty. Replace screen if damaged.
filter screens.
Defective or Insufficient rod load reversal. This can cause Replace plates, springs, or other
missing valves. damage to the crankshaft from excessive worn or broken parts.
heating, seizure of the crosshead pin, as well
Collateral damage from broken parts
entering the cylinder bore.
Open or Same as above. Replace defective parts.
defective fixed/
variable pocket
head.
Suction valve in Same as above. Properly install valves. Replace
discharge or any damaged parts.
discharge valve
in suction.
If all valves are reversed, excessive pressure can build
NDANGER up resulting in cylinder failure and injury.
Loose valves. Same as above. Possible damage to valve Remove valve and retainer.
seat, valve bodies or retainers. Replace any broken parts. Dye
check the cylinder valve seat.

Table 7-20 Cylinder Area Troubleshooting (Continued)

High interstage pressure Improper Rod load exceeding the design M.W.P. of the Reduce variable volume pocket
settings of lower stage cylinder that results in piston, setting or close the fixed volume
clearance rod, crosshead, or crankshaft damage pocket on the higher stage until
pockets on the the interstage pressure decreases
higher stage to an acceptable level
heads
Missing or Same as above Repair or replace the suction
defective suction valves in the higher stage cylinder
valve(s) on the
higher stage.
Worn piston Same as above Replace with new rings
rings in the high-
er stage cylinder
Defective relief Same as above Repair or replace defective valve
valve parts
High gas discharge Defective Damaged gaskets, damaged O-rings, and Replace defective parts
temperature discharge valves cylinder overheating
High discharge Rod load exceeding design. Insufficient rod Increase setting of variable
pressure load reversal exceeding the M.W.P. of the volume pocket(s) or open fixed
cylinder. High discharge temperature volume pocket(s) until discharge
pressure decrease to a proper
level. Unload the crank ends if this
does not reduce pressure. Open
all pockets before starting. Always
follow performance curves
provided with your compressor.
Low suction Insufficient rod load reversal which can lead Try corrective measures listed for
pressure to damage to the crankshaft from excessive Low Compressor Cylinder
heating, seizure of the crosshead pin, as well Discharge symptom.
High suction Leaking suction valves causing suction valve Replace springs or plates.
pressure damage. Overheating of compressor
cylinder.
Improper water Breakdown in cylinder lubrication causing Check pump for proper flow, heat
cooling overheating, cylinder scoring, and valve exchanger condition for proper
damage. cooling, and water supply for
proper level. Repair or clean
cooling system, or add water as
required.
Table 7-21 Troubleshooting Abnormal Noises

Growling in lube oil Suction side air leak. Pump rotor and drive gear Find and stop leak in line.
pump damage and lubricated part
damage.
Chatter in relief valve Air in oil lines. Damage to relief valve and Find and stop leak in line.
lubricated parts damage.
Knock in cylinder area Foreign material in cylinder Cylinder scoring, valve damage, Remove foreign material from
(including water). scored or bent rods and cylinder. If condensation is in gas,
crankshafts. Blown off cylinder use separators and check dump
head. valve operation.
Piston-to-cylinder end Bent rods and crankshaft. Set end clearance to proper value.
clearance set incorrectly.
Improperly installed valve. Piston, rod, pin, crosshead rod, Replace damaged parts.
or crankshaft damage.
Loose valve. Seat damage on cylinder and Remove valve and retainer. Dye
broken valve bodies and check valve seat.
retainers.
Loose piston nut. Head, piston, crosshead, or Replace damaged parts.
cylinder damage.

Table 7-21 Troubleshooting Abnormal Noises (Continued)
Incorrect piston to head Failure of piston and/or piston
Reset clearance. Check for
clearance. rod. Damage to crosshead. stretched piston rod and/or rod
studs. Check for loose crosshead
nuts.
Scored piston or cylinder. Piston seizure. Find and eliminate reason for
scoring.
Loose valve assembly. Damaged seating surfaces in Tighten assembly and check
cylinder or on valve. gaskets.
Loose packing assembly. Damaged seating surfaces on Tighten assembly and check
packing case. gaskets.
Loose piston. Scoured piston or cylinder. Tighten piston rod nuts. Check for
stretching of studs.
Excess carbon deposits. Same as above Remove carbon.
Foreign object in cylinder Same as above Remove any objects and repair da-
mage.Check separation equipment
Knock in cylinder area Loose cylinder head. Damage to gasket seal surface Tighten head.
(continued)
Loose variable volume pocket Damage to gasket seal surface. Tighten variable volume pocket.
unloader.
Whine in auxiliary end Worn, broken, or chipped gear Gear damage. Replace gear.
gear teeth.
Improper backlash setting. Gear damage. Reset gear lash.
Table 7-22 General Troubleshooting

Vibration Piping system improperly Potential failure of piping Install proper piping support to raise
supported. system. the frequency of the vibrations.
Loose piston or piston rod. Piston seizure, contact between Replace all damaged components.
piston and cylinder heads, bent Tighten components properly.
piston rods, or failure of running
gear.
Loose nuts on cylinder to Same as above. Tighten nuts.
frame mounting studs.
Unit loose on foundation or Piping strain. Tighten.
rails.
Low capacity Excessive pressure drop in Loss of production. Properly design piping system.
piping system.
Gas measurement Apparent production loss. Use correct measurement
techniques are not correct. techniques.
Poor mechanical condition of Failure of individual Restore to proper mechanical
unit. components. condition.
Gas pulsation in vicinity of Causes abnormal cylinder Modify piping to eliminate pulsation.
cylinders. capacity performance.
High load Excessive capacity being Overload. Determine cause and correct.
delivered.
Poor mechanical condition of Distortion of compression cycle Correct mechanical problems.
unit. resulting in excess load.
Gas pulsation in vicinity of Abnormal cylinder horsepower Modify piping to eliminate
cylinders. performance. pulsations.


Lubricator does not Feeds not vented of air. Overheated and/or damaged Prime lubricator pump to insure oil
discharge oil packing. Scored cylinder walls. passage to the pump.
Low oil level. Same as above. Add oil to proper level.
Plugged vent in lubricator Same as above. Unplug vent.
tank.
Line leaking or kinked. Same as above. Unkink or replace line.
Oil check valve on cylinder Same as above. Replace oil check valve.
faulty.
Incorrect adjustment of pump Same as above. Readjust pump stroke.
stroke.
Leak in line or fitting. Same as above. Retighten fitting or replace line as
needed.
High cooler pressure. Faulty suction valves in high Damage to cooler. Replace faulty compressor valves.
stage cylinder.
Defective gauge. Improper operation of the Replace gauge.
compressor.
High discharge Faulty valves. Cracked or broken cylinder, Replace valves.
temperature bent rod, or worn piston rings or
packing.
Scored piston or liner. Same as above. Repair damage and replace
damaged parts.
High discharge Insufficient lubrication Same as above. Increase lubrication.
temperature (lubricated cylinder only).
(continued)
Packing too tight. Same as above. Check rings for proper clearance
and packing case for clearance
around rod.
High suction gas Same as above. Check valves, coolers, and
temperature. process.
High discharge pressure. Same as above. Check valves and/or process
condition. On multistage units
check suction valves of next higher
stage.
Low suction pressure. Same as above. Check proceeding stages of
process.
Liquid in cylinder Condensate caused by cold Broken or bent rod. Cracked Raise cooling water temperature.
interstage piping. cylinder.
Liquids in process are not Same as above. Check process operating
removed from the gas stream conditions. Check operation of
by separation equipment. separation equipment and dump
valves.
Broken valve and Dirty gas or foreign matter in High gas temperatures. Clean up gas by proper separation
springs gas stream. Possible piston and cylinder and/or filtration.
damage.
Liquid in cylinder. Same as above. Find source of liquid and correct.
Excessive lubrication. Same as above. Reduce lubrication.
Carbon deposits. Same as above. Reduce lubrication. Change to
lubricant which forms less carbon.
Improper assembly. Same as above. Reassemble properly.
Insufficient control. Pressure Same as above. Check for possible control pressure
or leaking seal in variable leak.
volume pocket unloader.

Rupture disk ruptures Disk rating incorrect. Overheated and/or damaged Trace line from designated rupture
packing. Scored cylinder walls. disk and fix malfunctions.
Clogged filter. Same as above. Replace filter.
Blocked main line. Same as above. Unblock line.
Blocked secondary line. Same as above. Unblock line.
Divider block does not cycle. Same as above. Clean divider block interior.

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WG Compressor Frame Instruction Manual

Operation,Maintenance, and Parts

Table of Contents WG-8/24/03

Cooper Energy Services n Superior Compressor Product Group Page a

Table of Contents WG-8/24/03

Cooper Energy Services n Superior Compressor Product Group Page c

Page d Cooper Energy Services n Superior Compressor Product Group

Table of Contents WG-8/24/03

Cooper Energy Services n Superior Compressor Product Group Page e

Page f Cooper Energy Services n Superior Compressor Product Group

Cooper Energy Services is committed to continuous improvements and design advancements.

easily found by mainte-

Section 1: Introduction to Servicing the WG Series Compressor WG-4/3/03

Cooper Energy Services n Superior Compressor Product Group Page 1-1

Identifying Your Compressor Frame and Cylinder

Figure 1-2 Frame Nameplate

Compressor Frame Overview

Page 1-2 Cooper Energy Services n Superior Compressor Product Group

Vt Figure 1-4 WG Cylinder Head Options

Section 1: Introduction to Servicing the WG Series Compressor WG-4/3/03

Cooper Energy Services n Superior Compressor Product Group Page 1-3

Figure 1-6 WG Compressor

Page 1-4 Cooper Energy Services n Superior Compressor Product Group

t Figure 1-7 General WG Series Compressor Specifications

Table 1-8 Compressor Specifications

Section 1: Introduction to Servicing the WG Series Compressor WG-4/3/03

Cooper Energy Services n Superior Compressor Product Group Page 1-5

Discharge Valve Packing Connecting Rod

Page 1-6 Cooper Energy Services n Superior Compressor Product Group

Balancing Compressor Frames

Figure 1-10 Balance Sheet Example

The estimated balance for the original assembly

Section 1: Introduction to Servicing the WG Series Compressor WG-4/3/03

Cooper Energy Services n Superior Compressor Product Group Page 1-7

How to Use This Manual

Page 1-8 Cooper Energy Services n Superior Compressor Product Group

Our Quality Policy

Section 1: Introduction to Servicing the WG Series Compressor WG-4/3/03

Cooper Energy Services n Superior Compressor Product Group Page 1-9

Page 1-10 Cooper Energy Services n Superior Compressor Product Group

Improper operation, lubrication, maintenance or repair of this equipment can be dangerous

Note, Caution, and Danger Symbols

Section 2: Safety Precations and Guidelines WG-4/3/03

Cooper Energy Services n Superior Compressor Product Group Page 2-1

The CAUTION symbol indicates that if the specified precaution is

Warning Signs and Labels

Page 2-2 Cooper Energy Services n Superior Compressor Product Group

Temporary Shipping Plugs in Compressor Equipment 1

Small diameter threaded connections located on compressor frames,

Compressor Frame Crankcase Rapid Pressure Relief Valves2

1.Per CES Engineering Service Bulletin SB282

Section 2: Safety Precations and Guidelines WG-4/3/03

Cooper Energy Services n Superior Compressor Product Group Page 2-3

It is in the best interest of everyone involved in operation and

General Maintenance Precautions

Page 2-4 Cooper Energy Services n Superior Compressor Product Group

Compressor System Maintenance Precautions

Pressurized Air and Water Precautions

Section 2: Safety Precations and Guidelines WG-4/3/03

Cooper Energy Services n Superior Compressor Product Group Page 2-5

Pipes, Connectors, Fittings, Lines, Tubes and Hoses

Check for the following: