Compressor Manual

Compressor Type
2K158-2D_1
Serial No.
100822/100823
Process Gas
LNG/NH3/VCM
Project No.
Instruction Manual 2 000 697
IM 100822en Key Word

Norgas WZL 0601
for Purchaser
Norgas Carriers A/S, Oslo,
Norway
Laby Compressor Order No.

Multigas 363-001
Burckhardt Compression AG
Im Link 5
P.O. Box 65
CH-8404 Winterthur
Switzerland
Tel. +41 (0) 52 262 55 00
Fax +41 (0) 52 262 00 53
www.burckhardtcompression.com
Table of Contents
Table of Contents
1 Definitions for This Document
2 Elementary Safety Advice
3 Plant Configuration and Function
4 Compressor Design and Function
5 Transport, Installation and Pre-Commissioning
6 Operation
7 Trouble Shooting
8 Preventive Maintenance
9 Dismantle and Assemble Compressor Components
10 Clean and Degrease Plant and Compressor

Components
11 Decommissioning or Dispose Plant
12 Spare Parts
13 Appendix
14 Index
20.06.2007 Rev. 001/kaufmann_w 2K158-2D_1 IM 100822en

Table of Contents
IM 100822en 2K158-2D_1 Rev. 001/kaufmann_w 20.06.2007

Definitions for This Document
1 Definitions for This Document
1.1 Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.2 Purpose of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.2.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.2.2 Target Groups and Assumed Knowledge . . . . . . . . . . 1-4
1.2.3 Compressor Designation . . . . . . . . . . . . . . . . . . . . . . 1-5
1.3 Contact Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.4 Structure and Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.4.1 Document Structure . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.4.2 Visual Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.5 Term Used for Compression Media . . . . . . . . . . . . . . . . . . . . . 1-6
1.6 Warnings and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.6.1 Level of Hazard Seriousness . . . . . . . . . . . . . . . . . . . 1-6
1.6.2 Useful Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.6.3 Warning Symbols Used in This Instruction Manual . . 1-7
1.7 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.8 Registered Trademarks and Brands . . . . . . . . . . . . . . . . . . . . . 1-9
27.06.2007 Rev. 001/kaufmann_w 2K158-2D_1 IM 100822en 11

12 IM 100822en 2K158-2D_1 Rev. 001/kaufmann_w 27.06.2007

Revisions
1.1 Revisions
Book Chapter Technical Page Description

revision revision writer
001 WK First release
If there have been necessary technical modifications, the present Instruc-

tion Manual will only be adapted to these or corrected upon request.
Please integrate incoming revision sheets in the Instruction Manual imme-
diately.
We greatly appreciate new ideas and recommendations for this Instruction
Manual.

Purpose of This Manual
1.2 Purpose of This Manual
1.2.1 Scope
Reference Documents This Instruction Manual is part of the Technical Documentation (overall
compressor documentation). Some supplier documentation can be found
in the appendix of this Instruction Manual. Further documents and informa-
tion can be found in the Technical Documentation. Therefore the complete
Technical Documentation should always be kept near the compressor.
Retain this Instruction Manual as long as the compressor is in service and
hand it over to successive users.
Applicability All instructions given in this document are valid only for the compressor(s)
with serial number(s) mentioned on the cover page. The contents of this In-
struction Manual are subject to technical changes.
This Instruction Manual makes special reference to important details for the
use of the compressor. Only when the content of this Instruction Manual
has been read and understood can trouble-free operation be assured.
The Instruction Manual must be read carefully before commissioning, as

Burckhardt Compression AG (BCA) does not accept liability for damages
and operating troubles resulting from neglecting the instructions here.
1.2.2 Target Groups and Assumed Knowledge

These instructions have been written with the intention of being read and
understood by all who are responsible for the compressor described. Per-
sonnel working at the compressor site must be qualified through training
and experience.
Target group Description Tasks and responsibilities Chapter

Everyone All personnel working at the Taking care with regard to security 1,2,3,4
compressor site issues
Operator Personnel with profound Starting and stopping the plant 6,7
knowledge of process and Surveillance tasks during compres-
compressor operation sor operation
Field engineer Experienced field engineer Installation 5, 6, 7, 8, 9, 10,
who has visited a BCA ser- Commissioning 11
vice training or has been au-
thorized by BCA Maintenance
Repair
Purchasing Purchasing/service depart- Orders for spare parts and stock 12
ment personnel maintenance

Contact Address
1.2.3 Compressor Designation

Name Plate
LA_XX_0031b_01
Fig. 1-1 Location of the name plate
1 Name plate
The serial number is located on the name plate (1).

The IM number in the footer of the Instruction Manual corresponds with the
serial number of the compressor. If an order includes several compressors,
the IM number will comply with the lowest serial number.
4 D 250 B - 4 H_X
LA_XX_0002b_00
1 2 3 4 5 6 7
Fig. 1-2 Example for compressor designation
1 Number of crankthrows 4 Design of crankgear

2 Type of compression: 5 Number of stages
D, K = double acting; 6 Design of cylinder
E = single acting; 7 Revision index
L = long interspace
3 Piston stroke
1.3 Contact Address

Please contact our worldwide Customer Support Service in Switzerland or
visit our website to find details of a local agent near you.

Structure and Layout
Technical Customer Support
Im Link 5
P.O. Box 65
CH-8404 Winterthur
Tel. +41 (0)52 262 55 00 Fax +41 (0)52 262 00 53
24-Hour Emergency Service Tel. +41 (0)52 262 53 53
info@burckhardtcompression.com
1.4 Structure and Layout
1.4.1 Document Structure

The first four chapters are designed to familiarize you with the compressor
plant. The following chapters describe compressor installation, operation
and service. For your convenience, each page provides the chapter and
section title in its header to make browsing the document easier.
Chapter Structure The chapters are structured according to a bottom-up model, beginning
with fundament details and ending up with cylinder cover at the top of the
compressor. Chapter 9 Dismantle and Assemble Compressor Compo-
nents breaks this rule: its content is structured according to logical steps for
dismantling the components.
1.4.2 Visual Elements

Italicized letters emphasize the significance of a certain text passage. Bold
code numbers on spare parts drawings refer to detail drawings.
Illustrations may only be examples. Thus, you must not read out exact di-
mensions nor detailed visual appearance.
1.5 Term Used for Compression Media

Because the compression of cargo gas is a process within the refrigeration
cycle, we use the term process gas in this manual for your compression
media.
1.6 Warnings and Symbols
1.6.1 Level of Hazard Seriousness

The following signal words are used in this Instruction Manual. Please pay
careful attention to these.

Warnings and Symbols
DANGER
Your life or physical wellbeing are in serious danger if such warnings are
ignored.
Follow the prevention instructions carefully.
WARNING
Severe injuries or damage to the equipment can occur if such warnings are
ignored.
CAUTION
Damage to the equipment or your tools can be the consequence if such
warnings are ignored.
1.6.2 Useful Information
Useful information and tips make your life easier. Follow these notes for
your convenience.
1.6.3 Warning Symbols Used in This Instruction Manual

The symbols used for safety-related notices have the following signifi-
cance:
Common safety sign. Generally, the triangular warning

symbol indicates the possibility of personal injury or loss
of life if the instructions are not followed.
Whenever possible, the symbol indicates the hazard a person is exposed

to more specifically. The symbols used in this Instruction Manual have the
following significance:
Automatic start-up possible
Electrical danger or hazard
Machine under maintenance or overhaul

Warnings and Symbols
Flammable material or risk of fire
Oxidizing materials
Potentially explosive atmosphere
Risk of explosion
Hot surface, dont touch!
Pressurized vessel or pipe depressurize plant before

you start working!
Suspended loads
Slip hazard watch your step!
Corrosion hazard, avoid contact with caustic substances!
Toxic hazard
Risk of frost or low temperature
Read instruction for operation and maintenance
Wear hearing protection
Do not remove Instruction Manual from compressor site

Copyright
1.7 Copyright
The copyright for this Instruction Manual remains with Burckhardt Com-
pression AG. Instructions and drawings may be neither
partly or completely copied
nor
duplicated, used or passed on to third parties
without our authorization.

Anybody violating these terms will be prosecuted.
1.8 Registered Trademarks and Brands

Chockfast is a trademark of ITW Philadelphia Resins, 130 Commerce
Drive, Montgomeryville, PA 18936, USA.
ERMETO is a trademark of SENIOR AEROSPACE ERMETO, F-41330
Fosse, 8, rue du Clos Thomas, Cedex, France.
Laby is a trademark of Burckhardt Compression AG, Im Link 5, 8404 Win-
terthur, Switzerland.
MOLYKOTE is a trademark of Dow Corning Corporation, Corporate
Center, P.O. Box 994, MIDLAND MI 48686-0994, USA.
NORD-LOCK is a trademark of Nord-Lock GmbH, In der Waage 10, D-
73463 Westhausen, Germany.
PEEK is a trademark of Victrex plc, Hillhouse International, Thornton
Cleveleys, Lancashire FY5 4QD, United Kingdom.
SERTO is a trademark of SERTO AG, CH-8355, Aadorf, Switzerland.
SUPERBOLT is a trademark of SUPERBOLT Inc., P.O. Box 683, Carn-
egie, PA 15106, USA. The SUPERBOLT tensioner is supplied by P&S.
P&S is a trademark of P&S Vorspannsysteme AG, Rickenstrasse 55,
8735 St.Gallenkappel, Switzerland.
SWAGELOK is a trademark of Swagelok Company, Solon Ohio, 44139,
USA.
VIBRACON SM is a trademark of Machine Support B.V. Kaartenmaker-
straat 7, NL-2984 CB Ridderkerk, the Netherlands.

Registered Trademarks and Brands
1 10 IM 100822en 2K158-2D_1 Rev. 001/kaufmann_w 27.06.2007

Elementary Safety Advice
2 Elementary Safety Advice
2.1 Avoiding Dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3

2.2 Obligations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3
2.3 Safety Measures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4
2.3.1 Warning Signs at Compressor Site . . . . . . . . . . . . . . 2 - 4
2.3.2 Preventive Measures . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
2.3.3 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
2.3.4 Mechanical Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
2.3.5 Thermal Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
2.3.6 Electrical Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6
2.3.7 Protection against Loud Noise . . . . . . . . . . . . . . . . . . 2 - 6
2.3.8 Handling Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6
2.3.9 Handling Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 7
2.4 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 11
2.5 Compressor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 11
2.5.1 Operation with Flammable Process Gas . . . . . . . . . 2 - 11
2.6 Safe Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 12
2.6.1 Cleaning of Compressor Plant . . . . . . . . . . . . . . . . . 2 - 12
2.6.2 Compressor Maintenance . . . . . . . . . . . . . . . . . . . . 2 - 12
2.6.3 Commissioning after Maintenance . . . . . . . . . . . . . . 2 - 13
2.7 Process Gas and Purge Gas . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 13
2.7.1 Gas Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 13
2.7.2 Hazard Identification Diamond . . . . . . . . . . . . . . . . . 2 - 14
2.7.3 CH3Cl Methyl Chloride . . . . . . . . . . . . . . . . . . . . . . . 2 - 16
2.7.4 CH4 Methane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 18
2.7.5 C2H3Cl Vinyl Chloride (VCM) . . . . . . . . . . . . . . . . . 2 - 20
2.7.6 C2H4 Ethylene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 22
2.7.7 C2H6 Ethane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 24
2.7.8 C3H6 Propylene . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 26
2.7.9 C3H8 Propane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 28
2.7.10 C4H6 1,3-Butadiene . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 30
2.7.11 C4H8 1-Butene. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 32
2.7.12 C4H10 n-Butane. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 34
2.7.13 N2 Nitrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 36
2.7.14 NH3 Ammonia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 37


Avoiding Dangers
2.1 Avoiding Dangers

Safety means recognizing and avoiding dangers as well as knowing and
controlling the process.
The compressor is designed and built in accordance with the present state-
of-the-art technology and the recognized technical safety regulations. Nev-
ertheless, risks to users, property, and environment can arise when the
compressor is operated carelessly or improperly.
The compressor may only be operated if the following criteria are taken into
consideration:
the compressors intended use,
the compressors faultless operation, with special regard to safety re-
quirements.
2.2 Obligations
The safety of personnel can only be ensured if these safety instructions
and the safety notices in this manual are strictly observed and followed.
Therefore, the Instruction Manual must always be available to all people
performing the tasks described.
Additionally, general national rules of accident prevention and occupational
medicine must be observed.
Superior Authoritys It is the superior authoritys responsibility to

Obligations specify who is authorized to install, commission, prepare, operate,
maintain and repair the compressor,
prevent unauthorized persons from tampering with the compressor,
check personnels security awareness regularly,
induce inspection of all control equipment and safety devices on a reg-
ular basis,
equip personnel with adequate protective clothing,
integrate incoming revision sheets into the Instruction Manual,
inform personnel about revisions.
The superior authority may only allow personnel to operate the compressor
who are
qualified through practical experience and training on the compressor,
familiar with basic work safety and accident prevention regulations.
Trainees may only operate the compressor under supervision of an expe-

rienced person.
The compressor must be operated and maintained in such a way that the
safety of the operator, maintenance personnel or third party is guaranteed
at all times.

Safety Measures
Personnels Obligations Personnel charged with duties on the compressor plant

must check with their supervisor and/or safety officer if a work and entry
permit is required,
must have read and understood the respective parts of the Instruction
Manual,
must observe basic work safety and accident preventing regulations
before they start working on the compressor,
is obliged to report any changes on the compressor which might impair
safety, e.g modification of mode of operation or unusual noise,
must know the hazards and limitation of compressor operation im-
posed by the process.
Only operate the compressor when it is in faultless condition. Eliminate

faults which could impair safety immediately by professionals according to
chapter 13 Appendix.
2.3 Safety Measures
2.3.1 Warning Signs at Compressor Site

Corresponding warning signs must be fitted on the installation. Notices at
the compressor site must be easily legible, clearly understandable and of
durable quality.
Never remove warning signs nor safety alerts from the compressor.
Replace damaged signs or signs that have come off immediately.
Wear hard hat!
Wear protective goggles!
Wear hearing protection!
Wear protective gloves!
Wear safety shoes in this area!

Safety Measures
Slip hazard watch your step!
Pressurized vessel or pipe depressurize plant be-

fore you start working!
Hot surface, dont touch!
Corrosion hazard, avoid contact with caustic sub-

stances!
2.3.2 Preventive Measures

Provide approved fire-extinguishing equipment.
Provide marked escape routes furnished with emergency stop devices.
2.3.3 Safety Devices

The safety devices installed on the compressor plant must be neither re-
moved nor disabled during operation. If such devices have been removed,
e.g. for maintenance work, resume operation only after you have fully in-
stalled and checked all safety devices.
2.3.4 Mechanical Hazard
WARNING
Rotating components, drawing in and crush hazard!
Exposed rotating components can cause severe injury or death.
Do not operate the compressor with flywheel guard removed!
Follow lockout procedure before maintenance.
2.3.5 Thermal Hazard
WARNING
Hot or cold surface!
Burns, scalds and other injuries may arise from a possible contact of a
person with plant components with an extreme high or low temperature.
Fit installation with corresponding warning signs.

Safety Measures
2.3.6 Electrical Hazard

Installation of and maintenance on electrical parts must be performed by
professionals.
All the electrical equipment and the installations must be maintained peri-
odically to prevent danger. Burckhardt Compression AG strongly recom-
mend that this includes an appropriate visual inspection and testing, where
necessary.
DANGER
Electrical danger or hazard.
Before any inspection or repair on the compressor or any related elec-
trical item, turn high and/or low-voltage main switch off at the switch
box and padlock the switch in the off-position.
Always keep control panel and/or local operator panel locked. Only au-
thorized personnel may have access.
Do not allow work on or near exposed live parts of equipment unless it
is absolutely unavoidable. Suitable precautions must be taken to pre-
vent injury, both to the workers and to anyone else who may be in the
area.
2.3.7 Protection against Loud Noise

Personnel must be equipped with hearing protection if the continuous
sound pressure level meets 85 to 87 dB(A) per day or week. For sound
pressure level figures see section Technical Data in chapter 13 Appendix.
2.3.8 Handling Lubricants
For more detailed information see Material Safety Data Sheet (MSDS) from
supplier.
Hazards Under normal condition of use, lubricants are not considered hazardous
according to regulatory guidelines. Nevertheless, the superior authority is
obliged to inform the personnel handling lubricants about possible dangers
to humans and the environment which are imposed by the particular mate-
rial.
Hazard classification can be made according to:
flash point,
toxicity,
MAC-value (Maximum Allowable Concentration for working area).

Safety Measures
DANGER
Health hazard!
Excessive exposure can irritate the eyes, skin or respiratory system.
Slip hazard.
Wear oil-resistant gloves and/or other protective clothing when hand-
ling lubricants.
If eye contact is likely, wear protective goggles.
If mists are generated, and/or when ventilation is not adequate, wear
approved respirator mask.
Do not eat, drink or smoke.
DANGER
Fire hazard and explosion hazard!
No open fire.
No smoking.
Storage, Labeling Do not store in open or unlabeled containers.

Do not store near heat, sparks, flame or strong oxidants and combus-
tible materials.
Storage areas must be marked with clearly visible warning signs.
In storage rooms, good ventilation must be ensured.
Disposal Oils must be recycled, return them to the supplier.

Take care of the environment: dispose of lubricants according to na-
tional regulations.
It is strictly forbidden to dispose of lubricants in toilets, cleaning rooms,
water drains or to discharge to the ground or waste containers etc.
Leak Response Adsorb any spillage with appropriate material and remove mechani-
cally into containers.
Fire-Fighting Measures Extinguish fire with carbon dioxide, extinguishing foam or dry chemical.
Do not use water.
First Aid Should eyes have been affected, rinse immediately for 15 minutes with
large quantity of water (eye wash).
Remove oil soaked clothing.
Rinse affected skin with soap and water.
If irritation occurs, get medical attention.
2.3.9 Handling Chemicals

Hazards The superior authority is obliged to inform the personnel handling chemi-
cals about possible dangers to humans and the environment.

Safety Measures

flash point,
toxicity,
DANGER
Health hazard and fire hazard!
Chemicals can be toxic, caustic, flammable and explosive.
Do not eat, drink or smoke in the proximity to chemicals!
Before handling any chemicals,
pay attention to the warning symbols, peril indications and safety
advice on the label of the storage container,
familiarize yourself with procedures in the event of contamination,
poisoning, corrosion, spilling, leakage of unknown substance.
Always wear adequate protective clothing when handling chemicals.
Storage, Labeling Do not store chemicals in open containers.

Label chemical containers clearly in accordance with the valid regula-
tions (chemical act). Those who draw off chemicals are responsible for
labeling containers.
Combustibles must be kept in specially marked containers.
Storage areas must be marked with clearly visible warning signs.
Ensure good ventilation in storage rooms.
Handling Dont spill chemicals.

Use a funnel, transfer pump and collecting tub for drawing off chemi-
cals.
Disposal Take care of the environment: dispose of chemicals according to na-

tional regulations.
It is strictly forbidden to dispose of chemicals in toilets, cleaning rooms,
water drains, into the ground or waste containers etc.

Safety Measures
Acids and Lyes
DANGER
Health hazard!
If water is added to concentrated acids or lyes, it can boil and spit
dangerously.
Inhalation of vapors or aerosols may lead to severe lung damage.
Skin or eye contact leads to chemical burn (danger of blindness).
Avoid any contact with eyes and skin.
Use face shield or heavy protective goggles, suitable protective gloves
and apron.
If vapors form, wear approved respirator mask.
If large amounts of vapors occur, leave danger zone immediately.
Dilution: always pour concentrated acids or lyes/caustic soda into
water while stirring, never contrariwise.
DANGER
Fire hazard!
Flammable acids or lyes: danger of fire, vapors form explosive mix-
tures with air.
No open fire.
No smoking.
Leak Response
Adsorb any spillage with appropriate material (e.g. diatomaceous
earth, mountain flour).
Subsequently clean thoroughly with water.
Fire-Fighting Measures
If possible quench small fires by means of a fire blanket.
Extinguish fire with carbon dioxide or dry chemical. Do not use water.
First Aid
Should eyes have been affected, rinse immediately for 15 minutes with
Remove wetted clothing at once.
Rinse affected skin immediately with large quantity of water.
Get immediate medical attention take Material Safety Data Sheet
(MSDS) to physician with victim.

Safety Measures
Organic Solvents
DANGER
Health hazard!
Organic solvents can be toxic and narcotic. They degrease the skin.
Avoid all contact with eyes and skin.
Use protective goggles and suitable protective gloves.
If vapors form, wear approved respirator mask.
If large amounts of vapors occur, leave danger zone immediately.
DANGER
Fire hazard!
Organic solvents can be flammable. They evaporate quickly and can
form explosive mixtures with air or can ignite by contact with hot sur-
faces.
No open fire.
No smoking.
Avoid escape of vapors.
Eliminate any possible source of ignition including sparks and electro-
static discharge.
Leak Response
Adsorb any spillage with appropriate material (e.g. diatomaceous
earth, mountain flour) and remove mechanically into tightly closing con-
tainers.
Make sure that there is sufficient circulation of fresh air. Wear approved
respirator mask.
Eliminate any possible source of ignition.
Fire-Fighting Measures
If possible quench small fires by means of a fire blanket.
Extinguish fire with carbon dioxide, extinguishing foam or dry chemical.
Do not use water.
First Aid
Should eyes have been affected, rinse immediately for 15 minutes with
Remove wetted clothing at once.
Rinse affected skin immediately with large quantity of water.
Give artificial respiration if victim is not breathing.
Get medical attention take Material Safety Data Sheet (MSDS) to
physician with victim.

Intended Use
2.4 Intended Use

Correct Application This compressor type is exclusively designated for the compression of gas
as specified for this application (see section 2.7.1 Gas Specification). Any
other use is considered improper and is strictly forbidden.
Appropriate utilization includes adherence to instructions for installation,
dismantling, assembly, commissioning, operation and maintenance speci-
fied by the manufacturer.
Incorrect Application Any utilization beyond this specific designation is considered as not to con-
form to designation. Burckhardt Compression AG will not be liable for dam-
ages resulting from incorrect application. The risk of such non-permissible
applications must be borne solely and entirely by the operating company.
If you want to extend the contractual range of application, please consult

our worldwide operating Customer Support Service in Switzerland. Ad-
dress see section 1.3 Contact Address.
Design Changes of Modifications to the compressor plant are only permitted with the written
Compressor approval of Burckhardt Compression AG. We will decline any claim re-
sulting from unauthorized modifications.
Software Changes Do not change the code of software programs under any circumstances!
2.5 Compressor Operation

For the operation of the compressor, local, state, federal laws and safety
rules must be adhered to (e.g. smoking ban, open flame, placing spectacle
flanges or blanks etc.).
When operating with process gas, access to the compressor might be
hampered for safety reasons. Nevertheless, the safe operation of the plant
must be assured.
Prior to starting the compressor, make sure that nobody will be harmed
by the starting compressor.
Check compressor and plant for visible damages and for faults of
safety devices at least once per shift.
Check pressure and temperature values periodically.
2.5.1 Operation with Flammable Process Gas

For more detailed information about process gas see section 2.7 Process
Gas and Purge Gas.
The personnel involved with operating must be specially trained for opera-
tion with respective process gas and must strictly follow applicable rules
and regulations.
27.06.2007 Rev. 001/kaufmann_w 2K158-2D_1 IM 100822en 2 11

Safe Maintenance Practices
DANGER
Fire hazard!
Flammable process gas. May form explosive mixtures with air!
No open fire.
No smoking.
Depressurize the installation and purge with dry nitrogen before you
open the compressor.
Purge the compressor plant with dry nitrogen prior to operating com-
pressor with process gas.
2.6 Safe Maintenance Practices
2.6.1 Cleaning of Compressor Plant

Keep the compressor and surrounding area clean and tidy. Use appro-
priate cleansing agents and materials. For safe use of cleansing agents
see section 2.3.9 Handling Chemicals.
Please take care of the environment!
2.6.2 Compressor Maintenance

Carry out adjustments, preventive and corrective maintenance according
to intervals given in the maintenance manuals.
Before beginning any inspection or repair
protect all plant components such as main motor, oil and coolant
system pumps, pneumatic or hydraulic control systems etc. against un-
intended start-up,
depressurize compressor plant,
in case of flammable or toxic process gas, purge compressor plant with
dry nitrogen,
make sure there is sufficient circulation of fresh air.
Only use original equipment manufacturer (OEM) spare parts, otherwise

the operational safety of the compressor cannot be assured.

Process Gas and Purge Gas
WARNING
Limited operational safety!
The specially designed characteristics of the compressor or related plant
components and/or their operational safety may be influenced negatively
(= increased risk) by improper actions.
Do not modify parts or spare parts.
Use genuine spare parts only.
Do not use unsuitable material.
Do not modify clearances on compressor.
Eliminate troubles immediately.
Replace worn parts.
2.6.3 Commissioning after Maintenance

Before commissioning,
check working order of compressor and motor by turning the flywheel
several times in running direction,
fit flywheel guard and assure working order.
2.7 Process Gas and Purge Gas
2.7.1 Gas Specification
LNG Liquefied Natural Gas Normal Case

LPG Liquefied Petroleum Gas
CH3Cl Methyl chloride *
CH4 Methane *
C 2H 4 Ethylene *
C 2H 6 Ethane *
C 3H 6 Propylene *
C3H8/C2H6 Commercial propane *
C 3H 8 Propane *
C 4H 6 1,3 Butadiene *
C 4H 8 Butylene (1-butene) *
C4H10 Isobutane *
C4H10 n-Butane *
NH3 Ammonia *
C2H3Cl Vinyl chloride (VCM) *
* Operating data for several gases/cases see Technical Data in chapter

13 Appendix.

Purge Gas Normal Case

N2 Nitrogen 100%
Summary information about above mentioned gases or foreign matters in

process gas (if applicable) see later in section 2.7.
For in-depth safety information please consult the respective Material

Safety Data Sheets, e.g. on the internet.
2.7.2 Hazard Identification Diamond

The hazard identification symbol is a color-coded array of four numbers or
letters arranged in a diamond shape. Example: see Fig. 2-1. Hazard iden-
tification diamonds like this are placed on storage tanks, bottles of chemi-
cals and in various other places around the plant.
The blue (health hazard), red (flammability) and yellow (reactivity) fields all
use numbering scale ranging from 0 to 4, according to National Fire Pro-
tection Association (NFPA-Rating). A value of zero means that the material
poses essentially no hazard; a rating of four indicates extreme danger. The
white field (specific precautions) can have variable content, depending on
who prepared the signal.

Flammability
0 Material will not burn.
1 Material must be pre-heated before ignition can occur.
2 Material must be moderately heated before ignition can

occur.
3 Material can be ignited under almost all ambient

temperature conditions.
4 Highly flammable at all temperatures.

Reactivity
Health Hazard
0 Material that in itself is normally
0 No specific danger under fire conditions. stable.
1 Material that on exposure would cause 1 Material can become unstable at

irritation but only minor residual injury. elevated temperatures and
2 Material that on intense or continued but 3 pressures.
2 Violent chemical change at

not chronic exposure could cause
temporary incapacitation or possible
residual injury.
4 2 elevated temperatures and
pressures or violent reaction with
water (may form explosive
3 Material that on short exposure could
cause serious temporary or residual
W mixtures with water).
injury. 3 Explosion hazard under impact of

heat or shock/bash or explosive
4 Material that on very short exposure reaction with water.
could cause death or major residual
injury. 4 Material is highly explosive at
normal temperatures and
pressures.
Specific Precautions (National Fire Code)
W Shows unusual reactivity with water.

Dont use water as an extinguishing agent!
OX Material possesses oxidizing properties.
XA_XX_0038b_01
Fig. 2-1 Hazard identification diamond

2.7.3 CH3Cl Methyl Chloride
NFPA-rating for methyl chloride. Explanation see

section 2.7.2 Hazard Identification Diamond.
4
1 0

DANGER
Fire hazard!
Methyl chloride pose a serious fire hazard when exposed to heat,
flame or powerful oxidizers. Can form explosive mixtures with air.
The gas is heavier than air, and may spread long distances. Distant ignition
and flashback are possible. In case of fire, toxic carbon monoxide, hy-
drogen chloride and phosgene may be produced.
No open fire.
No smoking.
Use non-sparking tools.
Eliminate any possible sources of ignition.
During an emergency situation, before entering the area, check for
flammable gas level (explosion limits). Wear self-contained breathing
apparatus.

DANGER
Health hazard!
Methyl chloride is toxic! Inhalation of high concentrations of methyl
chloride can lead to central nervous system depression. Contact with
rapidly expanding gas can cause frostbite and burns from freezing.
Methyl chloride can hydrolyze in the bodys cells, producing hydrochloric
acid and methyl alcohol.
When working on the compressor, make sure there is sufficient circu-
lation of fresh air.
Be aware of any signs of dizziness or fatigue. Exposures to fatal con-
centrations of methyl chloride could occur without any significant
warning symptoms.
apparatus.
Fire-Fighting Measures In case of fire

shut off the gas source when possible without risk,
extinguish fires with water spray, carbon dioxide or dry chemicals.
Water spray should be used with care. Methyl chloride can be hydrolyzed,
and will form hydrochloric acid.
Leak Response In case of leak

evacuate the affected area,
eliminate any possible sources of ignition,
seal leak when possible without risk,
wear self-contained breathing apparatus and fire-retardant personal
protective equipment to rescue people and to seal leak.
First Aid In case of gas leak

remove victims to fresh air, as quickly as possible,
give artificial respiration if victims are not breathing,
if contact with skin occurs:
immediately flush skin with water for minimum 15 minutes,
remove affected clothing, taking care not to contaminate eyes,
get immediate medical attention take Material Safety Data Sheet


2.7.4 CH4 Methane
NFPA-rating for methane. Explanation see section

2.7.2 Hazard Identification Diamond.
4
1 0

DANGER
Fire and explosion hazard!
Methane is flammable! Can form explosive mixtures with air. Electro-
static discharges may be generated by flow or agitation resulting in
ignition or explosion.
The gas is lighter than air, and may spread long distances. Distant ignition
and flashback are possible. In case of fire, toxic carbon monoxide may be
produced.
No open fire.
No smoking.
flammable gas level (explosion limits) as well as oxygen-deficient at-
mospheres.
DANGER
Health hazard!
Risk of suffocation or narcotization! Methane gas is an asphyxiant
and presents a health hazard by displacing the oxygen in the atmo-
sphere.
In case of fire, toxic carbon monoxide may be produced.
mospheres.





2.7.5 C2H3Cl Vinyl Chloride (VCM)
NFPA-rating for vinyl chloride. Explanation see

4
2 2

DANGER
Vinyl chloride pose a serious fire hazard when exposed to heat, flame
or powerful oxidizers. Vinyl chloride polymerizes readily when ex-
posed to air, sunlight, heat or oxygen and so can form explosive air/
gas mixtures. Electrostatic discharges may be generated by flow or
agitation resulting in ignition or explosion. Contact with metals such
as copper, aluminum and certain catalytic impurities can cause vio-
lent polymerization.
The gas is heavier than air and will accumulate in low areas. Distant ignition
and flashback are possible. In case of fire, toxic carbon monoxide, hy-
drogen chloride and traces of phosgene may be produced.
No open fire.
No smoking.
Eliminate any possible sources of ignition.
Do not use copper and its alloys and aluminum in equipment used with
vinyl chloride.
apparatus. This gas is heavier than air and will accumulate in low
areas.

DANGER
Health hazard!
Vinyl chloride is a known human carcinogen and is toxic by all routes
of exposure. At high concentrations, unconsciousness or death may
occur. Contact with rapidly expanding gas can cause frostbite.
In case of fire, toxic carbon monoxide, hydrogen chloride and traces of
phosgene may be produced.
centrations of vinyl chloride could occur without any significant warning
symptoms.
apparatus. This gas is heavier than air and will accumulate in low
areas.

extinguish fires with carbon dioxide or dry chemicals. Do not use water
as vinyl chloride reacts with water.


if contact with skin occurs: immediately flush skin with water for min-
imum 15 minutes,
if contact with eyes occurs: flush eyes with water for minimum 15 min-
utes,

2.7.6 C2H4 Ethylene
NFPA-rating for ethylene. Explanation see section

4
1 2

DANGER
Ethylene is flammable! Can form explosive mixtures with air. Electro-
The gas is lighter than air, and may spread long distances. Distant ignition
produced.
No open fire.
No smoking.
mospheres.

DANGER
Health hazard!
Risk of suffocation or narcotization! Ethylene gas is an asphyxiant
sphere. At high concentrations, unconsciousness or death may
centrations of ethylene could occur without any significant warning
symptoms.
mospheres.




2.7.7 C2H6 Ethane
NFPA-rating for ethane. Explanation see section

4
1 0

DANGER
Ethane is flammable! Can form explosive mixtures with air. Electro-
produced.
No open fire.
No smoking.
mospheres.

DANGER
Health hazard!
Risk of suffocation or narcotization! Ethane gas is an asphyxiant and
presents a health hazard by displacing the oxygen in the atmosphere.
At high concentrations, unconsciousness or death may occur. Con-
tact with rapidly expanding gas can cause frostbite.
centrations of ethane could occur without any significant warning
symptoms.
mospheres.



imum 15 minutes,

2.7.8 C3H6 Propylene
NFPA-rating for propylene. Explanation see sec-

tion 2.7.2 Hazard Identification Diamond.
4
1 1

DANGER
Propylene is flammable! Can form explosive mixtures with air. Elec-
trostatic discharges may be generated by flow or agitation resulting
in ignition or explosion.
produced.
No open fire.
No smoking.
mospheres.

DANGER
Health hazard!
Risk of suffocation or narcotization! Propylene gas is an asphyxiant
occur.
centrations of ethane could occur without any significant warning
symptoms.
mospheres.




2.7.9 C3H8 Propane
NFPA-rating for propane. Explanation see section

4
1 0

DANGER
Propane is flammable! Can form explosive mixtures with air. Electro-
produced.
No open fire.
No smoking.
mospheres.

DANGER
Health hazard!
Risk of suffocation or narcotization! Propane gas is an asphyxiant
occur.
centrations of propane could occur without any significant warning
symptoms.
mospheres.




2.7.10 C4H6 1,3-Butadiene
NFPA-rating for 1,3-butadiene. Explanation see

4
2 2

DANGER
1,3-Butadiene is flammable! Can form explosive mixtures with air.
produced.
No open fire.
No smoking.
mospheres.

DANGER
Health hazard!
Risk of suffocation or narcotization! 1,3-Butadiene gas is an asphyx-
iant and presents a health hazard by displacing the oxygen in the at-
mosphere. At high concentrations, unconsciousness or death may
occur. Contact with rapidly expanding gas can cause frostbite. 1,3-
Butadiene is a suspect carcinogen.
centrations of 1,3-butadiene could occur without any significant
warning symptoms.
mospheres.



utes,

2.7.11 C4H8 1-Butene
NFPA-rating for 1-butene. Explanation see section

4
1 0

DANGER
1-Butene is flammable! Can form explosive mixtures with air. Electro-
produced.
No open fire.
No smoking.
mospheres.

DANGER
Health hazard!
Risk of suffocation or narcotization! 1-Butene gas is an asphyxiant
centrations of n-butene could occur without any significant warning
symptoms.
mospheres.



imum 15 minutes,

2.7.12 C4H10 n-Butane
NFPA-rating for n-butane. Explanation see section

4
1 0

DANGER
n-Butane is flammable! Can form explosive mixtures with air.
produced.
No open fire.
No smoking.
mospheres.

DANGER
Health hazard!
Risk of suffocation or narcotization! n-Butane gas is an asphyxiant
centrations of n-butane could occur without any significant warning
symptoms.
mospheres.



imum 15 minutes,

2.7.13 N2 Nitrogen
NFPA-rating for nitrogen. Explanation see section

2.7.2 Hazard Identification Diamond
0
0 0

DANGER
Health hazard!
Risk of suffocation! Nitrogen gas is an asphyxiant and presents a
health hazard by displacing the oxygen in the atmosphere. At high
concentrations, unconsciousness or death may occur.
Depressurize the installation before you open the compressor.
centrations of nitrogen could occur without any significant warning
symptoms.
During an emergency situation, before entering the area, check for ox-
ygen-deficient atmospheres.
Fire-Fighting Measures Nitrogen does not burn however, containers, when involved in fire, may
rupture or burst in the heat of the fire.

wear self-contained breathing apparatus to rescue people and to seal
leak.


2.7.14 NH3 Ammonia
NFPA-rating for ammonia. Explanation see sec-

tion 2.7.2 Hazard Identification Diamond.
1
3 0

DANGER
Health hazard!
Ammonia is toxic and corrosive! Inhalation of ammonia vapors or
gases may lead to irritation of the nose and throat. Exposure to the
eyes may cause temporary blindness, leading to permanent vision
impairment. At high concentrations, unconsciousness or death may
apparatus and fully encapsulating chemical-resistant protective equip-
ment.
Fire-Fighting Measures Ammonia only burns in high concentrations, at high temperatures and with
powerful sources of energy.
Ammonia is not readily ignited, but explosions of ammonia in confined
spaces can occur.
In case of fire

wear self-contained breathing apparatus and fully encapsulating chem-
ical-resistant protective equipment to rescue people and to seal leak.


utes,

Plant Configuration and Function
3 Plant Configuration and Function
3.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3
3.2 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3
3.3 Gas System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4
3.3.1 Suction Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4
3.3.2 Purge System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4
3.3.3 Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4
3.3.4 Refrigeration Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5
3.3.5 Pulsation Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9
3.3.6 Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10
3.4 Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11
3.4.1 Coolant Treatment Avoiding Deposits . . . . . . . . . . 3 - 12
3.4.2 Combined Cooling/Heating System . . . . . . . . . . . . . 3 - 12
3.5 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 15
3.5.1 Schematic Overview. . . . . . . . . . . . . . . . . . . . . . . . . 3 - 15
3.6 Control and Operating Elements . . . . . . . . . . . . . . . . . . . . . . 3 - 16
3.7 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 16
3.7.1 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 17
3.7.2 Temperature Monitoring . . . . . . . . . . . . . . . . . . . . . . 3 - 17
3.7.3 Pressure Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 17
3.7.4 Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 17
3.7.5 Non-Return Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 18
3.7.6 Flow Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 18
3.7.7 Level Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 18
3.7.8 Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 18


Overview
3.1 Overview
The process gas is compressed to the required pressure by a Laby com-
pressor with appropriate number of stages. The compression act gener-
ates heat, therefore certain compressor components and in most cases the
compressed gas must be cooled. The lubricating system assures that
bearing and crosshead are sufficiently lubricated.
3.2 Drive System
LK_L1_0001a_01
Fig. 3-1 Laby compressor type K with flexible coupling
The compressor is driven by a flexible coupled electric motor. The flexible

coupling is able to absorb shaft heat expansions, angular deviations and
parallel shifts. For better illustration, Fig. 3-1 shows a typical view without
flywheel guard.
WARNING
Do not operate the compressor with flywheel guard removed!
For the description of the electric motor refer to the documentation of the
motor manufacturer (see Technical Documentation).
For the description of the electric motor and the flexible coupling refer to
the documentation of the manufacturers (see Technical Documentation).

Gas System
3.3 Gas System
3.3.1 Suction Strainer

To prevent foreign matter from getting into the compressor from the suction
side, a strong conical suction strainer is fitted in the suction line to the first
stage.
1 2 3 4
XA_XX_0101b_01
Fig. 3-2 Suction strainer
1 Flange
2 Flow direction
3 Intermediate piece
4 Conical suction strainer
3.3.2 Purge System

Dependent on the chemical properties of the process gas, a purge system
is required to protect personnel and equipment.
Components of Purge For layout of the purge system see section P & I Diagram in chapter 13
System Appendix.
Purging prior to After operation of the compressor with a toxic, explosive or flammable pro-
Maintenance or Normal cess gas, the compressor plant must be purged with dry inert gas like ni-
Operation trogen prior to performing any maintenance work. The same applies after
maintenance, prior to normal operation with an explosive or flammable pro-
cess gas or if contamination of process gas with air must be prevented.
3.3.3 Bypass
Bypass Overall The bypass valve is used for commissioning, capacity control and for run-
ning-in of new pistons.The compressor is equipped with a bypass overall
stages. This allows to start the compressor without back pressure and a
continuous capacity control within a certain range.

Gas System
3.3.4 Refrigeration Cycles

For operating data of the respective refrigeration cycles, see section Tech-
nical Data in chapter 13 Appendix.
Examples for Typical

Refrigeration Cycles A
LK_XX_0003a_01
h1 h
h2
Fig. 3-3 Example without intercooling
A 1st stage
pd Discharge pressure
ps Suction pressure
h1 Net enthalpy
h2 Gross enthalpy
A B
LK_XX_0004a_01
h1 h
h2
Fig. 3-4 Example with intercooling
A 1st stage
B 2st stage
pd Discharge pressure
pi Interstage pressure
ps Suction pressure
h1 Net enthalpy
h2 Gross enthalpy
Definition of the Net refrigeration capacity = mass flow x h1

Refrigeration Capacity
To enable BCA the calculation of net capacity the following values shall be
specified by the purchaser:
refrigeration capacity
ps suction pressure or equivalent evaporating temperature
pd discharge pressure or equivalent condensing temperature

Gas System
NIC = No Intercooling A simple refrigeration cycle consists of an evaporator or a boil-off tank, a

compressor, a condenser and an expansion valve. Such a cycle with a 1-
or 2-stage compression is used for applications where either the total pres-
sure ratio is low or the suction temperature remains constant at a low level.
This process is normally used for pure gases such as butane, butadiene,
VCM, etc.
At some gases as 1,3-Butadiene, where discharge temperature limits ex-
ists, a conventional intercooler may be required.
WAC = Water or Air Cooling

2-stage compression and no intercooling after 1st stage in an interstage
vessel.
Single Expansion
A
1 2
3 2
0
0 1
3
h
A B
1 2 3
4 3
0
LK_XX_0005a_01
2
0 1
4
h
Fig. 3-5 NIC, single or multistage compression without intercooling
A 1st stage
B 2nd stage
h Enthalpy
DH = Deheating This cycle includes a multistage compressor. In order to keep the gas tem-
perature of the 2nd and/or 3rd compression stage under the gas tempera-
ture limit, liquid received from the condenser is injected between the
stages. Such multistage cycles are used for pure gases. A typical applica-
tion is ammonia.

Gas System
Single Expansion
A B
LK_XX_0006a_01
A B C
1 2 3 4 5 6
7 6
5 4 0
3 2
0 1
7
h
Fig. 3-6 DH, multistage compression with intercooling by liquid injection in be-
tween stages
A 1st stage
B 2nd stage
C 3rd stage
h Enthalpy
DEX = Double Expansion This refrigeration cycle includes beside the multistage compressor an inter-
stage vessel and a second expansion valve. The cooling of the 1st stage
discharge gas takes place in the interstage vessel. The hot gas of the 1st
stage is mixed with the liquid and flash received from the condenser. These
multistage cycles are used for pure gases such as ammonia, ethylene, etc.
Double Expansion
A B
LK_XX_0007a_01
h
Fig. 3-7 DEX, multistage compression
A 1st stage
B 2nd stage
h Enthalpy

Gas System
FLASH DEX = Flash This cycle is similar to DEX cycle. The difference is, that the interstage
Double Expansion vessel is only indirectly connected with the 1st and 2nd compressor stage.
The 1st stage discharge gas is therefore only cooled by means of flash gas
received from the interstage vessel. This process is also used for pure
gases only.
Double Expansion
A B
LK_XX_0009a_01
h
Fig. 3-8 Flash DEX, multistage compression
A 1st stage
B 2nd stage
h Enthalpy
LSC = Liquid Subcooling This refrigeration cycle includes beside the multistage compressor also an
interstage vessel and two expansion valves. The 1st stage discharge gas
is cooled down in the interstage vessel with liquid and flash received from
the condenser. The main liquid stream leaving the condenser is subcooled
in the interstage vessel and afterwards expanded to the evaporator resp.
boil-off tank. These multistage cycles are used for gas mixtures such as
commercial propane.
Single Expansion
A B
5C
LK_XX_0008a_01
h
Fig. 3-9 LSC, multistage compression with subcooling of liquid in interstage
bottle
A 1st stage
B 2nd stage
h Enthalpy
FLASH LSC = Flash Liquid This cycle is similar to LSC cycle. Also here, the only difference is that the
Subcooling interstage vessel is indirectly connected with the two compression stages.
This process is also used for gas mixtures.

Gas System
Single Expansion
A B
5C
LK_XX_0010a_01
h
Fig. 3-10 Flash LSC, multistage compression with subcooling of liquid in inter-
stage bottle with flash take-off
A 1st stage
B 2nd stage
h Enthalpy
3.3.5 Pulsation Damper

Pulsation dampers are fitted to reduce gas pulsations in the piping. For fur-
ther reduction of pulsations, orifice plates are fitted on the pulsation
damper.
XA_P3_0001b_01
Fig. 3-11 Pulsation damper (typical view)
1 Orifice plate (detail see section Technical Data in chapter 13 Appendix

Gas System
3.3.6 Separator
There are liquid separators upstream of each stage to remove any quanti-
ties of condensed liquid which may be present in the process gas. During
operation at design conditions, no condensation is expected. In addition,
the separators reduce gas pulsations in the piping. For further reduction of
pulsations, orifice plates are fitted on the separators.
CAUTION
Liquid knock due to condensate!
Liquid knock in cylinder possible, due to malfunction of condensate drains.
Condensate drains must function faultlessly.
Periodically check and maintain condensate drains.
CAUTION
Risk of condensation if compressor is stopped!
Liquid knock in cylinder possible when compressor is restarted.
After compressor stop, compensate pressure difference between 2nd
stage discharge side and 1st stage suction side: relieve process gas
from 2nd stage discharge side to 1st stage suction side via the bypass.

Cooling System
XA_P3_0002b_00
Fig. 3-12 Vertical separator (typical view)
1 Orifice plate (detail see section Technical Data in chapter 13 Appendix

2 Inspection hole
3 Level indicator
3.4 Cooling System

The compression of the process gas generates heat which is almost com-
pletely dissipated by the coolant. A clean, non-corrosive coolant with a suf-
ficient low freezing point must be used. Via a supply manifold, the coolant
is led to the individual elements.
At commissioning, the various control valves must be adjusted: the coolant
flow rates at minimum allowable coolant pressure must still be sufficient
even during the summer months to prevent the outlet flow temperature of
the coolant rising above the max. admitted value.
Manually operated control valves are installed in the individual coolant lines
allowing to optimize the outlet temperature of the coolant.
The drain valves in the cooling system can be used for blowing in air or
flushing suspended matters/deposits while the plant is in operation.
Thermal Barrier An integrated thermal barrier with circulating ethylene glycol/water mixture
prevents temperature transfer (due to the very low suction temperature)
from the cylinder to the crankgear.

Cooling System
3.4.1 Coolant Treatment Avoiding Deposits

The quality of the coolant must be checked at regular intervals. A minimal
flow of coolant must always be maintained.
Contamination of the coolant leads to deposits in the piping (reduction of
pipe diameter) and to deposits in the coolant spaces. This prevents proper
heat transfer and results in insufficient cooling.
The operating company is responsible for any deviations of the coolant or
its quality.
The coolant in a closed cooling system must be treated (adding chemicals)
in order to:
prevent deposits,
protect the walls of the coolant spaces against corrosion and cavitation.
CAUTION
Corrosive coolant or deposits!
Bad cooling capability of the whole system.
Do not use aggressive coolant. Make sure that the coolant does not at-
tack materials as copper, zinc, and aluminium (gaskets).
Do not use coolant that tends to build up deposits.
CAUTION
Deposits in piping!
Avoid stationary coolant.
The coolant is a mixture of ethylene glycol and fresh water. The mixing ratio
(concerning congealing temperature) must cover all possible operation
conditions.
WARNING
Health hazard!
Pure ethylene glycol is noxious. Harmful or fatal if swallowed. Harmful if in-
haled or absorbed through skin.
Avoid contact with ethylene glycol.
3.4.2 Combined Cooling/Heating System

The cooling/heating system is thermostatically controlled. The coolant cir-
culates in a closed system.
The 3-way valve maintains the defined coolant temperature.

Cooling System
The instruments of the control system (mixing valve and temperature con-
troller) maintain an outlet temperature of the coolant between 35 C and
45 C. The flow for cylinder and crosshead, however, should be adjusted
individually. The temperature difference between the inlet and outlet of the
compressor should remain within 5 C.
CAUTION
Too low coolant temperature!
Condensation within cylinder and crosshead possible.
The coolant must be pre-heated and the temperature controlled by
thermostatic valve.
CAUTION
Too low ambient temperature!
High risk of liquid knock.
The circulation of the coolant should never be interrupted. Even during
standstill periods, i.e. when process gas is in the compressor, the
coolant must circulate with an appropriate minimum temperature.
Operating Principle of All temperatures mentioned later in this section refer to point X (see fol-
Cooling/Heating System lowing diagram).
As the temperature drops below 40 C (e.g. compressor at standstill), the
entire coolant quantity is flowing through the heater again. This time the
heating elements are not in operation. At 35 C coolant temperature, the
heating elements are automatically switched on until 38 C is reached
again.
If, for any reason, the coolant temperature drops below 35 C (initial start-
up of compressor), the pump circulates the entire coolant quantity through
the compressor and over the mixing valve through the heater back to the
pump. The heating elements are in operation. If the temperature of 38 C
is reached, these heating elements will be shut off. The entire coolant
quantity, however, still flows through the heater. When the temperature
rises to 40 C, the mixing valve starts to operate and allows part of the
coolant to flow through the cooler. The control range of this mixing valve
must allow a temperature control between 40 C and 45 C.

3 14
Cooling System
OPERATING PRINCIPLE OF COOLING / HEATING SYSTEM
THIS IS THE DIAGRAM BURCKHARDT COMPRESSION RECOMMENDS! FOR MAINTENANCE THEREFORE PLEASE REFER TO AS BUILT DIAGRAM.
GLYCOL STORAGE TANK

TO COMPRESSOR NO. 2
LIQUID LEVEL MUST BE ABOVE THE HIGHEST
POINT OF THE COOLING SYSTEM.
IM 100822en
HV SEA WATER
2-107 FRESH WATER
EXCH
1-100
MIXING TANK
FROM COMPRESSOR NO. 2
HEA TANK
1-100 1-100
HEATER RATING xxx kW

FROM CROSSHEAD GUIDES
TI TI
TO CROSSHEAD GUIDES
FROM CYLINDER BLOCK

1-101 1-102
TO CYLINDER BLOCK
TCV PI
2K158-2D_1
1-103 1-100
TI HV HV
1-100 1-103 1-104
tmax. = 45 C tmax. = 47 C
TO COMPRESSOR NO. 1 FFIL FFIL
FG FG SPARE
TSH 1-101 1-100
1-101 1-102 ELEMENT
HV
"X" 1-100
HV 1-108 TSLH PUMP CONTINUOUSLY

FSLL HV HV tmin. = 34 C PU PU
1-107 1-100 IN OPERATION ALSO
1-100 1-101 1-102 1-101 1-100
TSL IF COMPRESSORS
tmin. = 35 C ARE STOPPED.
FROM COMPRESSOR NO. 1 1-100
tmax. = 38 C
Qmin. = 2Q / 3 = xxx m3/h (SEE INSTRUCTION MANUAL) RV RV
1-101 1-100
Rev. 001/kaufmann_w
VELOCITY OF THE COOLANT (WATER-GLYCOL MIXTURE) = 1.5 m/s COOLANT RETURN

TI104 HV HV
1-105 1-106
VELOCITY OF THE COOLANT (WATER-GLYCOL MIXTURE) = 1.5 m/s COOLANT SUPPLY PI

1-101
LOW AND HIGH POINTS OF THE COOLANT (WATER-GLYCOL COOLANT-CIRCUIT AND TEMPERATURE AT POINT "X". KEEP COOLANT TEMPERATURE AS ABOVE MENTIONED AND THE
MIXTURE) SYSTEM SHALL HAVE DRAINS AND VENTS PUMPS CONTINUOUSLY IN OPERATION TO AVOID
RESPECTIVELY. CONDENSATION WITHIN COMPRESSORS.
T (C)
45
COOLING-
LK_XX_0013a_01
RANGE
40
NEUTRAL RANGE
27.06.2007
38
HEATING RANGE
35
TIME
Lubricating System
3.5 Lubricating System

For information about the lubricating system see section P & I Diagram in
Technical information of components as well as operating and mainte-

nance instructions of accessories: see Technical Documentation.
The lubricating system guarantees that bearing and crosshead are lubri-
cated. The lubricating oil circulates in a closed system.
During compressor operation, lubrication is ensured by the gear oil pump,
which is driven by the crankshaft.
The oil pressure can be adjusted at the relief valve. The oil pressure and
crankgear pressure can be checked on the respective pressure gauges.
3.5.1 Schematic Overview
4 5 6 7 8 9 10 11
LK_P0_0002b_01
Fig. 3-13 Lubricating oil flow diagram
1 Oil flow upstream to gear oil pump 6 Not applicable

2 Oil flow downstream from gear oil 7 Non-drive end of compressor
pump 8 Main bearing
3 Oil flow in crankshaft and crosshead 9 Crosshead
4 Oil strainer 10 Drive end of compressor
5 Gear oil pump 11 Relief valve

Control and Operating Elements
3.6 Control and Operating Elements
DANGER
Electrical danger or hazard.
Before any inspection or repair on the compressor or any related elec-
trical item, turn high and/or low-voltage main switch off at the switch
box and padlock the switch in the off-position.
Always keep control panel and/or local operator panel locked. Only au-
thorized personnel may have access.
Do not allow work on or near exposed live parts of equipment unless it
is absolutely unavoidable. Suitable precautions must be taken to pre-
vent injury, both to the workers and to anyone else who may be in the
area.
DANGER
Automatic start-up possible!
Severe injuries caused by unexpected start-up of compressor.
Before any inspection or repair on the compressor turn high and/or low-
voltage main switch off at the switch box and padlock the switch in the
off-position.
If this is not possible, make sure there is no way of starting the com-
pressor (disconnect control panel, PLC etc.).
3.7 Safety Devices
For detailed description of safety devices refer to the documentation of the

manufacturer (see Technical Documentation).
For set values of safety devices see section Technical Data in chapter 13
Appendix.
The final settings of the safety devices are determined during pre-commis-
sioning of the compressor plant by our specialists according to the actual
operation values.

Safety Devices
DANGER
Inoperable safety devices!
Risk of severe injuries.
To ensure correct operation, the safety devices (setpoints, switching
points etc.) must be tested and calibrated periodically.
Safety devices must only be attended to by authorized personnel.
Safety devices must not be isolated, bypassed or have their settings
changed without authorization.
Defective safety devices must be replaced immediately.
3.7.1 Emergency Stop

To permit an immediate shut-down of the compressor in an emergency sit-
uation, an emergency-stop button must be installed nearby the com-
pressor.
Use this safety device only in emergency situations and not to shut down
the compressor under normal conditions.
3.7.2 Temperature Monitoring

Temperature safety devices protect the compressor against excessively
high or low temperatures.
Thermostats which protect the compressor against high temperatures must
be adjusted to a value of about 1015 C above the maximum operating
temperature (considering bypass operation, if applicable).
For set values of safety devices see section Technical Data in chapter 13
Appendix.
Various temperature indicators allow local observation and remote moni-
toring of temperature values.
3.7.3 Pressure Monitoring

Pressure safety devices protect the compressor against excessively high
or low pressures.
Pressure transmitters are used for remote monitoring of pressure values
and to control the control valves (if applicable). Pressure gauges allow local
observation of pressure values.
3.7.4 Safety Valve

Mechanical safety valves protect the compressor and its auxiliary equip-
ment against excessive pressures. Safety valves are the ultimate protec-
tion devices for compressor, vessels and pipes. They must be inspected
periodically with regard to plant operating conditions.

Safety Devices
Each stage is safeguarded by a mechanical safety valve which opens at

excessive pressure and exhausts to a process gas dependent safe loca-
tion. Under operating conditions, due to gas pulsations, the safety valves
can blow off at pressures 8 % to 12 % below the set values.
The coolant system is equipped with mechanical safety valves on the water
side. The oil system is equipped with a spring loaded relief valve.
3.7.5 Non-Return Valve

A non-return valve is installed in the discharge line to prevent process gas
from flowing back to the compressor system.
3.7.6 Flow Monitoring

The coolant system is equipped with a flow switch which protects the com-
pressor from coolant system failure. Sight glasses allow local observation
of coolant flow.
3.7.7 Level Monitoring

Gas System A level switch is installed in the separator to avoid possible accumulation
of condensate.
3.7.8 Level Indicator

Oil System A sight glass in the crankgear allows local observation of lubricating oil
level.
Gas System A sight glass or level indicator in the separator allows local observation of
condensate level.

Compressor Design and Function
4 Compressor Design and Function
4.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3
4.1.1 Design Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 6
4.2 Crankgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7
4.2.1 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 8
4.2.2 Crankshaft Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 8
4.2.3 Crankshaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 11
4.2.4 Oil Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 14
4.2.5 Oil Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 14
4.2.6 Oil Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 14
4.2.7 Oil Feeding Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 15
4.2.8 Gear Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 16
4.2.9 Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 17
4.2.10 Raschig Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 18
4.2.11 Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 19
4.2.12 Crosshead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 20
4.2.13 Guide Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 21
4.3 Distance Piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 22
4.4 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 23
4.4.1 Cylinder Configuration . . . . . . . . . . . . . . . . . . . . . . . 4 - 23
4.4.2 Piston Rod Gland . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 24
4.4.3 Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 25
4.4.4 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 25
4.4.5 Piston Nut SUPERBOLT . . . . . . . . . . . . . . . . . . . . 4 - 27
4.5 Suction Valves and Discharge Valves. . . . . . . . . . . . . . . . . . . 4 - 28
4.5.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 28
4.5.2 Valve Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 30
4.6 Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 31
4.6.1 Hand-Operated Control Unit. . . . . . . . . . . . . . . . . . . 4 - 31
4.6.2 Controlled Suction Valve and Actuator . . . . . . . . . . . 4 - 33


Overview
4.1 Overview
The compressor is completely closed and of gastight design with no pro-
cess gas leakage to atmosphere.
The process gas is compressed to the required pressure by a Laby com-
pressor having the appropriate number of stages. As there is no cylinder
lubrication, the compressed gas is not contaminated by oil.
In this description the function of the compressor is simplified. For technical
details and technical data see chapter 9 Dismantle and Assemble Com-
pressor Components and section Technical Data in chapter 13 Appendix.

Overview
3
A
23 4
5
6 B
7
22 9
10
11 C
12
13
14
16
LK_XX_0024b_01
21 20 18 19 17
Fig. 4-1 Typical view of a Laby compressor type K
A Cylinder 11 Connecting rod

B Distance piece 12 Frame cover
C Crankgear 13 Crankshaft seal
1 Cylinder cover 14 Fastening bolt
2 Valve 15
3 Piston 16 Flywheel
4 Piston rod gland 17 Crankshaft bearing
5 Piston rod 18 Connecting rod bearing
6 Oil shield 19 Crankshaft
7 Guide bearing 20 Oil strainer
8 Frame 21 Gear oil pump
9 Crosshead 22 Pressure gauge
10 Crosshead pin bearing 23 Thermal barrier
The gas is compressed by the labyrinth piston (3) which operates oil-free.
The labyrinth principle developed by Burckhardt Compression AG allows a
contact-free seal between piston and the cylinder wall.
Valves (2) are located in the cylinders (A), positioned by lanterns and valve
covers. The suction and discharge valves ensure the gas supply to the in-
dividual stages.
Suction valves can be equipped with valve unloaders to control the ca-
pacity.

Overview
The piston rod gland (4) reduces gas losses to a minimum. Gas leakage
occurring despite this measure is returned to a process gas dependent
safe location as indicated on the corresponding P&I Diagram in chapter
13 Appendix.
The part between crosshead and guide bearing is splash-lubricated. The
oil scraper inside the guide bearing prevents oil from entering the distance
piece (B).
By means of the oil shield (6) installed on the piston rod, the distance piece
divides a lower oil-lubricated area from the upper non-lubricated area.
The rotation of the crankshaft (19) is transformed via connecting rod (11) to
a reciprocating movement of the crosshead (9).
The piston rod (5) is connected to the crosshead. The piston rod is guided
by the crosshead, the guide bearing (7) and during operation by the
self-centering action of the piston due to gas forces.
Appropriate coolant is used for cooling cylinder and the crosshead area.
The crankshaft (19) is supported in the frame (8) by bearings (17).
At the drive end of the crankgear (C), a flywheel (16) is fitted to the crank-
shaft. With its rotating mass, the flywheel compensates uneven load from
the compressor to the motor.
At the drive end, there is a shaft seal (13) preventing oil and gas leakage
to the environment.
At the non-drive end, the crankshaft-driven gear oil pump (21) ensures
bearing and crosshead lubrication during compressor operation.
The oil and gas pressures can be checked on the respective pressure
gauges (22).
The compressor is anchored on the skid by fastening bolts (14).

Overview
4.1.1 Design Data
Specification Value
Key word Norgas WZL 0601
Compressor type 2K158-2D_1
Serial no. 100822/100823
Weight of compressor (without flywheel) 4700 kg
Year of manufacture 2007
Process gas LNG/NH3/VCM
Mass flow *
Standard volume *
Suction volume *
Suction temperature *
Suction pressure *
Discharge pressure *
Rotation speed 595 rpm
Maximum power requirement * kW
Electric motor rating 340 kW
* Value for several gases/cases see section Technical Data in chapter

13 Appendix.

Crankgear
4.2 Crankgear
1 2
19 3
18
LK_M0_0010b_01
17 10 16 15 14 11 7 6
Fig. 4-2 Typical view of crankgear
1 Frame 11 Connecting rod

2 Guide bearing 12
3 Piston rod 13
4 Crosshead 14 Crankshaft
5 Flywheel 15 Counterweight
6 Crankshaft seal 16 Oil strainer
7 Main bearing drive end 17 Main bearing non-drive end
8 18 Gear oil pump
9 19 Raschig filter
10 Connecting rod bearing
The crankgear is designed for a maximum operating pressure of 8.0 bar g.

All ports are closed by frame covers, sealed with O-rings. The crankgear
pressure can be checked on the respective pressure gauge on the gear oil
pump.

Crankgear
During operation, crankgear and distance piece are filled with process gas,
pressurized slightly higher than the 1st stage suction pressure. Therefore,
the lubricating oil must be compatible with the process gas. Process gas
remains in the frame during standstill of the compressor.
The crankshaft (14) is supported in the frame (1) by bearings.
4.2.1 Crankshaft
On the drive end, the crankshaft is coupled to the electric motor. The rota-
tion of the crankshaft is transformed via connecting rod to a reciprocating
movement of the crosshead.
The crankshaft can be dismantled through the non-drive end or drive end
side port.
Counterweights are used to reduce free forces and couples. These are typ-
ically bolt-on pieces or cast as part of the crankshaft.
4.2.2 Crankshaft Bearing
LK_M1_0005b_01
1 3 4 10
Fig. 4-3 Typical view of crankshaft bearings
1 Bearing bracket 6
2 7
3 Main bearing non-drive end 8
4 Crankshaft 9
5 10 Main bearing drive end
The main bearings (3), (10) can be replaced without removing the crank-
shaft.

Crankgear
Main Bearing Non-Drive

End 1 2 3
LA_M1_0016b_01
Fig. 4-4 Typical view of main bearing non-drive end
1 Bearing bracket
2 Main bearing non-drive end
3 Crankshaft
The main bearing (2) consists of a bearing bush. Bearing bush and bearing
bracket (1) are marked. Main bearing drive end and non-drive end must not
be interchanged. The bearing bracket is fitted to the frame by bolted con-
nections.

Crankgear
Main Bearing Drive End
LK_M0_0004c_01
1 2 3
Fig. 4-5 Typical view of main bearing drive end
1 Crankshaft
2 Main bearing drive end
3 Bearing bracket drive end
The main bearing (2) consists of a bearing bush. Bearing bush and bearing
bracket (1) are marked. Main bearing drive end and non-drive end must not
be interchanged. The bearing bracket is fitted to the frame by bolted con-
nections.

Crankgear
4.2.3 Crankshaft Seal

Gastight Design
1 2 3 4 5
LK_M0_0004b_01
9 7 6
Fig. 4-6 Typical view of a gastight crankshaft seal
1 Crankshaft 6 Crankshaft seal

2 Connecting rod 7 Oil leakage pipe
3 Bearing bracket 8
4 Main bearing drive end 9 Oil trap
5 Flywheel
The crankshaft seal (6) is a gastight type, located on the drive end side.
The oil trap (9) remains submerged with lubricating oil at all times. There-
fore, the crankshaft seal is never in direct contact with the process gas.
With the compressor in operation, the circulating lubricating oil is cooling
the crankshaft seal.
Oil leaking through the crankshaft seal is led to the outside of the com-
pressor through a oil leakage pipe (7). With the crankshaft seal working
properly, the oil leakage should not exceed 35 drops per minute.

Crankgear
Components
1 2 5 1 6
LA_M1_0013b_01
8 7 3 4 7 8
Fig. 4-7 Components of gastight crankshaft seal
1 Running ring 5 Spring

2 O-ring 6 Lip-seal
3 Spring guide ring with cylindrical pin 7 Sealing ring
4 Spring guide ring 8 Flat gasket (rubber)
The running rings (1), the O-rings (2) and the spring guide rings (3), (4) turn
together with the crankshaft. The sealing rings (7) are fixed and secured
against turning. While the crankshaft is moving, the faces of the running
rings slide against their counterpart on the sealing rings. Appropriate pres-
sure is applied by the built-in springs (5). The contacting faces of running
and sealing rings are lapped together prior to assembly.
The lip-seal (6) fitted to the cover prevents contaminants from entering the
crankshaft seal, respectively the compressor.

Crankgear
Fig. 4-8 Sectional view of gastight crankshaft seal
LA_M1_0015b_01
3
Fig. 4-9 Explanation of gastight crankshaft seal
1 Crankshaft seal, rotating part

2 Crankshaft seal, stationary part
3 Lubricating oil

Crankgear
4.2.4 Oil Drain
1 Gasket
1 2 3 4 5
2 Nipple
3 Gasket
4 Oil drain screw
5 Cap nut
LK_M2_0002b_01
Fig. 4-10 Oil drain
The oil drain for draining the oil sump is installed on the crankgear.
4.2.5 Oil Strainer

An oil strainer is installed in the oil sump of the crankgear to prevent solid
contaminants in the lubricating system.
4.2.6 Oil Sight Glass
1 Sight glass holder

2 Sight glass
3 Gasket
4 O-ring
1
4
LA_M2_0006b-01
Fig. 4-11 Oil sight glass
A sight glass in the crankgear allows local observation of lubricating oil

level.

Crankgear
4.2.7 Oil Feeding Valve
1 2 3 4 5 6 7
LK_M2_0001b_01
Fig. 4-12 Oil feeding valve
1 Screw plug R 3/8" 5 Conical spring

2 Valve housing 6 Stop
3 Gasket 7 Circlip
4 Ball
The oil feeding valve is installed in the crankgear to refill the oil sump during
compressor operation.

Crankgear
4.2.8 Gear Oil Pump
12
11
10
LK_M2_0005b_01
3 2 1
Fig. 4-13 Crankshaft driven gear oil pump
1 Crankshaft 7 Throttling valve

2 Bearing bracket 8 Driving flange
3 O-ring 9 Nylon bush
4 Housing 10 Crankcase pressure
5 Driven gearwheel 11 Gear oil pump outlet pressure
6 Driving gearwheel 12 Frame
During compressor operation, lubrication of bearing and crosshead is en-

sured by the gear oil pump.
The gear oil pump is fitted to the frame (12) at the non-drive end of the com-
pressor. Bearing bracket (2) and housing (4) are sealed with O-rings (3).
The gear oil pump consists of a driven gearwheel (5) and a driving gear-
wheel (6) attached to the driving flange (8), which is driven by the crank-
shaft (1). The two gearwheels are of the same size and fit snugly in the
pump body. The lubricating oil is carried from the inlet to the delivery side
of the pump by both gearwheels.
The oil pressure (p between pressure at gear oil pump outlet and inside
crankgear) must be between 3.5 to 4.0 bar with the lubricating oil warm
from operation of the compressor. Check the pressure of the gear oil pump
outlet and the crankgear at the respective pressure gauges on the gear oil
pump. Adjust the oil pressure by means of the relief valve (see section
4.2.9 Relief Valve).
It is possible to replace the pressure gauge on the gear oil pump during
compressor operation. Therefore close the throttling valve

Crankgear
4.2.9 Relief Valve
1 Spring guide
7 8 9 10
2 Washer
6 3 Valve housing
4 Spring
5 5 Valve body
6 O-ring for bearing bracket
4
7 Bearing bracket
3 8 Valve seat
9 Gasket for valve seat
2 10 O-ring for bearing bracket
LK_M2_0003b_01
Fig. 4-14 Relief valve installed in bearing bracket
pump. Adjust the oil pressure by means of the relief valve installed in the
bearing bracket (7) at the drive end side. The oil pressure can be raised or
lowered by accordingly inserting or removing of washers (2), installed to-
gether with the spring (4). The spring windings shall not touch against each
other.

Crankgear
4.2.10 Raschig Filter
LA_M0_0001b_01
Fig. 4-15 Raschig filter
1 Distance piece 4 Raschig rings

2 Pressure equalizing and oil return 5 Raschig filter
pipe 6 Frame
3 Perforated plate
The Raschig filter (5) in the crankgear (6) prevents oil mist in the pressure
equalizing and oil return pipe (2), respectively in the distance piece (1).
Pressure equalization between crankgear and distance piece takes place
over the Raschig filter and the pressure equalizing pipe which is attached
to the guide bearing.

Crankgear
4.2.11 Connecting Rod
Fig. 4-16 Connecting rod LK_M4_0002b_01
1 Piston rod 5 Crankshaft

2 Crosshead 6 Connecting rod bolts
3 Connecting rod 7 Connecting rod cover
4 Connecting rod bearing half
The connecting rod (3) converts the rotation of the crankshaft (5) into a re-
ciprocating movement and transmits it to the crosshead (2).
The connecting rod and connecting rod cover (7) have been machined to-
gether and match-marked as pairs. The connecting rod bearing halves (4)
and the connecting rod bolts (6) are also marked. Do not interchange them.
The connecting rod bearing consists of two halves; they have no shims.
Therefore, the bearing clearance cannot be readjusted. The upper and
lower halves are identical, hence they can be individually replaced, e.g. in
case of damage during transport/storage.

Crankgear
4.2.12 Crosshead
LA_M3_0004b_01
8
Fig. 4-17 Crosshead
1 Piston rod 5 Crosshead pin

2 Guide bearing 6 Crosshead pin bearing
3 Wedges 7 Connecting rod
4 Crosshead 8 Lubricating oil bore
The connecting rod (7) converts the rotation of the crankshaft into an up
and down movement and transmits it to the crosshead (4). Together with
the guide bearing (2), the crosshead ensures an exact guide for the piston
rod (1).
The lubrication of the crosshead takes place from the crankshaft bearing
via the bores in the crankshaft and the connecting rod to the crosshead pin
(5).
The piston rod is fitted with wedges (3) to the crosshead.

Crankgear
4.2.13 Guide Bearing
LA_C0_0012e_01
Fig. 4-18 Location of guide bearing
The guide bearing prevents contamination of the compressor lubricating

system and minimizes contamination of the distance piece by oil due to
pressure variation at the suction side (i.e. between distance piece and
crankgear).
By means of the oil shield installed on the piston rod, the distance piece di-
vides a lower oil-lubricated area from the upper non-lubricated area.
1 2 3 4
7
LK_M5_0003b_01
Fig. 4-19 Typical view of a guide bearing
1 Bearing housing 5 Oil scraper rings (according to

2 Piston rod application: 2 or 3 pieces)
3 Oil shield 6 Crown ring
4 Cover for oil scraper 7 Bearing bush

Distance Piece
In the upper part of the guide bearing, oil scraper rings (5) slide on the up
and down moving piston rod (2). If in good condition and correctly fitted, the
oil scraper rings keep the area above the guide bearing free of oil.
Above the guide bearing, an oil shield (3) which prevents oil creepage
along the piston rod is fitted on the piston rod.
The guide bearing is splash-lubricated (through the upward movement of
the crosshead). The oil is carried by the piston rod (2) through the guide
bearing clearance. The oil scraper rings (5) scrape the oil off the piston rod.
The oil scraped off the guide bearing is conducted back into the crankgear
through the respective bores and the Raschig filter.
4.3 Distance Piece

The distance piece is the area between piston rod gland and guide bearing.
The distance piece provides a distinct separation between the unlubricated
compression area and the lubricated crankgear.
The distance between guide bearing and piston rod gland is longer than the
piston stroke. This allows to fit an oil shield which prevents oil creepage
along the piston rod on the piston rod above the guide bearing.
All ports of the distance piece are closed by frame covers, sealed with O-
rings.

Cylinder
4.4 Cylinder
1 2 3 4 5
LK_C0_0004b_01
11 10 9 8 7 6
Fig. 4-20 Sectional view of cylinder
1 Cylinder 2nd stage 7 O-ring

2 Cylinder cover 2nd stage 8 Bolt framecylinder
3 Cylinder 1st stage 9 Piston 2nd stage
4 Cylinder cover 1st stage 10 Piston rod gland
5 Gas pipe 1st stage 11 Gas pipe 2nd stage
6 Piston 1st stage
4.4.1 Cylinder Configuration

The two stage Laby compressor has two individual cylinders. One for the
1st stage, the other one for the 2nd stage.
The gas is compressed in the 1st and 2nd stage by one labyrinth piston per
stage.
As the compression of the process gas generates heat, the cylinder 2nd
stage is water cooled.
The piston rod gland reduces gas losses to a minimum. Gas leakage oc-
curring despite this measure is returned to a process gas dependent safe
location as indicated on the corresponding P&I Diagram in chapter 13 Ap-
pendix.
The cylinder is accurately aligned with the piston and screwed on to the
frame.

Cylinder
4.4.2 Piston Rod Gland
LA_C0_0012d_01
Fig. 4-21 Location of piston rod gland
The piston rod gland is fitted to the bottom side of the cylinder and seals
the compression space from the distance piece.
The piston rod gland reduces gas losses to a minimum. Gas leakage oc-
curring despite this measure is returned to a process gas dependent safe
location as indicated on the corresponding P&I Diagram in chapter 13 Ap-
pendix.
Example of Configuration
2
6
3
5 4
LA_C5_0007b_01
Fig. 4-22 Typical view of a piston rod gland
1 Gland chamber (top) 4 O-Ring (optional)

2 Gland chamber (middle) 5 Gland flange
3 Intermediate ring (number and posi- 6 Gland ring (number according to
tion according to application) application)

Cylinder
The illustration above shows an example of a piston rod gland. The built-in
configuration for your installation is shown in section 9.12 Piston Rod
Gland.
The piston rod gland is equipped with 1-piece gland rings.
CAUTION
Risk of damage to sealing surface and front faces!
Handle gland rings with care.
The number of compression springs acting axially must be selected so that

each ring can still be moved as a single unit, when the piston rod is disman-
tled. Experience has shown that 3 to 6 springs are enough to hold the ring
during operation.
The intermediate ring collects leakage gas and leads it back to a process
gas dependent safe location as indicated on the corresponding P&I Dia-
gram in chapter 13 Appendix.
4.4.3 Piston Rod

The piston rod is in its upper part conical with a towards the piston reduced
diameter of approximately 0.1 mm. Therefore the required clearance be-
tween piston rod and gland ring is despite heat expansion during opera-
tion always ensured.
The part of the piston rod between crosshead and guide bearing is splash
lubricated.
4.4.4 Piston
LA_C0_0012b_01
Fig. 4-23 Location of piston
The piston is double acting i.e. it compresses the process gas as well on
its upper as on its lower piston crown.

Cylinder
1 Piston nut SUPERBOLT

1 2 3 4
2 Piston crown (upper)
3 Piston skirt
4 Cylinder wall
5 Chamfer
6 Piston crown (lower)
7 Piston rod
LA_C1_0003b_01
7 6 5
Fig. 4-24 Labyrinth principle
The labyrinth piston consists of three parts: the piston skirt (3) as well as
the upper and lower piston crowns (2), (6). The piston is fastened to the
piston rod with a piston nut SUPERBOLT (1). The labyrinth principle de-
veloped by Burckhardt Compression AG allows a contact-free sealing be-
tween piston skirt and cylinder wall (4).
The labyrinth grooves are machined into the sealing surface of the piston.
To facilitate the running-in process, the cylinder wall has been roughened
by means of a fine thread. This structure has an anti-seizing effect, but is
not intended to contribute to gas sealing.
The clearance between sealing surface of the piston and cylinder wall de-
pends on the piston diameter and the maximum operating temperature.
Because of the precise guidance of the piston rod (7) by means of cross-
head and guide bearing, the piston runs mostly contact free. Piston guid-
ance is supported by the gas leakage along the chamfer (5) of the piston
skirt, applying a centering force to the piston.

Cylinder
4.4.5 Piston Nut SUPERBOLT
Fig. 4-25 Piston nut SUPERBOLT
1 Admitted lubricant 5 Size

2 Pressure screw 6 Bore for piston nut wrench
3 Groove for O-ring (used with con- 7 Tightening torque with Burck-
taminated gas) hardt Lubrication Grease BLG05
4 Hardened washer 8 Piston nut SUPERBOLT
The piston is fastened to the piston rod with a piston nut SUPERBOLT (8).
The tensioning system is based on the principle to break down the force for
a single large screw connection into several manageable torques, using
the pressure screws (2) threaded through the nut body. The hardened
washer (4) provides a hardened, flat surface for the pressure screws to
push against. In order to avoid contamination/corrosion of pressure
screws in connection with certain gases, the piston nut SUPERBOLT has
a groove (3) to accommodate an O-ring.
The pressure screws must be tightened carefully with a torque wrench to
the required tightening torque (7).
The piston nut SUPERBOLT is prelubricated with the lubricant Burckhardt

Lubrication Grease BLG05. This lubricant is also permissible for oxygen
service. The stamped tightening torque applies for this lubricant only.

Suction Valves and Discharge Valves
CAUTION
Risk of piston nut seizure!
Please contact our Customer Support Service in case:
an unlubricated connection is required,
the admitted lubricant Burckhardt Lubrication Grease BLG05 is not
available.
4.5 Suction Valves and Discharge Valves
4.5.1 Description
LA_C0_0012c_01
Fig. 4-26 Location of valves
This Laby compressor is equipped

with original Burckhardt Plate
Valves. The components such as
valve seats, valve guards, valve
discs, etc. are manufactured in our
workshop.
Fig. 4-27 Burckhardt Plate Valve
Operational safety aspects have been taken into consideration while se-
lecting appropriate material, heat treatment and machining methods. Every
valve is completely custom designed.

The use of original valve parts guarantees that the valve assembly is ex-
actly suited to the compressors parameters of operation.
The suction valves and discharge valves work as non-return valves and
thus ensure the gas delivery from the suction side to the discharge side of
the compressor.
The valves are fixed in the cavities by means of lanterns, pressure screws
and valve covers.
Distinctive Features of Valve Diameter

Suction Valve and
Discharge Valve
The diameter of the suction valve is larger than the diameter of the dis-
charge valve. This prevents suction valves from being fitted in the com-
pressor in the place of discharge valves and vice versa.
S D
> <
3
LA_CX_0018b_01
G G
Fig. 4-28 Suction valve diameter > discharge valve diameter
S Installed suction valve 2 Gasket

D Installed discharge valve 3 Lantern
G Gas flow 4 Suction valve
Valve diameter 5 Discharge valve
1 Valve cover
Lantern Length
The lanterns on the suction side are shorter than those on the discharge
side.

4.5.2 Valve Details

Valve Components
Fig. 4-29 Sectional view of Burckhardt Plate Valve
1 Valve seat 6 Damper disc

2 Nut 7 Valve guard
3 Center bolt 8 Distance disc
4 NORD-LOCK washer pair 9 Valve spring
5 Valve disc
Gas Flow
1
XA_CX_0037b_01
4 3 2
Fig. 4-30 Gas flow
1 Gas flow
2 Valve seat
3 Valve disc
4 Valve guard
NORD-LOCK Securing The center bolt nut is secured by the NORD-LOCK principle.
System
NORD-LOCK is a pair of washers with a wedge-locking action meeting
DIN 25201 which is a unique method using tension instead of friction.

Capacity Control
1 Cams
2 Radial teeth
XA_CX_0039b_01
1 2
Fig. 4-31 NORD-LOCK washer pair
The rise of the cams between the

NORD-LOCK washers () is
greater than the pitch of the bolt
(). In addition, there are radial
teeth on the opposite side. The
XA_CX_0040a-01
washers are installed in pairs, cam
face to cam face.
> = locking effect
Fig. 4-32 NORD-LOCK locking principle
The NORD-LOCK washer is locked in place, allowing movement only

across the face of the cams. Any attempt from the bolt/nut to rotate loose
is blocked by the wedge effect of the cams.
NORD-LOCK washers positively lock the fastener in a joint which is sub-
jected to any kind of vibration or dynamic loads.
4.6 Capacity Control

For information about capacity control see P & I Diagram in chapter 13
Appendix.
For information about bypass see section 3.3.3 Bypass.
Components for Capacity The controlled suction valves are equipped with actuators. The actuators
Control are controlled by the control unit.
4.6.1 Hand-Operated Control Unit

The compressor is equipped with a hand-operated cutout regulation al-
lowing gradual adaptation of the discharge rate according to desired ca-
pacity. The capacity is controlled by means of pneumatically operated
suction valves.
Control Unit The control unit has the function of a 3-way valve. It is installed at com-
pressor non-drive end.

Capacity Control
In the partial-load position of the control unit the lower suction valves re-
main open.
To prevent cutting off the drive motor respectively actuating the alarm
signal while switching to partial load, the time relay of the pressure trans-
mitter shall be delayed by about 20 seconds (on and off).
LA_C3_0015b_01
3 2 1
Fig. 4-33 Hand-operated control unit
1 Lever
2 Connection for control medium (inlet)
3 Ball valve
4 Connection for control medium (outlet)
When ordering spare parts, please state the data shown on the respective
control unit.

Capacity Control
4.6.2 Controlled Suction Valve and Actuator
Fig. 4-34 Controlled Burckhardt Plate Valve
Functional Principle The controlled suction vales are equipped with actuators to operate the
compressor at 50 % and 100 % load. The actuators are controlled by the
control unit.
1 2 3 4 5 6 7
XA_C3_0003b_01
Fig. 4-35 Controlled suction valve with actuator operated by medium
P Control pressure 4 Pressure pin

1 Controlled suction valve 5 Spring F
2 Finger unloader 6 Actuator piston
3 Pressure sleeve 7 Actuator
With spring configuration F, the valve opens and closes normally if control
pressure P = 0.
In the no-load position of the suction valve, the control pressure (P) is
pressing the pressure pin (4) through pressure sleeve (3) and finger un-
loader (2) towards the valve disc, which is lifted against the valve guard.
Thus, the process gas can flow back to the suction side without compres-
sion.
Control Medium The actuators (7) are operated with nitrogen.

Required pressures for control medium:

Capacity Control
Nitrogen = 5.56.0 bar g
CAUTION
Too low control pressure leads to malfunction of the capacity control
system, thus results in damage on valves and pistons!
Maintain control pressure at required value.
Controlled Suction Valve

with Actuator 1 2 3 4 5
LT LV
9
Z
10
11
LA_C3_0009b_01
Fig. 4-36 Controlled suction valve with actuator (with leak gas outlet)
LT Total length of pressure pin 5 Control medium inlet

LV Reference dimension 6 Valve cover
Z Clearance 7 Leak gas outlet
1 Threaded bolt 8 Pressure pin
2 Cover for actuator piston 9 Lantern
3 Spring F 10 Controlled suction valve
4 Diaphragm actuator piston 11 Cylinder

Transport, Installation and Pre-Commissioning
5 Transport, Installation and Pre-Commis-

sioning
5.1 Important Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3

5.1.1 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3
5.1.2 Importance of Cleanliness . . . . . . . . . . . . . . . . . . . . . 5 - 3
5.1.3 Mandatory Tightening Torques . . . . . . . . . . . . . . . . . . 5 - 4
5.2 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5
5.2.1 Safety of Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5
5.2.2 Shipping Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5
5.2.3 Shipping Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7
5.2.4 Unload Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7
5.2.5 Check Scope of Supply . . . . . . . . . . . . . . . . . . . . . . . 5 - 7
5.2.6 Store Components prior to Installation . . . . . . . . . . . . 5 - 8
5.3 Dimensions, Weights, Space Requirement. . . . . . . . . . . . . . . . 5 - 9
5.4 Lifting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 10
5.4.1 Tightening Torques for Attachment Gear . . . . . . . . . 5 - 11
5.4.2 Lift Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 11
5.4.3 Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 12
5.5 Install Compressor on Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 13
5.5.1 Grouting Material . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 13
5.5.2 Prepare Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 14
5.5.3 Place and Level Compressor on Skid (Variant A) . . 5 - 14
5.5.4 Place and Level Compressor on Skid (Variant B) . . 5 - 15
5.5.5 Tighten Fastening Bolts . . . . . . . . . . . . . . . . . . . . . . 5 - 16
5.6 Assemble Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 17
5.6.1 Prepare Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 17
5.6.2 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 17
5.6.3 Check Crankshaft Deflection . . . . . . . . . . . . . . . . . . 5 - 20
5.6.4 Turn Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 23
5.6.5 Intermediate Piece . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 23
5.6.6 Shaft System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 24
5.7 Install Electric Motor and Coupling . . . . . . . . . . . . . . . . . . . . . 5 - 25
5.7.1 Place Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 25
5.7.2 Align Electric Motor. . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 27
5.7.3 Install Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 28
5.8 Install Skid on Hulls Steel Structure . . . . . . . . . . . . . . . . . . . . 5 - 31
5.9 Install Plant Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 33
5.9.1 Prepare Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 33
5.10 Install Pipe Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 34
5.10.1 Prepare Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 34
5.10.2 Fabricate Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 35
5.10.3 Check Fabrication. . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 37
5.10.4 Recommendation for Pipe Support . . . . . . . . . . . . . 5 - 39
5.10.5 Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 45
5.10.6 Hydraulic Pressure Test . . . . . . . . . . . . . . . . . . . . . . 5 - 46
5.11 Non-Return Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 47
5.12 Pre-Comissioning of Compressor Plant . . . . . . . . . . . . . . . . . 5 - 47
5.12.1 Prerequisite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 47
5.12.2 Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 48
5.12.3 Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 49

5.12.4 Check Cleanliness of Gas System . . . . . . . . . . . . . . 5 - 49

5.12.5 Turn Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 50
5.12.6 Blow-Out Gas Piping System . . . . . . . . . . . . . . . . . . 5 - 50
5.12.7 Run-In Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 52
5.12.8 Assess Vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 55
5.12.9 Inspect Compressor Plant . . . . . . . . . . . . . . . . . . . . . 5 - 55
5.12.10 Preserve Compressor Plant after Installation . . . . . . 5 - 55
5.12.11 Maintain Plant during Decommissioning . . . . . . . . . . 5 - 57
5.12.12 Recommission Plant . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 58

Important Notes
5.1 Important Notes
5.1.1 Technical Support

Service life and life span of the compressor greatly depend on the quality
of the installation works. An insufficient steel frame and/or non-appropriate
assembly can lead to increased vibrations (see section 5.12.8 Assess Vi-
brations) and, therefore, to problems and/or service interruptions. Exam-
ples of possible consequences are: bursting of pipes, excessive wear of
piston, gland rings and bearings.
We strongly recommend to install the compressor under the supervision of

a specialist from Burckhardt Compression AG. For damage caused by non-
professional installation, Burckhardt Compression will not assume any lia-
bility.
If you have any questions concerning transport, installation or pre-commis-

sioning procedures, please consult our Technical Customer Support, we
will be glad to assist you:
Technical Customer Support
Im Link 5
P.O. Box 65
CH-8404 Winterthur
Tel. +41 (0)52 262 55 00 Fax +41 (0)52 262 00 53
5.1.2 Importance of Cleanliness

Prior to dispatch, all assembled parts of the compressor as well as acces-
sories coming in contact with process gas have been cleaned either in our
works or by sub-suppliers. Parts from sub-suppliers have been checked for
cleanliness.
If any cleaning of surfaces is necessary, refer to section 10.1 Cleaning
Specification and the cleaning instructions in chapter 10 Clean and De-
grease Plant and Compressor Components.

Important Notes
CAUTION
Contamination of process gas!
All components coming in contact with process gas must be checked for
cleanliness prior to their installation.
When performing overhauls or exchanging spare parts, make sure that
all significant surfaces have been cleaned according to the cleaning
specification prior to assembling or installation.
If in doubt about cleanliness, repeat cleaning procedure.
5.1.3 Mandatory Tightening Torques

Plant For mandatory tightening torques and tightening method of bolted connec-
tions see section 8.5.4 Tightening Torques and Method.
Compressor For tightening methods of bolted connections see section 8.6.4 Tightening
Methods.
For mandatory tightening torques and applicable tightening method: see

section Compressor in chapter 13 Appendix.

Transport
5.2 Transport
5.2.1 Safety of Transport

Recognize and Avoid Load transport may only be carried out by qualified personnel, i.e. must be
Possible Danger supervised by responsible, skilled employees.
Observe warning symbols and marking of packages.
Obey Transport Rules Always secure loads.

Always store loads safely.
Protect loads against falling.
Accident Free Crane Know weight of load.

Transport Pay attention to center of gravity and attachment points.
Use proper lifting and transport devices.
Use appropriate attachment gear.
Attach load securely.
Give clear signals.
DANGER
Suspended loads!
Falling loads can cause serious injury or death.
Protect carrying ropes/straps against sharp edges.
Do not stand beneath suspended loads.
5.2.2 Shipping Package

The packing specification agreed upon in the contract constitute the basis
for conservation, package and transport. The measures taken shall prevent
damage to compressor and plant components as far as possible. Never-
theless, they will not protect these goods against the consequences of im-
proper handling.
Package The purpose of package is to protect the goods during transport and inter-
mediate storage. In addition a professional package has to simplify the
loading and transport procedures as well as the stacking of the packed
goods or units.

Transport
Three main types of packing are to be distinguished (for applied packing

specification please refer to the contract):
Land packing (truck, train or airfreight) is used for door-to-door delivery
without intermediate storage.
Sea packing is applied for goods with oversea destinations and several
handling as well as for shipments in containers from seaport to seaport.
This type of packing guarantees a protection of the material for a period
of 6 months when stored in a covered and dry place.
Long-term packing protects the goods during a longer storage period
(> 6 month) and is only applied when specifically requested by the cus-
tomer. Protection is only guaranteed when suppliers storage instruc-
tions are strictly followed.
All items are packed in wooden crates which provide a long-lasting seal
and protect its content against climatic and chemical influences. The
package is suitable to withstand high dynamic and static forces.
Marking of Packages The crates and boxes are marked on the two longitudinal sides in water-
proof paint. Packages requiring special handling are additionally marked
with the international standardized handling instructions:
XA_XX_0087a_01
This side up Fragile Keep dry Protect Center of Use no Sling here
goods from heat gravity hooks
Fig. 5-1 Package handling instructions
Pay attention to the instructions on the package concerning transport, han-

dling and storage.
Guarantee claims are not accepted if the package is untimely opened or
damaged as a consequences of improper handling.
Conservation Depending on the nature of the goods, different kinds of corrosion protec-
tion will be applied to compressor, plant components and spare parts sus-
ceptible to corrosion due to atmospheric or climatic influences.
Compressor
To protect the internal parts against corrosion, the compressor is filled with
dry nitrogen prior to dispatch. An adhesive label with corresponding
warning sign is affixed to respective component.
Tectyl is used to protect blank compressor parts. The wax-like coating can
be removed without difficulty with any hydrocarbon.

Transport
WARNING
Pressurized system part!
To protect the internal parts against corrosion, some components are filled
with dry nitrogen prior to dispatch.
Take notice of the corresponding warning sign.
Depressurize system part before you start installation work.
Components, Spare Parts

Material requiring particular corrosion protection is packed in VPI (Vapor
Phase Inhibitor) paper and wrapped into polyethylene sheeting or sealed
into polyethylene bags.
5.2.3 Shipping Condition

The shipping condition depends on transport conditions, local conditions
and on the lifting tackle available on site.
As a general rule the compressor should be transported as completely as-
sembled as possible. When leaving our works, the compressor is delivered
separated into the following component groups:
compressor complete,
flywheel,
coupling flange,
individual components palletized.
5.2.4 Unload Compressor

Please proceed according to sections 5.2.1 Safety of Transport and 5.4
Lifting Procedure.
5.2.5 Check Scope of Supply

The scope of supply is specified in the sales documents. If installation takes
place right away, check the delivery for completeness immediately after re-
ceiving of the goods. Any transport damage and/or missing parts must be
reported immediately. For conservation reasons, do not open long-term-
packages as long as you do not start installation work.
As soon as the crates are opened to check the individual items, com-
pressor components and plant components must be stored in a orderly
manner in a dry place, protected from environmental influences (store-
house).

Transport
CAUTION
Corrosion or contamination due to improper storage after opening
the consignment.
Do not check delivery in long-term packages beforehand. Wait till the
material is used.
For intermediate storage of opened consignment consult our Customer
Support Service (address see section 1.3 Contact Address) concerning
protective measures to be taken.
5.2.6 Store Components prior to Installation

Storage Guarantee for Our storage guarantee for this contract is limited to a period of 12 months
Unopened Package after delivery (ex works), providing the necessary measures have been
taken to avoid the entry of moisture and water during transport and storage.
Upon expiration of this time limit:
Open the crate and check conservation state of the complete consign-
ment.
If necessary, clean or renew the conservation.
Opened or Damaged Guarantee claims for the conservation are not accepted if the package is
Package opened for custom purposes during transport or at construction site, re-
spectively if damaged due to improper handling. In this case, we are not
liable for damaged parts. This also applies to any damage that may occur
during the period of guarantee, as a result of such damaged parts.
We request customers to check opened and/or damaged consignments as
early as possible and to immediately report to us any damage observed.
This will enable us to make suggestions to the customer concerning further
procedure to be adopted.
Intermediate Storage If the compressor plant is not installed immediately after transport, all com-
ponents must be stored in a dry place, protected from environmental influ-
ences (storehouse).
If this is not possible, the packed

goods must be protected against
water, namely by means of storage
under a roof.
The crates must also be protected
against the entry of water from be-
low, i.e. by placing them on wooden
beams.
XA_XX_0008a_02
Fig. 5-2 Intermediate storage
Components must be stored safely. They must not tip over or topple down
when jolted by vehicles or hooked onto by hanging crane cables.

Dimensions, Weights, Space Requirement
CAUTION
Corrosion due to improper preservation during long-term storage.
For long-term storage consult our Customer Support Service (address
see section 1.3 Contact Address) concerning protective measures to
be taken.
After the guarantee period is expired, inspect the stored parts in regular in-
tervals and in accordance with section 5.2.2 Shipping Package. Replace
moisture absorbent agent if necessary.
To protect the internal parts against corrosion, some components are filled
with dry nitrogen prior to dispatch. If these plant components are stored for
a longer time, pressure must be controlled and nitrogen filled up if neces-
sary.
DANGER
Health hazard!
Risk of suffocation! Nitrogen can leak from plant components such
as coolers, dampers, etc. into the storage rooms and displace the ox-
ygen in the atmosphere. At high concentrations, unconsciousness or
death may occur.
Before entering the area, check for oxygen-deficient atmospheres.
Make sure there is sufficient circulation of fresh air.
symptoms.
5.3 Dimensions, Weights, Space Requirement
Compressor Dimensions
Length 1750 mm
Width 1100 mm
Height 2410 mm
Weights (Approximative)
Compressor complete (without flywheel) 4700 kg

Flywheel 750 kg
Crankgear complete 2800 kg
Cylinder 1st stage (inclusive covers, valves and piston rod 880 kg
gland)
Cylinder 2nd stage (inclusive covers, valves and piston rod 740 kg
gland)
Cylinder cover 1st stage 90 kg

Lifting Procedure
Cylinder cover 2nd stage 60 kg

Piston with piston rod 1st stage 95 kg
Piston with piston rod 2nd stage 65 kg
Crankshaft 340 kg
Space Requirements
H
h
1
4
LA_XX_0044b_01
D
L F 2
Fig. 5-3 Space requirements
1 Cylinder
2 Flywheel
3 Crankshaft
4 Compressor
5 Piston
H Total height 3600 mm

h Height 1300 mm
L For crankshaft removal 1950 mm
B Space 1200 mm
F For flywheel removal 1150 mm
D Diameter of flywheel 1000 mm
5.4 Lifting Procedure
This section describes also the lifting procedure for cylinder despite the
fact that the compressor is transported completely assembled to use for
a later dismantling of the compressor e.g. for maintenance reason.

Lifting Procedure
5.4.1 Tightening Torques for Attachment Gear

Lifting Rings
Size of thread Tightening torque
M12 100 Nm
M16 150 Nm
M20 250 Nm
M24 400 Nm
M30 500 Nm
M36 700 Nm
XA_T9_0025b_01
M42 1500 Nm
Tab. 5-1 Lifting rings
The lifting rings remain fitted; do not remove them after use.
5.4.2 Lift Compressor

Take care to avoid any damage; please refer also to section 5.2.1 Safety of
Transport.
DANGER
Suspended loads!
Lift compressor only in the correct manner as described and illustrated
in this Instruction Manual.
Check correct tightening torque for attachment gear.
Make sure that the carrying capacity of the hoist corresponds at least
to the heaviest individual component weight.
Do not stand beneath suspended loads.

Lifting Procedure
mi
n.
45

LK_T9_0006a_01
Fig. 5-4 Transport and lifting of compressor
5.4.3 Lift Cylinder

Take care to avoid any damage; please refer also to section 5.2.1 Safety of
Transport.
DANGER
Suspended loads!
Lift cylinder only in the correct manner as described and illustrated in
this Instruction Manual.
Do not stand beneath suspended loads

Install Compressor on Skid

45
n.
mi
LK_T9_0003a_01
Fig. 5-5 Transport and lifting of cylinder
5.5 Install Compressor on Skid
5.5.1 Grouting Material

Product Information CHOCKFAST ORANGE is an epoxy based, pourable and non-shrinking
compound that cures at normal temperatures to become an extremely
tough and durable solid. CHOCKFAST ORANGE was designed to with-
stand severe marine and industrial environments involving a high degree
of both physical and thermal shock.
Tensile strength: 35 N/mm2.
If an other grouting material than CHOCKFAST ORANGE will be used,

please previously consult our Technical Support Service (address see sec-
tion 5.1.1 Technical Support).
Handling of Grouting Consider following points:

Material encasing method,
influences of temperature,
mixing process,
grouting procedure,
setting time.
WARNING
Health hazard! Material and environmental damage!
Grouting material can be toxic and caustic. Inappropriate use can lead to
injury, material and environmental damage.
Strictly follow grout manufacturers instructions.
For the protection of the grout surface against environmental influences

and/or infiltration of oil, we recommend the application of an oil-resistant
coating.

The specific loading arising from free forces and moments, compressor
weight and tensile forces present in the fastening bolts must not exceed
the specified tensile strength of 35 N/mm2.
5.5.2 Prepare Installation

Prepare Crankgear 1. Clean the bottom side of crankgear, getting into contact with the
grouting material. The supporting surface must be clean and absolutely
free of oil and grease.
2. In case of using epoxy grouting material, protect the contact area with
a silicone protective film according to manufacturers instructions.
3. Coat fastening bolt holes with silicone protective film, so that subse-
quent dismantling is possible.
Prepare Leveling Screws

1. To avoid seizure, lubricate the
threads of the leveling screws
before setting them, using
MOLYKOTE G-N Plus or ball-
bearing grease.
2. For each foundation bolt, use a
leveling screw and adjust to in-
tended height. Adjustment
range is 12 to 22 mm, de-
pending on leveling screw type.
3. For additional height adjust-
ment, add shims of 10 to 15 mm
Fig. 5-6 Leveling screw
of thickness.
4. Make sure that the leveling screws will have sufficient distance to the
foundation bolts. This permits to attach the casings for grouting and/or
facilitates the removal of leveling screws.
5. Use synthetic based mortar for the fixation and optimal power transmis-
sion.
To avoid vibration transmissions to the foundation, remove leveling screws

after grouting.
In case installation of compressor on skid will be performed according to

section 5.5.3 Place and Level Compressor on Skid (Variant A), levelling
screws are not necessary.
5.5.3 Place and Level Compressor on Skid (Variant A)

Transport and Lifting of For transport and lifting of compressor, take care to avoid any damage;
Compressor please refer to section 5.4.2 Lift Compressor.

Place Compressor on Skid 1. Place compressor onto the machined steel pads on the skid.
1 2
LA_XX_0049b_01
Fig. 5-7 Skid mounted compressor
1 Compressor
2 Flywheel
3 Steel pads
2. Finally tighten the fastening bolts with the mandatory tightening torque.
5.5.4 Place and Level Compressor on Skid (Variant B)
If an other grouting material than CHOCKFAST ORANGE will be used,

please previously consult our Technical Support Service (address see sec-
tion 5.1.1 Technical Support).
CAUTION
Inappropriate use of grouting material can lead to deformation of
crankgear!
Strictly follow grout manufacturers instructions (e.g. layer thickness,
treatment temperature etc.).
Grouting must be carried out or supervised by an authorized company.
1. Check preparations according to section 5.5.2 Prepare Installation:

Sufficient distance between leveling screws and fastening bolts.

Contact area between the crankgear and epoxy grouting protected

with a silicone protective film according to manufacturers instruc-
tions.
Fastening bolt holes coated with silicone protective film.
2. Place compressor on leveling screws.
3. Place a spirit level on top of a machined surface of the crankgear or the
cylinder. The spirit levels accuracy shall not exceed 0.2 mm per divi-
sion mark and per 1 m length.
1 2
LA_XX_0048b_01
Fig. 5-8 Skid mounted compressor
1 Compressor
2 Flywheel
3 Grouting material
4. Use the leveling screws to align the compressor.

Do not cast-in the leveling screws as they must be removable after
grouting. Prepare the encasing accordingly.
5. With respect to the grouting manufacturers instruction, grout the sup-
porting surface of the compressor.
5.5.5 Tighten Fastening Bolts
CAUTION
Deformation of crankgear due to prematurely pressure load of
grouting material.
Tighten fastening bolts only after the grouting material has hardened or
has at least reached a resistance to pressure of 40 N/mm2.

Assemble Compressor
1. Check the compressor for perfect seating.

2. Slightly grease the threads of fastening bolts and seating faces of the
nuts with MOLYKOTE G-N Plus.
3. Finally tighten the fastening bolts with the mandatory tightening torque.
4. Variant B: Remove leveling screws after the grouting material has hard-
ened.
5.6 Assemble Compressor
5.6.1 Prepare Assembly

Nitrogen Filling To protect the internal parts against corrosion, the compressor is filled with
dry nitrogen prior to dispatch. An adhesive label with corresponding
warning sign is affixed to respective component.
CAUTION
Corrosion hazard due to release of nitrogen filling.
During installation, entering of moist air is unavoidable.
If commissioning does not follow at once, flush compressor/plant con-
tinuously through with dry, oil-free nitrogen, respectively keep under a
slight overpressure of 0.20 bar g.
1. Release nitrogen prior to start with assembly of the compressor.
5.6.2 Flywheel
Tools
1 2 3
LA_T9_0023b_01
Fig. 5-9 Pull-off device for dismantling of flywheel

(complete with threaded rod and nut)
1 Crankshaft
2 Flywheel
3 Pull-of device

Assemble Compressor
LA_T9_0024a_01
Fig. 5-10 Flogging spanner for crankshaft nut
Transport and Lifting of For transport and lifting of flywheel, take care to avoid any damage; please
Flywheel refer to section 5.2.1 Safety of Transport.
DANGER
Suspended loads!
Lift flywheel only in the correct manner as described and illustrated in
Do not stand underneath suspended loads.
LA_XX_0044c_01
Fig. 5-11 Transport and lifting of flywheel
Assembly 1. Remove Tectyl from crankshaft and from flywheel hub.

Assemble Compressor
Tectyl is used to protect blank compressor parts. The wax-like coating

can be removed without difficulty with any hydrocarbon.
2. Check contact surfaces on flywheel as well as on crankshaft for pos-
sible damage or unevenness. Eliminate any unevenness using a bas-
tard file or a scraper.
3. Use a light oil with corrosion inhibitor to slightly lubricate flywheel hub
and conical part of crankshaft.
4. Attach carrying ropes in the safe manner as illustrated in this section
and lift flywheel.
1 2
6
LA_L1_0022b_01
Fig. 5-12 Fitting of flywheel
1 Crankshaft
2 Flywheel
3 Key
4 Washer
5 Castellated nut for crankshaft
6 Split pin

Assemble Compressor
5. Carefully slide flywheel (2) onto the conical part of crankshaft.

6. Mount washer (4), the washer shall not touch the crankshaft.
7. Tighten castellated nut (5) slightly, until flywheel is correctly positioned.
8. To check the clearance between key (3) and flywheel, remove castel-
lated nut and washer once again.
9. Measure clearance with a feeler gauge.
10. Refit castellated nut and washer, tighten castellated nut with the man-
datory tightening torque.
11. Fit split pin (6).
Required Checks 12. Check radial and face runout as illustrated in Fig. 5-13.
1 2 3 4 5 6
LA_L1_0001b_01
Fig. 5-13 Radial and face runout
1 Crankshaft 4 Dial gauge

2 Flywheel 5 Washer
3 Measuring head 6 Castellated nut for crankshaft
Tolerance of radial and face runout must not exceed 0.04 mm.
When checking the face runout, push the crankshaft to one side up to its
stop. The axial clearance of the crankshaft must be eliminated.
5.6.3 Check Crankshaft Deflection
1. After fitting of flywheel, measure crankshaft deflection on the crank-

throw at the drive end in 5 positions according to following figures.
For maximum permissible deflection on the dial indicator for a complete

turn of crankshaft see Tab. 5-2.

Assemble Compressor
Compressor type Flexible coupling

max. permissible
deflection in [mm]
K80 0.05
K90 0.06
K105 0.06
K120 0.06
K140 0.08
K160 0.08
K250 0.08
Tab. 5-2 Maximum permissible crankshaft deflection
2. If the deflection exceed this limit, consult our Technical Support Ser-
vice; address see section 5.1.1 Technical Support.
XA_M0_0001a_01
Fig. 5-14 First measurement
XA_M0_0002a_01
Fig. 5-15 Second measurement

Assemble Compressor
XA_M0_0003a_01
Fig. 5-16 Third measurement
XA_M0_0004a_01
Fig. 5-17 Fourth measurement

XA_M0_0005a_01
Fig. 5-18 Fifth measurement

Assemble Compressor
5.6.4 Turn Flywheel
1. Check compressor assembly by turning the flywheel several times by

hand using the bar in running direction.
2. Verify that everything is in proper mechanical condition.

3. While turning the flywheel, lavishly smear the piston rods below the
guide bearing with the operating oil of the compressor.
5.6.5 Intermediate Piece
1. Check contact surfaces on flywheel as well as on the intermediate

piece for possible damage or unevenness. Correct any unevenness by
using a bastard file or a scraper.
2. Check bores of coupling bolts for cleanliness and for damages. The
bores of the coupling bolts must be absolutely clean and free of any
damages. The bores in the flywheel and in the intermediate piece for
the coupling bolts with fit, were already reamed in the workshop.
3. Slightly lubricate bores of coupling bolts.
Make sure that markings on flywheel and intermediate piece are matching.
1. Insert the coupling bolts with fit into the corresponding bores.
2. Tighten nuts in a crosswise manner applying specified torque.

3. Check radial and face runout, see Fig. 5-19.

Assemble Compressor
1 2 3 4 5
LA_L1_0002b_01
Fig. 5-19 Radial- and face runout
1 Crankshaft
2 Flywheel
3 Bolts
5 Dial gauge
Tolerance of radial and face runout shall not exceed 0.04 mm.
When checking the face runout, make sure to push the crankshaft to one
side up to its stop. The axial clearance of the crankshaft must be elimi-
nated.
5.6.6 Shaft System

The flexible coupling must be able to absorb shaft heat expansions of 1.5
mm up to 3 mm depending on the layout. In addition, angular deviations
and parallel shifts must be absorbed as well. Such deviations are caused
by the deck elasticity, heat expansion and deformation of the deck plate.

Install Electric Motor and Coupling
LK_L1_0004c_01
f 0 mm
0 mm
Fig. 5-20 Shaft system
The permissible axial displacement of the shaft system must be taken into
account during installation. Push crankshaft towards drive end.
f = 1.0 0.3 mm
The flexible type coupling on the other hand must be of a torsion-proof de-
sign considering the irregularity of torque changes in size and direction of
rotation at the compressor shaft. Therefore, a careful selection of the cou-
pling is most important.
Checking of Crankshaft Recommendation: After fitting of coupling, the crankshaft deflection must
Deflection be measured on the crank-throw at the drive end in 5 positions shown in
following figures. For maximum permissible deflection on the dial indicator
for a complete turn of the crankshaft see Tab. 5-2. Should the deflection ex-
ceed this limit, consult our Customer Support Service, address see section
1.3 Contact Address.
5.7 Install Electric Motor and Coupling
Installation of electrical parts must be performed by professionals.

Please refer to manufacturers instructions.
5.7.1 Place Electric Motor
DANGER
Falling machine parts!
Serious injury or death
The electric motor may only be lifted according to manufacturers in-
structions.
The carrying capacity of the hoist must at least correspond to the
heaviest individual component weight.
Protect carrying ropes against sharp edges!

The alignment of the electric motor and the compressor must be done care-
fully and accurately. Prior to starting the assembly, the coupling parts must
be cleaned thoroughly.
Any rubber part of the coupling shall not come into contact with cleaning
solvents!
Before the electric motor can be placed, the runout of motor coupling flange
must be checked.
1 Dial gauge
1 2 3
2 Motor shaft
3 Coupling flange
LA_L1_0004b_01
Fig. 5-21 Radial- and face runout
Measure at the largest diameter of the coupling flange. To enable vertical

realignment of the electric motor (after maintenance/overhaul), thin stain-
less steel shims should be inserted between the sole plates and the sup-
port surfaces of the electric motor. These shims should have a thickness of
about 3 mm.
When checking the face runout, make sure to push the motorshaft to one
side up to its stop. The axial clearance of the motorshaft must be elimi-
nated.
Maximum run out shown on dial gauge shall not exceed 0.04 mm.

5.7.2 Align Electric Motor
For coupling and electric motor operating instructions and drawings see
Drive System in chapter 13 Appendix.
In the same way as for the compressor, place electric motor. Approximately
line up the electric motor.
In relation to the flywheel/intermediate piece, carefully align the electric
motor.
1 2 3 4 5 6 7
Fig. 5-22 Align electric motor LA_L1_0005b_01

2 Flywheel 6 Dummy shaft
3 Bolts 7 Motor flange
When checking the face runout, make sure to push the motorshaft to one
side up to its stop. The axial clearance of the motorshaft must be elimi-
nated.
Maximum run out shown on dial gauge shall not exceed 0.04 mm.

In general, the magnetic/mechanical center of the electric motor is marked

on the motor shaft in respect to the housing.
The permissible axial displacement of the motor shaft must be taken
into account during installation of the machinery.
For applicable crankshaft clearances: see Compressor in chapter 13
Appendix.
5.7.3 Install Coupling
The electric motor is connected

to the compressor by a flexible
rubber disc coupling.
Such flexible coupling is able to
absorb shaft expansions due to
heat, angular deviations and par-
LA_L1_0024a_01 allel shifts.
Fig. 5-23 Flexible coupling

For detailed description and drawing of flexible coupling, see section Drive
System in chapter 13 Appendix.
1. Re-check the alignment of motor and flywheel in accordance to section

5.7.2 Align Electric Motor.
2. Check contact surfaces on motor coupling flange for possible damage

or unevenness. Correct any unevenness by using a bastard file or a
scraper.
3. Check contact surfaces on intermediate piece for possible damage or

unevenness. Correct any unevenness by using a bastard file or a
scraper.
4. Prior to starting the assembly, the coupling parts must be cleaned thor-
oughly. The rubber parts shall not come into contact with cleaning sol-
vents!
5. Check bores of coupling bolts for cleanliness and for damages. The
bores of the coupling bolts must be absolutely clean and free of any
damages.
6. Assemble the coupling according to manufacturers instructions.


Recommendation: After fitting of coupling, the crankshaft deflection must
be measured on the crank-throw at the drive end in 5 positions shown in
following figures. For maximum permissible deflection on the dial indicator
for a complete turn of the crankshaft see Tab. 5-2. Should the deflection ex-
ceed this limit, consult our Customer Support Service, address see section
1.3 Contact Address.
XA_M0_0001a_01

XA_M0_0002a_01
XA_M0_0003a_01

XA_M0_0004a_01

Install Skid on Hulls Steel Structure
XA_M0_0005a_01
5.8 Install Skid on Hulls Steel Structure

The compressor and the electric motor must be installed on a common
solid skid (steel/base frame).
The skid must be accomplished according to the technical specification of
Burckhardt Compression AG. Install compressor skid parallel to the longi-
tudinal axis of the carrier. In addition, the vibration characteristics and deck
structure must be checked by a competent specialist. Should vibrations
occur, see allowable values in section 5.12.8 Assess Vibrations.
1. Connect the skid with a solid hull substructure.

2. To avoid excessive vibrations, reinforce the rigidity of the deck plate by
means of strong cross and longitudinal rigid beams.
3. After fixation of the skid, check the skid-mounted equipment for any
tensions between compressor respectively motor and the skid.
4. Machine the steel pads, matching the compressors base without
stress points (no soft feet).

Install Skid on Hulls Steel Structure
1 2 3
LA_XX_0051b_01
5 4
Fig. 5-29 Skid mounted compressor (Variant A)
1 Compressor
2 Flywheel
3 Motor
4 Grouting material
5 Steel pads
1 2 3
LA_XX_0050b_01
Fig. 5-30 Skid mounted compressor (Variant B)
1 Compressor
2 Flywheel
3 Motor
4 Grouting material

Install Plant Components
5.9 Install Plant Components
5.9.1 Prepare Installation

Nitrogen Filling To protect the internal parts against corrosion, some plant components are
filled with dry nitrogen prior to dispatch. An adhesive label with corre-
sponding warning sign is affixed to respective component.
CAUTION
Corrosion hazard due to release of nitrogen filling.
During installation, entering of moist air is unavoidable.
If commissioning does not follow at once, flush compressor/plant con-
tinuously through with dry, oil-free nitrogen, respectively keep under a
slight overpressure of 0.20 bar g.
1. Release nitrogen prior to start with assembly of the plant components.
Plant accessories (e.g. gas coolers and pulsation dampers) are normally
assembled after the compressor has been installed. Finally, the piping is
fitted. If you proceed in another sequence contact our Customer Support
Service.
Inaccurate installation of gas coolers and pulsation dampers must be cor-
rected by weld seams with length additions. This is often necessary when
the piping has not been made according to our isometries.
If the piping has already been prefabricated, e.g. for displacement and/or
to save time during installation, it must be fitted before the gas coolers and
pulsation dampers are installed.
CAUTION
Bearings in the crankgear can be damaged by welding current!
Never run welding current (grounding) through compressor parts.
Attach the power clamp of the welding equipment to the piping/flanges
as close to the weld seams as possible.
Carry out welding work according to national or international standards.

Install Pipe Work
5.10 Install Pipe Work
5.10.1 Prepare Fabrication
CAUTION
Bearings in the crankgear can be damaged by welding current!
Never run welding current (grounding) through compressor parts.
Attach the power clamp of the welding equipment to the piping/flanges
as close to the weld seams as possible.
Carry out welding work according to national or international standards.
Carefully clean and degrease all material fitted in the gas circuit after
welding and before final fitting in place.
CAUTION
Wrongly applied solvents!
Observe the manufacturers instructions about the use of solvents!
The contractor shall ensure that the piping associated with the compressor
and accessories complies with the manufacturers and clients require-
ments/specifications.
The followings instructions describe adjustment, welding, fastening and

cleaning of piping at the installation site. They are of a general, nonbinding
character and in no way influence the agreements made with the customer
in the main contract.
To prevent ingress of dirt and foreign matter, all openings (e.g. of com-
pressor, dampers, coolers and separators) must be covered and sealed.
Dust blinds shall remain installed until final alignment.
Piping for gas and water are usually pre-manufactured and delivered with
additions for assembly welding. Coolant pipes with diameters less than
50 mm are delivered in separate pieces and must be adjusted and welded
at site.
Piping delivered in separate pieces means additional expenditures at the
installation site and additional personnel.
Ensure stress-free mounting of piping between the cylinders/dampers/
coolers and other piping. Otherwise, stress will build up leading to vibration
problems and pipe cracking. The life span of mounted elements such as
control valves, safety relief valves, temperature and pressure transmitters
and other instruments will be affected, too. Excessive wear of parts may
occur and satisfactory operation/running cannot be guaranteed.
Piping must be welded by skilled personnel with suitable equipment. Per-
sonnel must adhere to normal guarantees concerning material quality and
standard of work.

Install Pipe Work
Pipes marked and provided with material certificates may only be sepa-
rated, cut, re-welded and re-stamped according to local regulations in the
presence of quality control personnel.
Welding must be carried out according to local welding specifications.
Paint and other protective coatings on the pipes, flanges, pipe bends, pre-
formed components, reducers etc. are to be removed before further pro-
cessing. A method suitable for the removal of the particular protective
coating is to be used for cleaning, e.g. sand blasting, mechanical action,
burning off, acid pickling or solvent.
Weld seams which cannot be ground internally have to be welded under
inert gas at least on the root side.
Care is to be taken that sufficient flange pairs per piping run are provided
so that the piping lengths can be dismantled after fitting for acid treatment
and cleaning.
Gas piping fitted to the compressor must be installed allowing for axial re-
moval. This is required to be able to clear the piping from the studs on the
cylinder block (i.e. by means of a spool piece or 90-flanged connection).
Arrange the piping system in such a way, that no liquid accumulation in the
gas pipes is possible even with closed isolating suction valve.
5.10.2 Fabricate Piping

Lube oil pipes, with the exception of stainless steel pipes welded with inert
gas, must be cleaned with acid according to the following section after com-
pletion.
Deinstall and clean piping by sand-blasting, with acid or mechanically after
it has been fitted.
Some main pipe supports may be installed first to install the piping in the
right position.
Weld ends of pipe sections must be parallel and fit together without any
misalignment. For a correct full penetration welding, the required size of the
root face must be fixed or tack-welded.
As a rule, tack-welding is carried out in the same welding procedure as for
the root layer. If so stipulated, the same pre-heating temperatures for
welding also apply to tack-welding. Uneven and/or faulty tack-weldings
must be removed prior to welding of the root layer. Welded-on fixations to
pipe ends are not permitted.
If welded connections are locally heat-treated (if applicable) make sure that
at least for the length of the weld seam the parameters for heat treat-
ment are observed on both sides of the weld seam and at the complete cir-
cumference of the seam.
Flange Face Alignment Two types of alignment are recognized:

Install Pipe Work
The following instruction only describes flange face alignment when flat
gaskets are used.
Lateral alignment, that is the offset of the aligned flange center lines,
applicable for the complete flange set as well as the relevant position
of bolt holes (Fig. 5-32).
Parallelism, of the aligned flange faces, sometimes referred as angular
alignment (Fig. 5-31).
X1
XA_XX_0103a_01
Fig. 5-31 Parallelism of aligned faces
X2
X2
XA_XX_0073a_01
Fig. 5-32 Lateral alignment
Set-Up prior to The flanges shall be lined up so that the bolts can be inserted without
Measurement force.
A gasket and 25 percent of the bolts, at least four, shall be inserted. The
bolts shall be uniformly fastened using manual spanners to take out the
free slack, to ensure the real misalignment will be measured.
The fitting of the pipes to the connections on the compressor (stub ends)
has to be carried out very carefully. Special attention is required so that no
distortion of the stub ends takes place due to welding, i.e. due to thermal
stress. It is advisable to screw two stub ends of the same size together
during welding of same. This is a means of largely eliminating distortion of
the stub ends.

Install Pipe Work
Should, however, the sealing surfaces of the weld-on pieces be distorted

due to welding in spite of this measure, these surfaces are to be faced up
square and checked by means of a surface plate.
Spare gaskets should be built in for pipe adjustments. Consider the settle-
ment of final gaskets when using spare gaskets for pipe adjustments.
Consider pipe layout and dimension of piping. Stress-relieved with regard
to operating temperature, also consider the temperature during assembly,
i.e. install piping having been negatively or positively prestressed in order
to compensate for large temperature differences.
Reference value, e.g. for carbon steel: t = 100 C = 1 mm/m.
The flange connections of the pipes, especially those on the gas cooler and
pulsation damper, have to be symmetrical and either square or accurately
aligned to the design angle with regard to each other. If this is not done,
high stresses occur which can lead to material fractures in lines and ves-
sels.
While mounting pipe sections, e.g. welding of T-pieces, special care must
be taken that no impurities (burnt out material, etc.) remain within the bore
of the pipe after treatment. Hence the line has to be cleaned thoroughly be-
fore mounting and welding in the next pipe. The same applies for the fitting
of connections for thermometers, pressure gauges, etc.
5.10.3 Check Fabrication
Acceptance Criteria for Misalignment
Stub End Flange The stub end flange alignment at the cylinder side can not be checked
Connections to easily because of a recess. Procedure:
Compressor Cylinder Install the piping to the cylinder with the other end free but aligned to
damper, etc.
Do not remove the studs from cylinder.
Snug tighten the nuts.
Check the gap between the flange and cylinder.
Check the opposite flange for parallelism and make sure the bolts are
inserted loosely.
Consider the heat expansion of gas discharge pipes.
Flange faces shall be aligned parallel within 0.05 degrees in all directions.
Maximum deviation (X1) from parallel across flange diameter, see Tab. 5-3.
The measured lateral misalignment (X2) shall not exceed the values given
in Tab. 5-4.
Flange Diameter [mm] Deviation X1

<300 0.2mm
300 to 600 0.3mm
600 0.5mm
Tab. 5-3 Deviation X1

Install Pipe Work
Flange Diameter [mm] Deviation X2

100 2mm
>100 3mm
Tab. 5-4 Deviation X2
Flange connections to compressor requires an even surface. Recheck

after welding of stub ends. The maximum flatness tolerance is 0.2 mm.
Standard Flange
X
Connections 3
XA_XX_0074a_01
Fig. 5-33 Maximum deviation
Lateral Alignment
For standard flanges, the free insertion of the bolts is generally suffi-
cient to demonstrate acceptable alignment. Lateral alignment may also
be checked by laying a straight edge along the outside diameter of the
flange. Measurements should be taken at locations 90 degrees apart
around the flange circumference.
The measured lateral misalignment (X2) shall not exceed the values
given in table Tab. 5-4.
Bolt holes shall straddle the natural center line unless specified other-
wise. The maximum deviation from the required theoretical bolt hole
position (X3), as measured along the bolt circle, shall be 1.5 mm
(Fig. 5-33).
Parallelism
Flange face alignment shall be checked by measuring the distance be-

tween the mating flanges of the pre-assembled joint. Measurements
shall be taken around the circumference at equal distances from the
center line (the outside rim of the flange will normally be the most con-
venient position).
The difference between the measurements shall not exceed the fol-
lowing values: ASME B 16.5 flanges, all sizes, all ratings: 2.5 mm/m.

Install Pipe Work
Flanged Accessories Accessories are flanged items which are rigid in themselves (e.g. valves,
strainers etc.). The individual flange face misalignment from the design
plane shall not exceed 2.5 mm/m. Also, the misalignment of the two flange
faces shall not exceed 2.5 mm/m.
Gap between Flanges Gasket type, material and size shall be checked. The gap between the
flanges shall be just sufficient to slide in the gasket without damaging the
gasket or the flange faces.
Decrease of Pipe Wall The maximum allowable decrease of wall thickness shall not exceed 10 %
Thickness and Pipe Bend of nominal wall thickness.
Flattening
Pipe wall thickness shall be in accordance with ANSI B 31.3.
Radiographic and/or pressure tests are to be carried out according to local
regulations. After the pipes have been fitted, they are to be dismantled and
cleaned, e.g. by sand blasting, acid treatment or mechanical action.
WARNING
In the case of this installation, the process gas pipes have to be washed out
with an oil and grease removing solvent.
Observe the manufacturers instructions regarding the use of solvents!

After assembly of the complete gas piping system incl. dampers, coolers
and all fittings, the system may be submitted to a leak test at design pres-
sure according to local regulations.
After the compressor has been successfully test run, all flange connections
and pipe fastenings are to be thoroughly tightened up again.
Should pipe vibrations occur, please see section 5.12.8 Assess Vibrations.
5.10.4 Recommendation for Pipe Support

Pipe Support (Fixed Point) BCA recommends to use a pipe support of this type (fixed point) for oil and
for Oil and Cooling Water cooling water piping to max. DN150.
Piping
1 U-bolt
1
2 Support beam
2
XA_XX_0075b_01
Fig. 5-34 Pipe support with u-bolt

Install Pipe Work
Pipe Support (Gliding For gas piping from DN50 to DN500 BCA recommends to use a pipe sup-
Point) for Gas Piping port of this type (gliding point), consisting of 2 pipe clamps.
2
Z1
3
XA_XX_0076b_01
4
Fig. 5-35 Pipe support (gliding point)
1 Pipe clamp
2 Shim
3 Plate
4 Support beam
5 Shim (non-metallic)
During installation, the gap Z1 (theoretically 56 mm) must be bridged with

2 shims (2). The pipe must remain movable in longitudinal direction.
After the fixation screws have been tightened, the supporting surfaces of
the pipe clamps must be parallel to the support beam.
The fixation screws must be tightened with two nuts.
A 3 mm plate (3) must be mounted between pipe/pipe clamp and support
beam.
A non-metallic shim (5) must be mounted between the pipe and the 3 mm
plate in order to absorb vibrations.

Install Pipe Work
Pipe Support (Gliding For insulated gas piping from DN50 to DN500 BCA recommends to use a
Point) for Insulated Gas pipe support of this type (gliding point), consisting of 2 pipe clamps.
Piping
Z1
XA_XX_0079b-02
4
Fig. 5-36 Pipe support (gliding point)
1 Pipe clamp
2 Shim
4 Support beam
During installation, the gap Z1 (theoretically 720 mm) must be bridged

with 2 shims (2).
The pipe must remain movable in longitudinal direction.
A non-metallic shim (5) must be mounted between the pipe and the pipe
clamp in order to absorb vibrations.

Install Pipe Work
Pipe Support (Fixed Point) For gas piping from DN50 to DN500 BCA recommends to use a pipe sup-
for Gas Piping port of this type (fixed point), consisting of 2 pipe clamps.
2
Z1
XA_XX_0077b_01
3
Fig. 5-37 Pipe support (fixed point)
1 Pipe clamp
2 Plate
3 Support beam
During installation, the fixation screws must be tightened to such extent

that the pipe is tightly in the piping support and cannot be moved in longi-
tudinal direction. The theoretical gap Z1 (56 mm) must remain open.
beam.
A non-metallic shim (4) must be mounted between the pipe and the 3 mm
plate in order to absorb vibrations.

Install Pipe Work
Pipe Support (Fixed Point) For insulated gas piping from DN50 to DN500 BCA recommends to use a
for Insulated Gas Piping pipe support of this type (fixed point), consisting of 2 pipe clamps.
Z1
XA_XX_0080b_02
4
1 Pipe clamp
2 Open distance
4 Support beam

A non-metallic shim (4) must be mounted between the pipe and the pipe
clamp in order to absorb vibrations.

Install Pipe Work
Pipe Support (Fixed Point) For gas piping from DN15 to DN40 BCA recommends to use a pipe support
for Gas system of this type (fixed point).
2
Z1
XA_XX_0078b_01
1 Pipe clamp
2 Plate
3 Support beam

After the fixation screws have been tightened, the supporting surface of the
pipe clamp must be parallel to the support beam.
beam.

Install Pipe Work
5.10.5 Final Assembly
Flange Connections
1. Clean nuts and bolt threads.

2. Grease with MOLYKOTE G-N Plus.
3. Tighten nuts manually, do not use wrench. Make sure that the flanges
remain parallel.
4. In a first operation, tighten nuts to 1/5 of the required tightening torque
according to Fig. 5-40.
5. Check the parallelism of the flanges.
6. If the flanges are not parallel to one another, start the second operation
at the position where the flanges are the furthest apart (see allowable
clearance).
7. In the second operation, the nuts are tightened to 1/3 of the required
tightening torque.
8. Check the parallelism of the flanges.
9. In a third operation, tighten nuts to 2/3 and then in a fourth operation to
the full amount of the required tightening torque. Re-check the paral-
lelism of the flanges after the third operation.
Start
1 16
6 11
9 8
14 3
4 13
XA_XX_0083a_01
7 10
12 5
15 2
Fig. 5-40 Tightening sequence of nuts according to this figure
Gas pipes must be mounted stress-free (see section 5.10.4 Recommenda-

tion for Pipe Support). Do not apply force to the flange bolts in order to pull
the pipes in their correct position.
For admissible clearances: refer to Flange Face Alignment in section
5.10.2 Fabricate Piping.
Do not use more than one gasket between the flange contact faces.
Cooling Water Lines

When the cooling water lines are fitted, make sure that the supply and dis-
charge lines to the cooling water spaces are connected properly to the
mains supply (cooling water inlet below), otherwise the respective spaces
will not be properly filled with water (no back pressure).

Install Pipe Work
Ensure sufficient ventilation for the highest spots of closed cooling water
systems.
Arrange coolant piping in such a way that the system can quickly be
drained and easily ventilated.
Particular attention should be given to the internal cooling water connec-

tions when testing for tightness.
5.10.6 Hydraulic Pressure Test

Hydraulic pressure tests must be carried out by trained specialists only.
Parts to be pressure tested must be air vented. Please ask for our technical
assistance (address see section 1.3 Contact Address) for permitted design
pressure on the gas side. Use approved pressure gauges only. For the gas
and oil spaces only treated water must be used.
WARNING
Pressurized plant components.
Incorrect pressure testing may result in bursting plant components!
Do not exceed the maximum permitted pressure!
Observe the correct measuring unit on the pressure gauge.

Non-Return Valve
5.11 Non-Return Valve

Installation Install the non-return valve according to following figure:
XA_L2_0003a_01
Fig. 5-41 Non-return valve
5.12 Pre-Comissioning of Compressor Plant
5.12.1 Prerequisite
Emergency Stop for To permit an immediate shut-down of the compressor in an emergency
Running-In Procedure during running-in, the electrician must install an emergency stop push
button with a sufficiently long cable around the compressor.
CAUTION
Check the emergency stop push button for proper functioning before the
running-in procedure.
Instruction of Operating Our assembly personnel will instruct the personnel charged with monitoring
Personnel to the best of their ability.

Pre-Comissioning of Compressor Plant
5.12.2 Coolant System

Check that all pipe screw connections are firmly tightened.
Fill the cooling system with coolant and make sure that the coolant system
is vented.
Do not operate any equipment at conditions which exceed those specified
on the name plate(s).
Consider manufacturers instruction first.
General Advice In all installations, take care to eliminate or minimize transmission of pulsa-
tions and mechanical vibrations to the coolers.
Avoid Thermal Shocks
Open all vent valves.
Open cold medium first.
In order to guarantee the formation of a perfect protective coating, the

cooling water shall circulate continuously (even if the compressor is not
running).
Bolted Joints All external bolted joints may require re-tightening after installation and, if
necessary, after the cooler has reached operating temperature.
Performance When performance does not meet specified requirements, investigate the
following:
Fouled tube surfaces resulting from sludge or scale.
Trapped air due to improper venting or lack of vents.
Piping connections incorrect.
Operating at conditions other than design, check performance data
sheet.
Bypassing or short circuiting of either medium, check pass partition
gaskets, seal strips and baffle clearance.
Cylinder Cooling Cylinders and crosshead housings are cooled separately.

Orifice plates (diameter 10 mm) are fitted on the pipe connections of the
cylinder outlets (Fig. 5-42). If there is a large difference in temperature be-
tween the coolant outlets it must be minimised by boring out the orifice
plates.

1
G 1" G 3/4"
LK_C0_0002a_01
Fig. 5-42 Typical view of cylinder cooling orifice plates
1 Orifice diameter 10mm
5.12.3 Oil System

Clean the crankgear with a sponge (do not use any fibrous, fuzzy cloth). Fill
the compressor sump with lubricating oil till the oil strainer is covered by
about 30 mm. Oil quality and viscosity must conform to the specifications
as mentioned in section Lubricating System in chapter 13 Appendix.
Turn the flywheel several times by hand in running direction. Check that lu-
bricating oil is being distributed to all the bearing points of the crankshaft
and the crossheads.
Check tightness of oil system. If the oil system is tight, fill oil to about 3/4 of
the sight glass. Required oil quantity: see section 8.6.5 Oil Change.
5.12.4 Check Cleanliness of Gas System

Before the initial start-up of the compressor, make absolutely sure that the
suction and discharge lines are properly cleaned. Small foreign bodies on
the intake side (welding beads etc.) may cause damage to valves and pis-
tons.
To prevent foreign matter from getting into the compressor from the suction
side, a strong conical suction strainer is fitted in the suction line to the first
stage.
If the pipe fitting has not been supervised by one of our specialists, the
cleanliness and quality of the pipe assembly will be sample checked before
compressor start-up.
Before running-in the compressor, blow out the gas conducting pipes as
well as the condensers, separators and pulsation dampers with the com-
pressor.

5.12.5 Turn Flywheel
WARNING
Unlubricated crankgear parts.
Damage of bearings and guide bearings.
Never turn compressor by electrical motor. Just use barring device or
bar to turn flywheel manually!
Before switching on compressor for the first time, turn the flywheel several
times manually in running direction. Verify that everything is in proper me-
chanical condition. While turning the flywheel, lavishly smear the piston
rods below the guide bearing with the operating oil of the compressor.
LA_XX_0021a_00
WARNING
Remove bar always from flywheel after use.
Do not operate the compressor with flywheel guard removed.
5.12.6 Blow-Out Gas Piping System

Before running-in the compressor, blow out the suction line before the first
stage with air/nitrogen.
Blow out the interstage pipes, condensers and pulsation dampers with the
compressor.

The blowing-out method is defined on site. The chosen method depends

on the pipe system installed at the plant. The following general procedure
of blowing-out is a good guideline.
General Procedure of 1. Prepare the cylinders of all stages for blowing-out: Remove the valve
Blowing-Out covers, lanterns and valves on the suction sides of each stage.
2. Remove covers of distance piece.
3. Remove suction strainer.
XA_XX_0101a_01
Fig. 5-43 Suction strainer
4. Blow out the suction line before the first stage:

Insert blind flanges (5) with mounted distance pieces (4) on the
suction side of the first stage. The distance piece must guarantee
that the distance between cylinder and the valve covers is 58 mm.
Install the valve covers on the suction side of the first stage. The
threaded bolts (2) of the valve covers must be tightened.
1
LA_CX_0005b_01
5 4 3 2
Fig. 5-44 Blind flange with distance piece
1 Valve cover
2 Threaded bolt
3 Valve chamber
4 Distance piece
5 Blind flange

Blow out the suction line before the first stage and the valve cham-
bers (3) of the first stage with nitrogen (if there is enough available).
You can also use air for blowing-out the suction line.
Remove all valve covers and all blind flanges (with mounted dis-
tance pieces) from the suction side of the first stage.
Install suction valves, lanterns and valve covers of the first stage.
5. Blow out the pipe between the first and the second stage:
Provide an opening in the suction line before the first stage. Fit a
fine stainless steel wire screen of 0.3 mm mesh size between the
opening and the first stage.
Insert blind flanges (5) with mounted distance pieces(4) on the suc-
tion side of the second stage. The distance piece must guarantee
that the distance between cylinder and valve cover is 58 mm.
Install the valve covers on the suction side of the second stage. The
thread bolts (2) of the valve covers must be tightened.
Run the coolant to the compressor and coolers.
Turn the flywheel several times in running direction.
Switch on the electric motor (= compressor start). Check immedi-
ately the direction (arrow on gear oil pump housing). The lubricating
oil pressure should reach approx. 3.5 to 4.0 bar g.
Listen carefully to the crankgear. Shut down after about 3 minutes
and check all bearing temperatures.
Repeat bearing temperature check after 5, 10 and finally after 20
minutes of compressor running. The maximum bearing tempera-
ture is approximately 60 C.
Blow out the pipe between the first stage and the second stage with
air from the opening in the suction line.
Remove valve covers and blind flanges (with mounted distance
pieces) from the suction side of the second stage.
Install the suction valves, lanterns and valve covers of the second
stage.
6. Blow out all interstage pipes (with compressor) of the following stages
as described in step 4.
7. Blow out the discharge line after the last stage.
8. Remove the steel wire screen from the suction line.
5.12.7 Run-In Pistons

Also applicable for new piston skirts after replacement (except bearing
temperature checks and blowing out of piping).
The compressor the pistons that is must be run in with dry, oil-free ni-
trogen.

DANGER
Process gas can form explosive mixtures with air.
Never use process gas for running-in!
Purge the system with nitrogen.
Measure piston clearances before running-in (see section 8.8.3 Piston).

This is to ensure stress-free mounting of piping to the cylinders.
The pistons must be run in to the maximum temperature that will be

reached during normal operation. Labyrinth pistons require a specially
careful method of running-in due to the very small diametrical clearance
between cylinder and piston. During running-in, piston and cylinder may
rub against each other, thus nitrogen is used for this procedure.
Due to pulsations resulting from pressurized gas running through the pipes
and coolers, large forces and vibrations can occur, especially in long gas
lines with several bends. This can lead to operating trouble of the com-
pressor and to damage in weld seams. If necessary, additional pipe sup-
ports must be fitted prior to start-up of the plant (example of pipe fastenings
see section 5.10.4 Recommendation for Pipe Support).
During the entire running-in period, the compressor must be carefully ob-
served.
Listen at short intervals for abnormal sounds at the compressor frame. An

emergency stop bottom should be on hand. Before each pressure in-
crease, gas temperatures and pressures must be recorded.
Start up and gradually increase the discharge pressure during a period of
about 3 hours. Throttle the gas in the discharge line until the outlet temper-
atures are approx. 10 C above the maximum temperatures reached under
most extreme conditions. Refer also to section Instrumentation in chapter
13 Appendix.
At the same time, closely observe the running of the compressor. Throttling
is done in such a manner so as to increase the stage discharge tempera-
tures from 10 to 15 C every 15 minutes.
Should a piston start to rub at the cylinder wall during running-in, stop the
compressor at once. Rubbing can be noticed by an irregular sound from
within the compressor. For continuation of the running-in procedure, wait
with restarting until pistons are cooled off (15 minutes).

1 Spring guide
7 8 9 10
2 Washer
6 3 Valve housing
4 Spring
5 5 Valve body
6 O-ring for bearing bracket
4
7 Bearing bracket
3 8 Valve seat
9 Gasket for valve seat
2 10 O-ring for bearing bracket
LK_M2_0003b_01
Fig. 5-45 Relief valve installed in bearing bracket
1. After the final stage temperatures are reached, keep the compressor at
this load for at least 1 hour. A final bearing check must be made after
this period. The lubricating oil pressure must be adjusted with warm lu-
bricating oil to approx. 4.0 bar g at the relief valve fitted into bearing
bracket at the drive end.
2. The oil scrapers must seal properly. In case oil leaks over the oil shield
onto the piston rod, the oil scrapers must be checked as described in
section 8.7.6 Guide Bearing. For this procedure the respective piston
must be removed from the compressor.
3. The oil leakage at the shaft seal should not exceed 3 drops per minute.
If there is an oil leakage at the crankshaft, see section 8.7.2 Crankshaft
Seal
4. Adjust the safety instruments in accordance with section Instrumenta-

tion in chapter 13 Appendix and check their proper functioning.
5. Check piston clearances with a feeler gauge according to the table of
clearances (see section Compressor in chapter 13 Appendix). The
piston nut, the connection of crosshead with piston rod and the con-
necting rod bolts must be checked for proper tightening. Check tight-
ening torque of piston nut according section Compressor in chapter
13 Appendix.
6. It is recommended to remove all the valves for cleaning and to dry out
all condensate in the valve chambers, flash drums and gas pipes. All
flanged connections and pipe fastenings must be re-tightened. Due to
pulsating delivery of the gas through pipes and coolers, powerful forces
and hence pronounced vibrations may set up, especially on long gas
lines with several bends. Apart from damaging the weld seams, this
may also lead to the smooth running of the compressor being impaired.
If necessary, additional pipe supports must be fitted prior to start up of
the plant.

5.12.8 Assess Vibrations

Due to pulsating delivery of the gas through pipes and coolers, powerful
forces and hence, pronounced vibrations may set up, especially on long
gas lines with several bends. Apart from damaging the weld seams, this
may also lead to the smooth running of the compressor being impaired. If
necessary, additional pipe supports must be fitted prior to start up of the
plant.
Vibrations of the pipes are prevented by fitting snubbers and additional
pipe supports. The supports should be fitted in such a manner that trans-
mission of any undesirable vibrations is avoided.
If, during test run on board, some of the pipes should vibrate excessively,
additional pipe supports should be installed according to the instructions
given by our specialist on board. Insufficient supporting of pipes may lead
to cracks in the pipes and/or damages to the welding seams.
Guideline for acceptable vibration values (displacement) at compressor
cylinder level:
horizontal 0.075 mm
vertical 0.15 mm
For pipes associated with the compressor, the amplitude of vibration shall
not exceed 0.15 mm. For frequencies above about 16 Hz, maximum ac-
ceptable root mean square (RMS) of velocity 35 mm/s.
5.12.9 Inspect Compressor Plant

After assembly of the complete gas piping system incl. dampers, coolers
and all fittings, perform a system leak test at design pressure according to
local regulations. All safety and monitoring instruments must be connected.
Their functionality must be tested and ensured.
Following the successful compressor test run, thoroughly re-tighten all
flange connections and pipe fixations applying applicable tightening torque
see Compressor in chapter 13 Appendix.
Should pipe vibrations occur, please refer to section 5.12.8 Assess Vibra-
tions.
It is advisable to check the following points:
Suction strainer in the gas lines
Some of the suction and discharge valves
Visual check of the pistons
Visual check of crankgear
5.12.10 Preserve Compressor Plant after Installation

Period of Standstill If a compressor plant cannot be put into operation for more than 2 month
Exceeds 2 Month after installation, the compressor and its auxiliary equipment should be pro-
tected against possible standstill damage by taking appropriate measures
for the respective period of time.

CAUTION
Standstill damage possible!
Due to the numerous possibilities of installation and employment of our
compressors, instructions on preservation depend on application.
Please contact our Customer Support Service (CSS), address see sec-
tion 1.3 Contact Address.
General Procedure The following procedure is intended to provide general advice. Depending
on your application, our instructions on preservation are liable to amend-
ment or supplement at any time.
1. Drain the cooling chambers of the compressor and the coolers. Leave
the drain valve open.
2. Fill crankgear with lubricating oil.

A special corrosion protecting oil from a reputable supplier may be
used during the standstill period.
3. Oil the piston rods well by hand up to the oil shield. Turn the flywheel a
number of times.
Generally, the gas conducting compressor and plant components should

not be protected by oil or grease (leave surfaces dry and untreated).
4. Fill the compressor or the entire compressor system with dry, oil-free
nitrogen.
During the whole standstill period, the plant/compressor should be flushed

continuously through with nitrogen, respectively kept under a slight over-
pressure of 0.20 bar g.
DANGER
Pressurized vessel or pipe!
Plant/compressor under nitrogen pressure.
Fit a corresponding warning sign on the installation.
Depressurize plant before you start working.
Under all circumstances, prevent moist air from entering the compressor/
system.

DANGER
Health hazard!
symptoms.
5. To prevent corrosion in the vicinity of the cylinder and down to the guide
bearings, insert moisture absorbent agent e.g. VCI mats (Volatile
Corrosion Inhibitor) in the cylinder, valve spaces and distance piece.
Experience has shown that in the area of the lubricated crankgear, ab-
sorbent agents are not necessary.
CAUTION
Forgotten absorbent agent mats can damage the compressor!
Record number and location of absorbent agent packs/mats in the
compressor.
Make sure the flywheel can still be turned manually.
5.12.11 Maintain Plant during Decommissioning
1. Check condition of moisture absorbent agent every six month and re-
place if necessary.
2. To protect the bearings, turn the flywheel for a few minutes by hand
every week (approximately 10 rotations).
Be careful about absorbent agent packs/mats in the cylinders!
3. Large difference between day and night temperatures can lead to con-
densation in the electric motor. Due attention should be given to this oc-
currence during the standstill period and before putting into operation
again (dry out, heat, ventilate, check insulation resistance, etc.).
4. Annually conduct an condition check of the complete compressor

system.

5.12.12 Recommission Plant

Carefully check the complete compressor system before recommissioning.
In particular, the functionality and operation of the mechanical and elec-
trical safety devices.
Perform a hydrostatic pressure test of all the cooling chambers, using
the specified pressure test data.
We advise customers to arrange for one of our specialists to be present

when this work is carried out.

Operation
6 Operation
6.1 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.1.1 Prepare Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.1.2 Purge Plant with Nitrogen. . . . . . . . . . . . . . . . . . . . . . 6-4
6.2 Operation with Process Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.2.1 Safety of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.2.2 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.2.3 Monitor Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.3 Standstill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Operation

Operation
Commissioning
6.1 Commissioning
6.1.1 Prepare Operation
Carry out the following tasks before starting the compressor:

1. Make sure that all instruments are calibrated.
2. Check that all safety devices are fitted and operational.
3. Check all control loops for continuity.
4. Open all valves to safety instruments.
5. Open supply valves (from pneumatic medium) to all pneumatically con-
trolled valves.
6. Check dampers and separators for liquid by briefly opening drain
valves.
7. Open required coolant valves to the process gas condensers.
8. Check that spectacle flanges (if applicable) have been set to position
for normal operation (gas flow open).
9. Check oil level in crankgear (must be roughly at 3/4 of oil sight glass).
10. Check lubrication for motor bearings according to manufacturers rec-
ommendation.
After maintenance work or after long periods of standstill:
DANGER
Unintended start-up of compressor is possible!
Turn the current off at the switch box and padlock the switch in the OFF
position.
11. Turn flywheel of compressor several times by hand using the bar in
running direction and verify that everything is in proper mechanical
condition.

Operation
Commissioning
LA_XX_0021a_00
WARNING
12. Open the discharge valve.
13. Check hook-up of suction valve actuators and verify that they are
working properly.
6.1.2 Purge Plant with Nitrogen
DANGER
Explosion and/or fire hazard!
Explosive and/or flammable process gas!
We recommend the corresponding parts of the plant be completely purged

with dry inert gas or nitrogen.
To evacuate the air trapped in the compressor, proceed as follows:

Operation
Operation with Process Gas
1. Close the suction and discharge shut-off valves.

2. Connect an inert gas supply line to the suction side of compressor.
3. Pressurize the plant section between suction and discharge shut-off
valves with dry inert gas up to the lowest safeguarded pressure limit
within this section, however, not higher than 8 bar g.
4. Stop inert gas supply and slowly vent the gas trapped in the system
through a gas vent valve on the discharge side until the gauge pressure
has reached approximately 0.20 bar g.
A sudden pressure release in the compressor crankgear would result
in excessive oil foaming and thus oil contamination of the compressor
distance piece and cylinder spaces.
5. Repeat steps 3 and 4 until the analysis of the vented gas shows that
the content of O2 is below the limits set by work rules.
6.2 Operation with Process Gas
6.2.1 Safety of Operation

Safety Precaution Process gas may be dangerous. Read the detailed gas description and
warnings in section 2.7 Process Gas and Purge Gas.
WARNING
Limited operational safety!
components and/or their operational safety may be influenced negatively
(= increased risk) by improper actions.
WARNING
Hot surface burn hazard!
Gas discharge pipes may have surface temperatures above 70 C.
Do not touch.
To avoid possible skin burns, allow surface to cool before servicing.
CAUTION
High sound level!
Be aware that communication in the plant may be impaired due to
noise.
Wear hearing protection.

Operation
WARNING
Slip hazard!
Watch your step.
6.2.2 Handling
See handling instructions in the Engineering Manual of re-liquefaction
plant.
Start Compressor Starting the compressor can be carried out when running the capacity con-
trol system of the compressor at 100% or 50%. It is of course best to start
on 50% load to minimize the start-up torque on the motor.
Under certain circumstances, the suction pressure must be throttled during

start-up procedure to a low positive pressure to avoid condensation within
piping and compressor. Suction shut-off valve must be fully opened only
after having reached the normal operating temperatures.
1. Open suction shut-off valve, at the beginning only partially.

2. Open discharge shut-off valve.
3. Check coolant circulation.
4. Switch on the motor. The lubricating oil pressure must increase imme-
diately to a p of about 4.0 bar (pressure difference between the two
pressure gauges fitted to the gear oil pump).
Tank Evacuation To evacuate the tanks, it is permissible to run the compressor with a suction
pressure of 0.3 bar a, i. e. 70 % vacuum as long as the final stage delivers
to the atmosphere (without back pressure).
Continuous Operation The compressor must be supervised by well-trained operators. To facilitate

checking, the readings of pressures, temperatures, etc. and inspections
listed below must be recorded in a log sheet (see example in section 6.2.3
Monitor Operation). Have a hour meter installed or record operating hours
in the log sheet. This guarantees better and more reliable care and main-
tenance of the compressor.
Check periodically:
Suction, (intermediate, if applicable) and final pressure. The hands of
the pressure gauges must continuously oscillate slightly.
Lubricating oil pressure.

Operation
pump. Adjust the oil pressure by means of the relief valve (see section
4.2.9 Relief Valve).
Gas temperatures at suction and discharge side of the compressor.
The temperature on suction side must be higher than the corre-
sponding dew point of the gas to avoid condensation (danger of liquid
knock).
Process gas temperature can be affected by a change of operating or at-

mospheric conditions (e.g. warm cooling water, high ambient temperature)
or due to a technical defect.
Cooling liquid temperature. The coolant outlet temperatures should be

maintained within 35 C to 45 C. Sudden temperature variation must
be avoided.
Ampere reading of electric motor.
Oil leakage of crankshaft seal (maximum 3 drops per minute).
For applicable compressor operating data see section Technical Data in
Stop Compressor 1. Switch off the compressor retaining the full back pressure.
2. According to the necessity and disposition of the installation, close the
suction and/or discharge shut-off valve.
3. The coolant should circulate also during standstill periods with a tem-
perature of at least 35 C to prevent gas condensation within the com-
pressor and dilution of the lube oil.
4. In all cases where the gas pressure in the crankgear may exceed 8 bar
when the compressor is stopped or where the gas may condense, the
trapped gas volume should be relieved slowly.
For a standstill of about 24 hours to 2 months: see section 6.3 Standstill.

If the standstill period of the compressor exceeds 2 month, refer to section
11.1 Preserve Compressor Plant or consult our Customer Support Service
(address see section 1.3 Contact Address).

Operation
6.2.3 Monitor Operation

Example of a Log Sheet:
Log Sheet TDO_2005678_E01_00.doc
Compressor S/N: Compressor Type: Order / Job No.:
Speed min-1: Gas: Operating hours:

Date
Time / Start
G Suction pressure barg / psig
A Discharge 1. Stage barg / psig
S Discharge 2. Stage barg / psig
Discharge 3. Stage barg / psig
Purge gas Packing Inlet barg / psig

Distance piece pressure barg / psig
Crankcase pressure barg / psig
Suction Temp. 1. Stage C / F

Disch. Temp. 1. Stage C / F
Packing Temp. 1. Stage C / F

Capacity mode %
st
By-pass 1 Stage open
%
(open=100%)
By-pass over all open
%
(open=100%)
Template TDO 2005678 Rev. Date Sign. Ersatz fr

Page 1 / 2
erstellt / prepared 11.07.2003 MUELLER_RN Replace for
berprft / reviewed Revision
31.05.2006
Freigabe DVS 15.09.2005 ASCH_T vom / date
Fig. 6-1 Example of a log sheet

Operation
Standstill
6.3 Standstill
Period of Standstill During the whole standstill period, the plant/compressor should be kept
24 h to 2 Month under a slight overpressure of 0.20 bar g. If no process gas is available, ni-
trogen shall be used. In this case full isolation from gas system may be re-
quired.
DANGER
Plant/compressor under process gas/nitrogen pressure.
system.
CAUTION
Deposits in piping!
Avoid stationary coolant.
A minimal flow of coolant must always be maintained.

During longer periods of standstill (exceeding a month):
2. Blow out the cooling chambers of the piston rod guide bearing with
compressed air.
If an antifreeze solution is used, drainage is not necessary under certain

circumstances.
To protect the bearings, turn the flywheel for a few minutes by hand every
week (approximately 10 rotations).
Large difference between day and night temperatures can lead to conden-
sation in the electric motor. Due attention should be given to this occur-
rence during the standstill period and before putting into operation again
(dry out, heat, ventilate, check insulation resistance, etc.).
Period of Standstill If the standstill period of the compressor exceeds 2 month, refer to section
Exceeds 2 Month 11.1 Preserve Compressor Plant or consult our Customer Support Service
(address see section 1.3 Contact Address).

Operation
Standstill

Trouble Shooting
7 Trouble Shooting
7.1 Prerequisites before Handling Troubles . . . . . . . . . . . . . . . . . . 7 - 3

7.2 Trouble Shooting List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3
7.2.1 Process Gas System . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4
7.2.2 Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 10
7.2.3 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 12
7.2.4 Compressor Noise . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 18
7.2.5 Compressor Vibrations . . . . . . . . . . . . . . . . . . . . . . . 7 - 24
7.2.6 Compressor Shutdown . . . . . . . . . . . . . . . . . . . . . . . 7 - 25

Trouble Shooting

Trouble Shooting
Prerequisites before Handling Troubles
7.1 Prerequisites before Handling Troubles
DANGER
Personal injury or loss of life!
The compressor must be maintained in such a way that the safety of the
operator, maintenance personnel or third party is guaranteed at all times.
See chapter 2 Elementary Safety Advice.
Before you start any trouble shooting activity take all safety measures ac-
cording to section 8.2 Prerequisites for Maintenance.
7.2 Trouble Shooting List

Use this trouble shooting list as soon as any faults or troubles have been
observed.
The first column from the left with the pictogram follows up the display and/
or control elements on the compressor.
The changes of operating conditions can be identified in the Location
column.
In the Cause column, the most common reasons for the origin of the
trouble are listed.
The Trouble Elimination column gives keywords for the settling of the
trouble, the column See Section refers to the respective detailed instruc-
tions.
If no Instruction Manual section is mentioned in this column, the documen-
tation as listed in these footnotes must be consulted:
CSS1) Please contact our Customer Support Service (CSS), address see
section 1.3 Contact Address.
CD2) See Control Description in chapter 13 Appendix. If CD is not part of
this appendix, please refer to customers/operators approved operating in-
struction.
TD3) For detailed description see documentation of the manufacturer in
Technical Documentation.
4)
For tightening torques see Compressor in chapter 13 Appendix.
5) For orifice plates see Technical Data in chapter 13 Appendix.
6) For vibration switch, see Instrumentation in chapter 13 Appendix.

74
Trouble Shooting List

Trouble Shooting
7.2.1 Process Gas System
Pressure Rise Location Cause Trouble Elimination See Section

Suction side of a stage (within Wear of piston Check piston clearance 8.8.3 Piston
about 2 months)
IM 100822en
Replace piston or piston skirt 8.8.4 Piston Nut SUPER-

Repair/replace cylinder BOLT
P
9.10 Piston and Piston Rod
9.13 Cylinder
CSS1)
Discharge side of a stage Increased suction pressure Reduce suction pressure/flow CD2)
rate
2K158-2D_1
Defective suction or discharge Check valve function 8.9.2 Valve Failures (Malfunc-
valve next stage Replace/repair valve tion)
8.9.3 Maintenance of Con-
trolled Suction Valves
9.5 Suction Valves and Dis-
charge Valves
Defective piston next stage Replace piston or piston skirt 9.10 Piston and Piston Rod
Rev. 001/kaufmann_w
Pressure ratio over a stage Wear of piston previous stage Replace piston or piston skirt 9.10 Piston and Piston Rod
(within about 2 months) Wear of piston following stage Replace piston or piston skirt 9.10 Piston and Piston Rod
Pressure difference between Wear of lowest piston rod Replace piston rod gland ring 9.12 Piston Rod Gland
crankgear and suction pres- gland ring
sure 1st stage too high (>1 bar Excessive suction pressure Reduce suction pressure/flow CD2)
eff)
20.06.2007
rate
20.06.2007
Pressure Drop Location Cause Trouble Elimination See Section

Piping Fracture Repair/replace piping 5.10 Install Pipe Work
P
Separator Blocked condensate drain Clean/repair condensate drain TD3)
valve in open position valve
Rev. 001/kaufmann_w
Flange connection Defective gasket Replace gasket 8.5.3 Flange Connections and
Pipe Fastenings
Loose connection Tighten flange connection 8.5.3 Flange Connections and
Pipe Fastenings
Insufficient elongation length Rework piping 5.10.3 Check Fabrication
through thermal stress
2K158-2D_1
Suction side 1st stage Insufficient gas flow in suction Increase suction pressure/ CD2)
pipe flow rate
Clogged suction strainer Clean/repair strainer 5.12.9 Inspect Compressor
Plant
Wrong position of shut-off Adjust valve position TD3)
valve in suction pipe 1st stage Check/repair control system
Wrong position of bypass Adjust valve position TD3)
IM 100822en
valve overall Check/repair control system

Wrong position of vent valve Adjust valve position TD3)
Check/repair control system

Trouble Shooting
75
76

Trouble Shooting
Discharge side 1st stage Clogged suction strainer Clean/repair strainer 5.12.9 Inspect Compressor
Plant
Leaking of pressure safety Repair/replace PSV TD3)
valve (PSV)
Defective suction or discharge Repair/replace valve 8.9.2 Valve Failures (Malfunc-
IM 100822en
valve tion)
charge Valves
Defective piston Replace piston or piston skirt 9.10 Piston and Piston Rod
Discharge side 2nd or higher Insufficient suction pressure Increase pressure/flow rate CD2)
2K158-2D_1
stage on respective stage

Wrong position of previous Adjust valve position CD2)
stage bypass valve Check/repair control system TD3)
Leaking pressure safety valve Repair/replace PSV TD3)
(PSV)
valve tion)
Rev. 001/kaufmann_w

charge Valves
Defective piston Replace piston or piston skirt 9.10 Piston and Piston Rod
Pressure ratio over a stage Wear of piston Replace piston or piston skirt 9.10 Piston and Piston Rod
(within about 2 months)
20.06.2007
20.06.2007
Oil trap of crankshaft seal No oil in oil trap (during gas Fill oil trap with oil (use prelu- 9.24 Oil Trap and Crankshaft
tightness check, before com- brication pump, if applicable) Seal
missioning or after overhauls)
Rev. 001/kaufmann_w
Temperature Rise Location Cause Trouble Elimination See Section

Suction side (general) Defective suction valve Repair/replace valve 8.9.2 Valve Failures (Malfunc-
tion)
T
charge Valves
2K158-2D_1
Suction side 1st stage To hot process gas Check function of previous 8.5.5 Cooling System
gas cooler (if applicable)
Leaking piston rod gland Replace piston rod gland rings 9.12 Piston Rod Gland
Suction side 2nd or higher Insufficient cooling of cooler Clean/repair cooler 8.5.5 Cooling System
IM 100822en
stage previous stage

Trouble Shooting
77
78

Trouble Shooting
Discharge side (general) Defective suction or discharge Repair/replace valve 8.9.2 Valve Failures (Malfunc-
valve on corresponding stage tion)
IM 100822en
charge Valves
valve on following stage tion)
charge Valves
Wear of piston on correspond- Replace piston or piston skirt 9.10 Piston and Piston Rod
ing stage
2K158-2D_1
Wear of piston on following Replace piston or piston skirt 9.10 Piston and Piston Rod
stage
Incorrect adjustement of cool- Adjust setting CD2)
ant system
Insufficient coolant flow Adjust setting CD2)
through cylinder
Fouled cooling chamber of cyl- Clean cooling chamber 8.5.5 Cooling System
Rev. 001/kaufmann_w
inder
Too small cylinder clearance Adjust piston position 9.10 Piston and Piston Rod
20.06.2007
20.06.2007
Condensate Location Cause Trouble Elimination See Section

Forming
Distance piece, coming from Too low suction temperature of Increase temperature of pro- CD2)
cylinder (piston rod gland) the process gas (below the cess gas
dew point)
Too low cylinder temperature Adjust cooling system setting CD2)
Rev. 001/kaufmann_w
Increase temperature of pro-

cess gas
No condensate/leakage con- Drain separator/cooler CD2)
trol made before start-up in
separator and/or cooler
Separator, cooler (condensate Defective condensate drain Repair/replace drain valve TD3)
level rise) valve
Blocked drain line Clean drain line 10 Clean and Degrease Plant
2K158-2D_1

and Compressor Components
No condensate/leakage con- Drain separator/cooler CD2)
trol made before start up in
separator and/or cooler (man-
ually)
Liquid Level Drop Location Cause Trouble Elimination See Section

IM 100822en
Separator, cooler Defective condensate drain Repair drain valve/system TD3)

valve (system)

Trouble Shooting
79
7 10

Trouble Shooting
7.2.2 Coolant System

Pressure difference, from sup- Restricted cross-sectioncross- Clean cooling system (interior) 8.5.5 Cooling System
ply to return section due to fouling
IM 100822en

Coolant return Restricted cross-section due Clean cooling system (interior) 8.5.5 Cooling System
to fouling
Leakage Repair/replace defect compo- 8.5.5 Cooling System
2K158-2D_1
P
nents 8.5.3 Flange Connections and
Pipe Fastenings

Coolant supply Incorrectly maintained and/or Service cooling system 8.5.5 Cooling System
adjusted cooling system Adjust setting CD2)
Too high ambient temperature Adjust setting CD2)
Rev. 001/kaufmann_w
T (summer)
Temperature difference from Insufficient flow in the respec- Adjust setting CD2)
inlet to outlet of a cooling sec- tive cooling section
tion Insufficient coolant differential Adjust setting CD2)
pressure
20.06.2007
20.06.2007
Temperature Drop Location Cause Trouble Elimination See Section

Coolant supply Incorrectly maintained and/or Service cooling system 8.5.5 Cooling System
adjusted cooling system Adjust setting CD2)
Too low ambient temperature Adjust setting CD2)
T (winter)
Rev. 001/kaufmann_w
Coolant return Fouling in cooling chambers: Clean cooling system (interior) 8.5.5 Cooling System
deposits of mud, sand, algae,
calcium etc.
Poor coolant quality (no or Change coolant 8.5.5 Cooling System
wrong coolant treatment) Correct coolant quality
Temperature difference from No coolant flow/too low flow Clean cooling system (interior) 8.5.5 Cooling System
inlet to outlet of a cooling sec- rate in respective section
2K158-2D_1
tion through fouling

Excessive coolant flow in re- Adjust setting CD2)
spective section
Liquid Level Drop Location Cause Trouble Elimination See Section

Coolant system Leak in coolant system Repair coolant system 8.5.3 Flange Connections and
Pipe Fastenings
IM 100822en
8.5.5 Cooling System

Trouble Shooting
7 11
7 12

Trouble Shooting
7.2.3 Lubricating System

Crankgear Too low ambient temperature Change oil viscosity 8.6.5 Oil Change
(oil too thick)
IM 100822en
P
Gear oil pump (inlet) Wrong adjusted relief valve Adjust setting 4.2.9 Relief Valve
Defective relief valve Replace/repair valve 4.2.9 Relief Valve

2K158-2D_1
Crankgear Clogged oil strainer in Clean oil strainer 9.9 Oil Strainer
crankgear
Too low oil level Refill oil 4.2.7 Oil Feeding Valve
8.6.6 Lubricating Oil Specifica-
Rev. 001/kaufmann_w
tions
Blocked gear oil pump Remove foreign object 9.20 Gear Oil Pump
Check oil pump components
for damages
Replace defect components
Excessive oil loss at the con- Replace bearing shell 9.17 Connecting Rod Bearing
necting rod bearing through
excessive bearing clearance
20.06.2007
20.06.2007

Excessive oil loss at the cross- Replace bearing bush 9.19 Crosshead Pin Bearing
head pin bearing through worn (with Cylinder Removal)
bearing
Fouled cooling chamber in Clean cooling chamber 8.5.5 Cooling System
crosshead area
Rev. 001/kaufmann_w
Defective oil pressure gauge Replace pressure gauge 4.2.8 Gear Oil Pump
Gear oil pump (inlet) Too low oil viscosity Change oil 8.6.5 Oil Change
8.6.6 Lubricating Oil Specifica-
tions
Too high oil temperature due Adjust setting of cooling CD2)
to insufficient coolant flow system
through oil cooler or cooling
chamber in crosshead area
Too high oil temperature due Clean cooling system/compo- 8.5.5 Cooling System
2K158-2D_1
to fouled coolant chambers in nents interior

oil cooler or cooling chamber
in crosshead area
Broken gear oil pump drive de- Repair pump drive 9.20 Gear Oil Pump
vice
IM 100822en
Relief valve Wrong adjusted relief valve Adjust setting 4.2.9 Relief Valve
Defective relief valve Repair/replace valve 4.2.9 Relief Valve

Trouble Shooting
7 13
7 14

Trouble Shooting
Oil cooler Insufficient coolant flow Adjust setting of cooling CD2)
through oil cooler system
Fouled oil cooler (coolant side) Clean oil cooler (interior) 8.5.5 Cooling System
T
Crankgear Insufficient coolant flow Adjust setting of cooling CD2)
IM 100822en

through cooling chamber of system
crosshead area
Fouled cooling chamber in Clean cooling chamber 8.5.5 Cooling System
crosshead area
Temperature Drop Location Cause Trouble Elimination See Section

Temperature indicating Excessive cooling Adjust setting of cooling CD2)
system
2K158-2D_1
T
Rev. 001/kaufmann_w
20.06.2007
20.06.2007
Level Rise Location Cause Trouble Elimination See Section

Crankgear Leaking of internal coolant Repair/replace cooler 8.5.3 Flange Connections and
pipes (emulsion) Pipe Fastenings
TD3)
Generation of condensate in Adjust cooling system setting 8.6.5 Oil Change
Rev. 001/kaufmann_w
crankgear (emulsion) Change oil 8.6.6 Lubricating Oil Specifica-

tions
CD2)
Generation of condensate in Increase process gas temper- 8.6.5 Oil Change
cylinder (emulsion) ature 8.6.6 Lubricating Oil Specifica-
Adjust cooling system setting tions
Change oil CD2)
Leaking cooler or cylinder Replace/repair cooling system 8.5.5 Cooling System
2K158-2D_1

cooling chamber (emulsion) component 9.13 Cylinder
Level Drop Location Cause Trouble Elimination See Section

Crankgear Leaking oil piping Repair/replace piping 8.5.3 Flange Connections and
Pipe Fastenings
Leaking oil cooler Repair/replace cooler 8.5.3 Flange Connections and
Pipe Fastenings
IM 100822en
TD3)
Leaking oil scrapers (into the Replace oil scraper rings 9.14 Oil Scraper
distance piece)
Leaking gasket/O-ring on Replace gasket/O-ring 9.20 Gear Oil Pump

bearing bracket drive end or 9.25 Bearing Bracket and
Trouble Shooting
non-drive end Main Bearing
7 15
7 16

Trouble Shooting
Crankshaft seal (oil loss higher Wear on pressure- and sealing Replace sealing rings 9.24 Oil Trap and Crankshaft
than 35 drops per minute) rings Seal
Damaged sealing surface on Replace sealing rings 9.24 Oil Trap and Crankshaft
pressure- and/or sealing ring Seal
Hard and brittle rubber O-rings Replace O-rings 9.24 Oil Trap and Crankshaft
IM 100822en
Check seal housing for ele- Seal

vated temperature, improve oil
circulation
No axial movement of O-rings Repair crankshaft surface, re- 9.24 Oil Trap and Crankshaft
due to grooved crankshaft place O-rings Seal
CSS1)
Incorrect axial shaft alignment Correct crankshaft position 5.7 Install Electric Motor and
Coupling
2K158-2D_1
Contaminated lubricating oil, Change oil 8.6.5 Oil Change

(abrasive residues in the pro- 8.6.6 Lubricating Oil Specifica-
cess gas) tions
Unsuitable lubricating oil qual- Change oil 8.6.5 Oil Change
ity (oil contains additives lead- 8.6.6 Lubricating Oil Specifica-
ing to problems) tions
Rev. 001/kaufmann_w
20.06.2007
20.06.2007

Oil scrapers (leaking into the Too low oil viscosity Change oil 8.6.5 Oil Change
distance piece) 8.6.6 Lubricating Oil Specifica-
tions
Insufficient cooling of guide Adjust setting of cooling 8.5.5 Cooling System
bearing system CD2)
Rev. 001/kaufmann_w
Clean coolant cavity

Wear of oil scraper rings Replace oil scraper ring 9.14 Oil Scraper
Wear of spring plate Replace spring plate 9.14 Oil Scraper
Insufficient tension force of Replace garter springs 9.14 Oil Scraper
garter springs
Damaged piston rod surface Repair/replace piston rod sur- 9.10 Piston and Piston Rod
(rough, scratched) face 9.14 Oil Scraper
Check oil scraper rings CSS1)
2K158-2D_1
Replace oil scraper rings

Incorrectly installed oil scraper Replace oil scraper rings 9.14 Oil Scraper
rings: rings tilted on piston rod,
no offset of inclined cuts be-
tween the rings or contact sur-
face to piston rod too narrow
IM 100822en

Trouble Shooting
7 17
7 18

Trouble Shooting
7.2.4 Compressor Noise
Regular, dull Location Cause Trouble Elimination See Section

knocking
Connecting rod Loose connecting rod bolts Tighten bolts 9.17 Connecting Rod Bearing
IM 100822en
Excessive clearance of con- Replace bearing shell 9.17 Connecting Rod Bearing
necting rod bearing
Excessive clearance of cross- Replace bearing bush 9.19 Crosshead Pin Bearing
head pin bearing (with Cylinder Removal)
Crosshead Insufficient clearance of cross- Rework crosshead body/ 9.18 Crosshead and Connect-
head body guide ing Rod
CSS1)
2K158-2D_1
Piston Seizing piston Replace piston or piston skirt 8.8.3 Piston

Check/repair cylinder 9.10 Piston and Piston Rod
9.13 Cylinder
CSS1)
Loose piston nut Tighten piston nut 8.8.4 Piston Nut SUPER-
BOLT
Rev. 001/kaufmann_w
Piston rod Loose connection piston rod to Tighten connection 9.10 Piston and Piston Rod
crosshead
20.06.2007
20.06.2007
Irregular dull Location Cause Trouble Elimination See Section

knocking
crosshead
Rev. 001/kaufmann_w
4)
Crankshaft Loose counterweight on Tighten counterweight
crankshaft
2K158-2D_1
IM 100822en

Trouble Shooting
7 19
7 20

Trouble Shooting
knocking
Piston Loose piston nut Tighten nut 8.8.4 Piston Nut SUPER-
BOLT
Excessive pretension of piston Adjust pretension 8.8.4 Piston Nut SUPER-
IM 100822en
BOLT
Chafing piston, due to one Correct guide bearing clear- 9.15 Guide Bearing Bush
sided heating of piston rod ance 9.12 Piston Rod Gland
caused by insufficient clear- Replace piston rod gland rings
ance between guide bearing
and piston rod or between pis-
ton rod gland rings and piston
rod
2K158-2D_1
Seizing piston Replace piston or piston skirt 8.8.3 Piston

Check/repair cylinder 8.8.4 Piston Nut SUPER-
BOLT
9.13 Cylinder
CSS1)
Liquid knock Check piston or piston compo- 8.8.3 Piston
Rev. 001/kaufmann_w
nents for cracks 8.8.4 Piston Nut SUPER-

Check piston rod to crosshead BOLT
connection for tightness 9.10 Piston and Piston Rod
Check connection rod bearing 9.17 Connecting Rod Bearing
for tightness
20.06.2007
20.06.2007

knocking
Cylinder Damaged suction or discharge Replace/repair valve 8.9.2 Valve Failures (Malfunc-
valve tion)
Rev. 001/kaufmann_w

charge Valves
Loose valve lantern Tighten lantern 9.5 Suction Valves and Dis-
charge Valves
Foreign object in the cylinder Remove foreign object 8.8.3 Piston
Check piston 8.8.4 Piston Nut SUPER-
Replace piston or piston com- BOLT
ponent 9.10 Piston and Piston Rod
2K158-2D_1
Check cylinder 9.13 Cylinder

Repair/replace cylinder CSS1)
IM 100822en

Trouble Shooting
7 21
7 22

Trouble Shooting
Regular metallic Location Cause Trouble Elimination See Section
knocking
crosshead
IM 100822en
Piston Insufficient pretension of the Adjust pretension 8.8.4 Piston Nut SUPER-
piston crowns BOLT
Loose piston skirt Adjust pretension 8.8.4 Piston Nut SUPER-
BOLT
2K158-2D_1
Cylinder Loose valve lanterns Inspect lantern 9.5 Suction Valves and Dis-
Repair/replace lantern charge Valves
Tighten lantern
Too small cylinder clearance Adjust piston position 8.8.4 Piston Nut SUPER-
BOLT
Rev. 001/kaufmann_w
20.06.2007
20.06.2007
Regular high Location Cause Trouble Elimination See Section

pitched ringing
crosshead
Rev. 001/kaufmann_w
Cylinder Axial lantern clearance Inspect lantern 9.5 Suction Valves and Dis-
Tighten lantern
2K158-2D_1
IM 100822en

Trouble Shooting
7 23
7 24

Trouble Shooting
7.2.5 Compressor Vibrations
Vibrations Location Cause Trouble Elimination See Section

Process gas piping Inadmissible pulsations Installation/replacement of ori- 5.10.3 Check Fabrication
fice plates
IM 100822en
5.12.8 Assess Vibrations

Elimination of stress raisers CSS1)
5)
Chafed areas on: Loose mounting parts Repair/replace defective parts 8.5.3 Flange Connections and
piping Check chafed parts for func- Pipe Fastenings
supports tion 8.5.4 Tightening Torques and
accessories Method
Tighten loose parts
2K158-2D_1
Cracks in: Loose mounting parts Repair/replace defective parts 8.5.3 Flange Connections and
piping, pipe junctions Tighten loose parts Pipe Fastenings
supports 8.5.4 Tightening Torques and
accessories Method
Insufficient elongation length Rework piping/supports 5.10.3 Check Fabrication
through thermal stress CSS1)
Rev. 001/kaufmann_w
20.06.2007
20.06.2007
7.2.6 Compressor Shutdown
Safety Shutdown Location Cause Trouble Elimination See Section

Instrumentation Failure of instrument air (con- Repair control medium system TD3)
trol medium)
Rev. 001/kaufmann_w
Failure of control voltage Repair control voltage system TD3)

Failure of auxiliary supply Repair control voltage system TD3)
Compressor Failure of purge system Repair purge system CD2)

TD3)
2K158-2D_1
Main motor Failure of main power supply Repair power supply TD3)
Failure of purge system Repair purge system TD3)
Vibraswitch Damaged crankshaft bearing, Replace bearing shell 9.16 Guide Bearing
connecting rod bearing or Adjust bearing installation 9.17 Connecting Rod Bearing
crosshead pin bearing
9.19 Crosshead Pin Bearing
IM 100822en
(with Cylinder Removal)

Loose connecting rod bolts Tighten bolts 9.17 Connecting Rod Bearing
Loose connection piston rod to Tighten connection 9.10 Piston and Piston Rod
crosshead

Trouble Shooting
7 25
7 26

Trouble Shooting
Safety Shutdown Location Cause Trouble Elimination See Section
Seizing piston Replace piston or piston skirt 8.8.3 Piston
Check cylinder 8.8.4 Piston Nut SUPER-
Repair/replace cylinder BOLT
9.13 Cylinder
IM 100822en
CSS1)
Loose piston nut Tighten piston nut 8.8.4 Piston Nut SUPER-
BOLT
Axial lantern clearance Inspect lantern 9.5 Suction Valves and Dis-
Tighten lantern
2K158-2D_1
Broken suction or discharge Repair/replace valve 8.9.2 Valve Failures (Malfunc-

valve tion)
charge Valves
Incorrect setting Adjust setting 6)
Rev. 001/kaufmann_w
Start-Up Interlock Location Cause Trouble Elimination See Section

Prelubrication pump Prelubrication time not yet Operate prelubrication pump CD2)
elapsed for necessary duration TD3)
20.06.2007
Capacity control Low pressure of control me- Increase control medium pres- CD2)
dium sure TD3)
20.06.2007
Start-Up Interlock Location Cause Trouble Elimination See Section
Control system (not delivered Active restart interlock Check control logic
by BCA)
Electronic fault Repair control logic
Rev. 001/kaufmann_w
Flywheel guard Not correctly closed Close guard correctly TD3)

Incorrect position of safety Adjust safety switch TD3)
switch
Vibraswitch Not yet resetted Reset switch 6)
Pneumatic shutoff/bypass Wrong valve position Adjust valve position CD2)

valves TD3)
2K158-2D_1
Main motor Failure of main power supply Repair power supply TD3)
Failure of purge system Repair purge system TD3)
For further defects, please re- Consult technical documenta- TD3)
fer to main motor manufactur- tion of manufacturer
ers instruction
IM 100822en
Monitoring system Input requirement not fulfilled Check input signals/moni- CD2)
toring system TD3)

Trouble Shooting
7 27
Trouble Shooting
Preventive Maintenance
8 Preventive Maintenance
8.1 Importance of Preventive Maintenance . . . . . . . . . . . . . . . . . . 8 - 3

8.2 Prerequisites for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 3
8.2.1 Depressurize and Purge Plant . . . . . . . . . . . . . . . . . . 8 - 5
8.2.2 Clean Compressor Plant . . . . . . . . . . . . . . . . . . . . . . 8 - 6
8.3 Tools .......................................... 8-7
8.3.1 Standard Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 7
8.3.2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 10
8.4 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 11
8.4.1 Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 12
8.4.2 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 12
8.5 Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 14
8.5.1 Electrical Motor and Coupling. . . . . . . . . . . . . . . . . . 8 - 14
8.5.2 Gas System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 14
8.5.3 Flange Connections and Pipe Fastenings . . . . . . . . 8 - 14
8.5.4 Tightening Torques and Method . . . . . . . . . . . . . . . . 8 - 15
8.5.5 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 17
8.5.6 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 20
8.5.7 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 20
8.5.8 Hydraulic Pressure Test . . . . . . . . . . . . . . . . . . . . . . 8 - 20
8.6 Compressor in General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 21
8.6.1 Dimensions, Weights, Space Requirement . . . . . . . 8 - 21
8.6.2 Marking of Compressor Components. . . . . . . . . . . . 8 - 21
8.6.3 Clearance Measurement . . . . . . . . . . . . . . . . . . . . . 8 - 23
8.6.4 Tightening Methods . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 25
8.6.5 Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 25
8.6.6 Lubricating Oil Specifications . . . . . . . . . . . . . . . . . . 8 - 27
8.7 Crankgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 27
8.7.2 Crankshaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 30
8.7.3 Connecting Rod Bearing . . . . . . . . . . . . . . . . . . . . . 8 - 30
8.7.4 Crosshead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 31
8.7.5 Crosshead Pin Bearing. . . . . . . . . . . . . . . . . . . . . . . 8 - 32
8.7.6 Guide Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 33
8.8 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 34
8.8.1 Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 34
8.8.2 Piston Rod Gland . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 34
8.8.3 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 35
8.8.4 Piston Nut SUPERBOLT . . . . . . . . . . . . . . . . . . . . 8 - 40
8.9 Suction Valves and Discharge Valves. . . . . . . . . . . . . . . . . . . 8 - 46
8.9.1 Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 46
8.9.2 Valve Failures (Malfunction) . . . . . . . . . . . . . . . . . . . 8 - 47
8.9.3 Maintenance of Controlled Suction Valves . . . . . . . . 8 - 49


Importance of Preventive Maintenance
8.1 Importance of Preventive Maintenance

By doing preventive maintenance at regular intervals, these improvements
arises:
increased life time
prevention of breakdowns and damages
increased safety for man and machine
8.2 Prerequisites for Maintenance

Safety Precaution Process gas may be dangerous. Read the detailed gas description and
CAUTION
Maintenance Guidelines Carry out adjustments, preventive and corrective maintenance in due-
date time.
Regularly check plant components like pressure vessels, coolers,
dampers, separators etc. for deposits and corrosion.
Recondition loose contacs and damaged cables immediately.
Protect all plant components such as main motor, oil and coolant
system pumps, pneumatic or hydraulic control systems etc. against un-
intended start-up.
before beginning any inspection or repair, turn the current off at the
switch box and padlock the switch in the OFF position.
Always adhere to local and company safety regulations (e.g. warning
sign Machine under maintenance or overhaul, put up safe work plat-
forms, setting spectacle flange etc.).
Depressurize and purge the compressor plant (see section 8.2.1 De-
pressurize and Purge Plant).


Prerequisites for Maintenance
Lockout and Tagging of

Circuits
DANGER
Before beginning any inspection or repair, turn the current off at the
The first step before beginning any inspection or repair job is to turn the cur-
rent off at the switch box and padlock the switch in the OFF position. This
applies even on so-called low-voltage circuits. Securely tagging the switch
or controls of the compressor or equipment being locked out of service clar-
ifies to everyone in the area which equipment or circuits are being in-
spected or repaired. Only qualified electricians who have been trained in
safe lockout procedures should maintain electrical equipment.
No two of the locks used should match, and each key should fit just one
lock. In addition, one individual lock and key should be issued to each
maintenance worker authorized to lock out and tag the equipment. All em-
ployees who repair a given piece of equipment should lock out its switch
with an individual lock. Only authorized workers should be permitted to re-
move it.
Do not start work prior to a written confirmation that safety measures have
been taken.
Transport and Lifting of For transport and lifting of heavy components, take care to avoid any
Heavy Components damage; please see section 5.2.1 Safety of Transport., for weights see
section 5.3 Dimensions, Weights, Space Requirement;
Restart Compressor Perform functional test on protection devices after maintenance.

Turn flywheel of compressor several times in running direction and verify
that everything is in proper mechanical condition.

LA_XX_0021a_00
WARNING
8.2.1 Depressurize and Purge Plant
1. Close the suction nd discharge valve.

2. Open vent valves to flare. Always run prelubrication pump (if appli-
cable), as it removes process gas that is solved in the oil.
3. Supply nitrogen to the suction line and to the frame of the compressor.
Purge the compressor system for approximately 15 minutes.
4. Close nitrogen supply.
5. Close vent valves of process gas line and distance piece.
6. Set spectacle flanges in process gas lines to maintenance position
(gas flow blocked).
7. Close bypass valves (if not already done).
8. Pressurize the plant section between the suction and delivery valves
with nitrogen to the lowest safe pressure limit within this section (usu-
ally lower than set pressure of crankgear safety valve).
9. Vent gas in the crankgear first, then vent gas in the process gas line.
10. Repeat steps 8 and 9 until the analysis of the vented gas shows that
the content of process gas is below the limits set by work rules.
11. Make sure that all spectacle flanges are set in maintenance position
before starting any maintenance work at the compressor or accesso-
ries.

Further information, see section Control Description in chapter 13 Ap-

pendix.
8.2.2 Clean Compressor Plant

Assure cleanliness and tidiness of compressor and surrounding area. Use
appropriate cleansing agents and materials. For safe use of cleansing
agents 10.3 Select Cleansing Agent.
Please take care of the environment!
When using leach, solvents and cleansing agents, observe manufacturers
instructions for use. When working on the compressor, make sure there is
sufficient circulation of fresh air.

Tools
8.3 Tools
Txxxxx = code no. for ordering special tools and standard tools.
8.3.1 Standard Tools
XA_T9_0005a_01
Fig. 8-1 Combination spanners
T96100: Set of combination spanners 17 46 mm

T96101: 55 mm

Tools
XA_T9_0007a_01
Fig. 8-2 Flogging spanner
T96110: Set of flogging spanners T96111: 55 mm
LA_T9_0024a_01
Fig. 8-3 Flogging spanner for crankshaft nut
T97040: 145 mm
LA_T9_0009a_01
Fig. 8-4 Eye bolt
T96060: Set of eye bolts

T96061: 2 eye bolts M12:
T96062: 2 eye bolts M16

Tools
XA_T9_0008a_01
Fig. 8-5 Torque wrench
T96010
XA_T9_0009a_01
Fig. 8-6 Extension for sockets
T96030
XA_T9_0010a_01
Fig. 8-7 Hexagonal socket
T96020: Set of hexagonal sockets

T96021: 7 mm:
XA_T9_0012a_01
Fig. 8-8 Square insert for socket
T96040: Set of square inserts for socket

T96041: 11 mm
XA_T9_0003a_01
Fig. 8-9 Inner circlip pliers
T96070

Tools
XA_T9_0004a_01
Fig. 8-10 Outer circlip pliers
T96080
8.3.2 Special Tools
XA_T9_0013a_01
Fig. 8-11 Round bar for turning of flywheel
T97230: Dia. 32 mm x 1050 mm
1 2 3
LA_T9_0023b_01

1 Crankshaft
2 Flywheel
3 Pull-of device
T97030

Maintenance Schedule
1 2 3
LA_T9_0022b_01
Fig. 8-13 Cotter key in 3 pieces
1 Crosshead
2 Piston rod
3 Cotter key
T97010
9
5 4
6 3 10
2
7 1
1 7
2
3 6
5 XA_T9_0014b_01
4
Fig. 8-14 Piston nut wrench for piston nut SUPERBOLT (position 17 = SUPER-
BOLT size)
1 G 1" 6 G 2 1/2"
2 G 1 1/4" 7 G 3"
3 G 1 1/2" 8 Piston nut wrench
4 G 1 3/4" 9 Pin (dia. 6 mm/dia. 8 mm)
5 G 2" 10 Hexagon 22 mm
T97364
8.4 Maintenance Schedule

(see following pages)

8 12
8.4.1 Plant
OBJECT / WORK see on Hours of operation

chapter
8000 16000 24000 32000 40000 48000
IM 100822en
Functioning test of the safety and control instrument, check set points 8.5.7
x x x x x x
of the safety instruments
Remark: The above indications serve as general guideline only. The final schedule should be worked out together with our Customer Support Service.
We refer to the specific maintenance requirements in the instruction manual.
8.4.2 Compressor
2K158-2D_1

chapter
8000 16000 24000 32000 40000 48000
Visual check of oil scrapers and piston rod surface (without disman- 8.7.6
tling)
Oil change, clean oil strainer and crankcase of the compressor (first 8.6.58.6.6
time after 4'000 running hours) x x x x x x
Check valves, lanterns and gaskets 8.9
Rev. 001/kaufmann_w
Check clearance between guide bearing and piston rod (with feeler 8.7.6
gauge or dial gauge)
Check gland rings and replace if required 8.8.2 In case of gas leaks to intermediate piece
Check oil scrapers and piston rod surface 8.7.6 In case of insufficient function of oil scrapers
27.06.2007
27.06.2007

chapter
Check clearances of: crankshaft bearing, connecting rod bearing, 8.7
crosshead pin bearing and crosshead without removing (by feeler
gauge or dial gauge)
Check tightening of connecting rod bolts 8.7.3
x x x
Rev. 001/kaufmann_w
Check piston clearance by feeler gauge and the preload force/tighten- 8.8.38.8.4
ing of piston nut
Check pretension of piston crowns (piston with diameter 480 mm and 8.8.3
larger)
Check alignment of flexible coupling 5.7 At least every 16'000 hours but each time after coupling of elec-
tric motors
Remove some crankshaft bearings, connecting rod and crosshead pin 8.7 x x
bearings for inspection (spot check)
Clean the cooling water chamber of the frame and cylinder. Check the 8.5.5 According to fouling factor and water treatment
2K158-2D_1
corresponding gaskets
Check the crankshaft seal (replace if necessary) 8.7.2 If shaft seal is leaking
Remark: The above indications serve as general guideline only. The final schedule should be worked out together with our Customer Support Service.
We refer to the specific maintenance requirements in the instruction manual.
IM 100822en
8 13
Plant
8.5 Plant
8.5.1 Electrical Motor and Coupling

Electrical Motor After the electric motor has been removed for overhaul and/or if the crank-
shaft deflection of the compressor crankshaft is larger than the permitted
limit (see section 5.7.4 Check Crankshaft Deflection) the electric motor
must be realigned.
Here it proves useful if the electric motor had been fixed with positioning
pins during installation.
For realignment proceed according to section 5.7 Install Electric Motor and
Coupling.
Coupling Inspections are limited to a visual assessment of the condition of the cou-
pling. Where identifiable, damage or cracks in the rubber disc element,
binding screws and any damage caused by force must be watched out for.
The inspection of the coupling should always be carried out at the same
time as the inspection of the entire system, or at least once a year.
For coupling operating instructions and drawings see Drive System in
8.5.2 Gas System

Cooler, Damper and Plant components under pressure, such as pressure vessels, coolers,
Separator dampers, etc. must be inspected periodically for deposits or corrosion ac-
cording to local and/or work regulations. If pressure test must repeated pe-
riodically, see section 8.5.8 Hydraulic Pressure Test.
8.5.3 Flange Connections and Pipe Fastenings

Gaskets/Seals Gaskets and seals become brittle in the course of time.
Replace them on a regular basis and use them only once.
Flange Connections/Pipe Check all flange connections and pipe fastenings on a regular basis.
Fastenings
Retighten all flange connections and pipe fastenings according to specified
tightening torques.
Pipe Supports Defective or loose pipe supports can lead to pulsations and therefore inter-
fere with the smooth running of the compressor.
To avoid damage to welds, check coolers, dampers etc. periodically for
tightness.
Re-tighten bolt connections of their supports on a regular basis.
Check bolt connections for tightness on a regular basis.
Fit additional pipe supports if necessary.
Examples for pipe supports, see section 5.10.4 Recommendation for Pipe
Support

Plant
Information regarding admissible vibrations, see section 5.12.8 Assess Vi-

brations
WARNING
If the ambient temperature and/or process gas temperature drop below
0C the cooling water can freeze. If the wrong anti-freeze solution is used
the cooling water can, nonetheless, freeze.
Add anti-freeze solution.
Pipe System To avoid damage to pipes, coolers, pulsation dampers etc. due to vibra-
tions, the bolts of the pipe connections must be checked for tightness and
if necessary re-tighten periodically. Loose pipe fastenings may lead to pipe
damage and/or to fractures of weld seams. This may also lead to distur-
bances in the smooth running of the compressor.
Examples for pipe supports, see section 5.10.4 Recommendation for Pipe
Support
For information regarding vibrations, see section 5.12.8 Assess Vibrations
Gas leakage must be repaired immediately. Gaskets may become hard
and brittle after a certain time; they must be replaced periodically. Gaskets
should be used once only. Pipe connections must be accurately aligned to
the design angle with regard to each other. Damaged surfaces of flanges
must be re-machined. Flange connections must be checked periodically for
tightness and re-tightened if necessary.
Process gas may be dangerous. Read the detailed gas description and
8.5.4 Tightening Torques and Method
The information for correct lubrication tightening torque, tightening angle

and/or bolt elongation are listed in the respective tables.
Tightening Method I Bolted Connections of Secondary Level

This category includes all bolts not being particularly stressed during
operation.
Tightening is usually done using a standard-sized wrench without ex-
tension.
Tightening torques depend on bolt size and material.
Torque values are listed in attached list.
The tightening torques for bolts which dont affect operating performance,
safety and maintenance are listed in the following table.
Bolt quality class and bolt material are marked on the head of a bolt (see
Fig. 8-15).

Plant
Should questions arise, please contact our Customer Support Service (ad-
dress see section 1.3 Contact Address).
XA_XX_0111b_01
Fig. 8-15 Marking on bolts
1 Marking (quality class and material)
Data only applicable if no other tightening methods or torque values are

specified.
CAUTION
If gaskets are used, follow and adhere the specifications of gasket manu-
facturer!
Tightening Method Clean areas of support (connecting parts) free of grease

Apply lubricant to gliding surfaces of bolt (thread with head- and nut
support)
Tighten screw at least twice using torque wrench (tightening torque ac-
cording to table)
Lubricant MOLYKOTE G-N Plus

Other suitable lubricants
Tightening Torques
Bolt quality standard Bolt quality heat-treated
4.6-2, 5.6, G, YK 6.9, 8.8, VCN 35
Thread Nm mkp ft-lbs Nm mkp ft-lbs

M12 25 2.5 18.4 39 4 28.8
M14 39 4 28.8 64 6.5 47.2
M16 59 6 43.5 93 9.5 68.6
M18 83 8.5 61.2 132 13.5 97.4
M20 113 11.5 83.3 177 18 130.6
M22 147 15 108.4 245 25 180.7

Plant
Bolt quality standard Bolt quality heat-treated
4.6-2, 5.6, G, YK 6.9, 8.8, VCN 35
Thread Nm mkp ft-lbs Nm mkp ft-lbs

M24 186 19 137.2 324 33 239
M27 265 27 195.5 461 47 340
M30 343 35 253 638 65.1 470.6
M33 422 43 311.3 834 85 615.2
M36 530 54 390.9 1080 110.1 796.6
M39 667 68 492 1373 140 1012.7
M42 1766 180.1 1302.6
M45 2256 230 1664
Data valid only using MOLYKOTE G-N Plus!

Initial Operation In order to guarantee the formation of a perfect protective coating, the
cooling water shall circulate continuously (even if the compressor is not
running).
Periods of Standstill Avoid stationary cooling water.

A minimal flow of cooling water must always be maintained. During longer
periods of standstill (exceeding a month), the system must be purged and
the cooling water spaces be dried with compressed air.
Contamination of the cooling water leads to deposits in the pipework (re-
duction of pipe diameter) and to deposits in the cooling water spaces. This
prevents proper heat transfer and results in insufficient cooling.
Increasing discharge gas temperatures, increasing lubricant temperatures
and decreasing cooling water temperatures are a clear sign of deposits in
the cooling water spaces.
To avoid overheating of critical points, cooling water spaces must be in-
spected regularly; the length of the inspection intervals depends on the
quality of the cooling water.
If the cooling system is closed, the quality of the cooling water must be
checked at regular intervals.
CAUTION
Do not use aggressive cooling water which easily builds up deposits.
Bubbles in the cooling water indicate that either ambient air or process gas
enter the cooling water.

Plant
Oil in the cooling water indicates leaky oil coolers (if any).
WARNING
If the ambient temperature and/or process gas temperature drop below
0C the cooling water can freeze. If the wrong anti-freeze solution is used
the cooling water can, nonetheless, freeze.
Add anti-freeze solution.
Cooling Water Treatment The cooling water in a closed cooling system must be treated (adding
chemicals) in order to:
prevent encrustation,
protect the walls of the cooling water spaces against corrosion and cav-
itation.
CAUTION
Chemicals in the cooling water of closed cooling circuits must not attack
materials like copper, zinc and aluminium (gaskets).
Subcontract a specialized company for cooling water treatment.
Check the concentration of the chemicals added to the cooling water peri-
odically. The mixture must be corrected according to the results obtained.
The coolant is a mixture of ethylene glycol and fresh water. The mixing ratio
(concerning congealing temperature) must cover all possible operation
conditions.
WARNING
Health hazard!
Pure ethylene glycol is noxious. Harmful or fatal if swallowed. Harmful if in-
haled or absorbed through skin.
Avoid contact with ethylene glycol.
Inspecting Cooling Water Drain the cooling water system and open the covers on each front side of
Spaces the frame leading to the cooling water space.
Also inspect the cooling water spaces of the cylinder blocks.
If there are sediments of sand, chalk or algae in the cooling water spaces,
we recommend to subcontract a specialized company to remove them and
to clean the cooling water spaces, as they have the necessary know-how
and the required materials and equipment.
Cleaning of cooling water spaces and removal of deposits can be carried

out by the maintenance personnel as well (this is, however, not recom-
mended). Cleaning is described in the following sections Removal of Cal-
cium Deposits, Removal of Algae and Removing Deposits of Sand.

Plant
Proceed according to following section Leak Test.
Removal of Calcium Circulate the cleaning agent by means of a pump in order to ensure a reli-
Deposits able decomposition of the sediment.
WARNING
Observe instructions of the manufacturer (see Technical Documentation).
Remove calcium deposits with (for example):

Formic acid (HCOOH)
or
Sulphamic acid (NH2SO3H) with inhibitor.
CAUTION
Grey cast iron, steel, nonferrous heavy metals and aluminium must not
come in contact with these chemicals.
Removal of Algae If the cooling water is not properly treated with chemicals the growth of
algae may result. This is particularly the case in open cooling water circuits
and in cooling towers.
WARNING
Remove algae with (for example):

BIOSPERSE 250, DREW AMEROID
NALFLOC 7330, NALFLOC
VARICID AC, SCHILLING CHEMICAL
The treatment time depends on the extent of algae growth. After removal
of algae, the cooling water must be carefully filtered and properly treated
by a specialized company.
Removing Deposits of Remove solidified crusts of sand manually and flush out the cooling water
Sand spaces afterwards.
CAUTION
Chemical agents for dissolving deposits of sand are too aggressive for the
metallic components of compressors.
Leak Test After each cleaning operation, a leak test must be performed. Special at-
tention must be given to the internal cooling pipes and connections.

Plant
CAUTION
Water in the lubricating oil!
Do not exceed the maximum permitted cooling water pressure!
For the set pressure of the safety relief valve in the coolant line (if installed)
see corresponding P&I Diagram in chapter 13 Appendix.
8.5.6 Lubricating System

Instrumentation
For detailed description of the instrumentation refer to the documentation

of the manufacturer (see Technical Documentation).
8.5.7 Safety Devices

Functional Check of Safety For technical information about safety devices, e.g. temperature sensors,
Monitoring Systems AMOT valves, level switches, vibraswitches, etc. please see the respective
sections in chapter 13 Appendix.
Safety and monitoring systems must be checked for their switching points
and their indicating values according to the safety requirements (for set
points see section Instrumentation in chapter 13 Appendix).
By means of a suitable electrical circuit, the monitoring devices which
switch off the motor can be overridden for checking the individual or collec-
tive functional ability of the devices.
The safety and monitoring devices must be switched on again after func-
tional checks.
Safety Valves Safety valves are the last safety devices for vessels and piping. Establish
inspection intervals with regard to ambient and/or plant operating condi-
tions as well as regulations and work rules.
Control and Shut Off Control valves as well as shut off valves must be maintained as given by
Valves the manufacturer.
CAUTION
8.5.8 Hydraulic Pressure Test

Hydraulic pressure tests must be carried out by trained specialists only.
Parts to be pressure tested must be air vented. Please ask for our technical
assistance (address see section 1.3 Contact Address) for permitted design
pressure on the gas side. Use approved pressure gauges only. For the gas
and oil spaces only treated water must be used.

Compressor in General
WARNING
Pressurized plant components.
Incorrect pressure testing may result in bursting plant components!
Do not exceed the maximum permitted pressure!
Observe the correct measuring unit on the pressure gauge.
8.6 Compressor in General
8.6.1 Dimensions, Weights, Space Requirement

Please see section 5.3 Dimensions, Weights, Space Requirement for de-
tails.
8.6.2 Marking of Compressor Components
Compressor parts which must always be fitted in the same position are
numbered.
On the assembled compressor, these markings must lie on the right hand
side when looking from the non-drive end towards the drive end.
The numbering of the individual parts starts with a V1 from the non-drive
end and ascends to V2, V3 etc. towards the drive end. Furthermore, the se-
rial no. is stamped on important compressor components.
Some parts are only marked with a matching number, like the following:
Connecting rod connecting rod bearing shells
Crankshaft main bearing bearing cover
Connecting rod connecting rod bolts

10
11
12
LK_XX_0024c_01
Fig. 8-16 Important markings on a Laby compressor type K
1 Cylinder cover 7 Wedge (V1/V2 etc. only)

2 Upper piston crown 8 Crosshead
3 Cylinder (Serial No. only) 9 Name plate
4 Frame (Serial No. only) 10 Crosshead pin
5 Piston rod gland flange 11 Connecting rod
6 Guide bearing 12 Connecting rod cover

8.6.3 Clearance Measurement
PL1 Clearance $tmp_TDO_2005513_E01_00.doc

Measurement
Compressor S/N: Compressor type: Order / Job No.:
Piston radial clearances: in 1/100 mm, measured with the piston in bottom and top dead center.
Piston: V 1 mm V2 mm V mm V mm
Before overhaul
TDC TDC TDC TDC
BDC BDC BDC BDC
Indicate the area with the most significant wear on piston and/ or cylinder
After overhaul
TDC TDC TDC TDC
BDC BDC BDC BDC
V1 V2 V V
Spacer installed
yes / no
Spacer width
Dead TDC
space BDC
Dead space checked by: Lead wire __ Feeler gauge __
Piston rod packing: The clearances of the rings are to be checked with a gauge tool or on the cylindrical part of the piston rod
Top ring V1 V2 V V
clearances before overhaul after overhaul before overhaul after overhaul before overhaul after overhaul before overhaul after overhaul
in mm Clear- Clear- Clear- Clear- Clear- Clear- Clear- Clear-

type type type type type type type type
ance ance ance ance ance ance ance ance
Ring 1
Ring 2
Ring 3
Ring 4
Ring 5
Ring 6
Ring 7
Mark the ring 4116 with a * to the ring No. and note the total segment joint clearances of these rings.
Marking of the Type box : One (1) piece rings / Quality 9001 1 Quality 9002 2
Three (3) segment rings \ Quality 9003 3 Spec./others 4
Number of springs installed per spring holder ring; V1 V2 V V
LA_XX_0045A_01

Page 1 / 2
berprft / reviewed 15.09.2005 SCHNEIDER_H Revision
13.12.2006

PL1 Clearance $tmp_TDO_2005513_E01_00.doc

Measurement
Bearing clearances, in mm
Measured values Required values
according instruction
Radial manual
Crank No. V1 V2 V V Radial
Guide bearing
Crosshead
Crosshead pin bearing
Con-rod big end bearing
Pump side Center Flywheel side Motor DE Motor NDE
Main bearing
Axial clearances D comp.
Axial clearances K comp. 0.0
Oil scrapers
Replaced; V1 V2 V V
yes / no
Checks made: Yes No Yes No

Piston nut tighten, SUPERBOLT Internal water piping tight
Piston nut tighten, Standard nut Internal oil piping tight
Crosshead <wedges> tight Oil filter cleaned & checked
Crosshead <wedges> safety device
Crosshead <nut> connection tight Connecting rod tight
Crosshead <nut> safety device Con rod safety device checked
Cast-
Shaft seal material Bronze
iron
Leakage; Drops per min. approx.:
Lube oil foam level during operation approx: cm Oil level at the sight glass; __ __ __
Oil sort / quality:
Setting of safety instruments: Checked by:

Suction pressure switch min. Temp. Switch 1. Stage max.
Discharge pressure switch max. Temp. Switch 2. Stage max.
Oil pressure switch min. Temp. Switch 3. Stage max.
Cooling water pres. Switch min. Temp. Switch 4. Stage max.
Cooling water flow switch min. m3/min Vibraswitch type: = divisions
Remarks in the final report.
Place : Signature / Name; BCA:

Date : Signature; Client:
LA_XX_0046a_01

Page 2 / 2
berprft / reviewed 15.09.2005 SCHNEIDER_H Revision
13.12.2006

Table of clearances see section Compressor in chapter 13 Appendix.
8.6.4 Tightening Methods

Tightening Method II Bolted Connections with Specified Torque Values
Tightening is done using a torque wrench.
If required, use a multiplier with the torque wrench.
Torque wrenches to be calibrated periodically.
Tightening Method III Bolted Connections with Specified Tightening Angle

Without using force, manually tighten nut several times until the con-
nection is well set.
To be able to tighten nut up to specified angle, use wrench extension.
For higher values, use extension or multiplier.
Tightening Method IV Bolted Connections with Specified Bolt Elongation

Check length of bolt before tightening.
Tighten nut until the bolt elongation is as specified.
Tightening Method V SUPERBOLT

For tightening of piston nut SUPERBOLT see section 8.8.4 Piston Nut
SUPERBOLT.

8.6.5 Oil Change

For lubricating oil specifications see section Lubricating System in
For oil change interval see section 8.4 Maintenance Schedule. Analyze the
oil periodically to check if the oil still fulfils the qualitative requirements.
In any case the oil must be changed if:
coolant has penetrated into the oil (oily emulsion).
the oil has been diluted by condensation.
bearings have been replaced.

The required lubricating oil quantity for the compressor crankgear is about
64 litres.
3/4
LA_M2_0008b_01
2
Fig. 8-17 Check oil level
1 Oil sight glass

2 Lubricating oil
3 Crankcase
The oil is contained in the crankgear. The oil level can be checked through
the oil sight glass. When the compressor is at standstill, 3/4 of the oil sight
glass must be covered.
6
LK_M2_0007b_01
Fig. 8-18 Gear oil pump
1 Gauge for crankcase pressure 4 Oil strainer

2 Gauge for lubricating oil pressure 5 Oil drain
3 Gear oil pump 6 Oil sight glass
Proceed as follows when changing oil:

1. Shut down the compressor.
2. Protect main motor against unintended start-up.

Crankgear
Depressurize and purge the compressor plant (see section 8.2.1 Depres-
surize and Purge Plant).
3. Drain the oil from the oil sump.
4. Remove and clean the oil strainer of the compressor.

5. Clean the crankcase with a sponge (do not use fibrous textile).
6. The Raschig filter must be cleaned if polymerization or damages with

abrasion of cast iron occurs.
7. Shut oil outlets, refit oil strainer, etc. and fill the compressor with fresh
oil
8.6.6 Lubricating Oil Specifications

The lubricating oil must be compatible with the process gas because it is in
direct contact in the crankgear.
Reference is made to the list of recommended lubricating oils in section
Lubricating System, chapter 13 Appendix.
8.7 Crankgear
1. After fitting of flywheel, measure crankshaft deflection on the crank-

throw at the drive end in 5 positions according to following figures.
For maximum permissible deflection on the dial indicator for a complete

turn of crankshaft see Tab. 8-1.
Compressor type Flexible coupling

max. permissible
deflection in [mm]
K80 0.05
K90 0.06
K105 0.06
K120 0.06
K140 0.08
K160 0.08
K250 0.08
Tab. 8-1 Maximum permissible crankshaft deflection

Crankgear
XA_M0_0001a_01
XA_M0_0002a_01
XA_M0_0003a_01

Crankgear
XA_M0_0004a_01
XA_M0_0005a_01

Crankgear
8.7.2 Crankshaft Seal
1 2 5 1 6
LA_M1_0013b_01
8 7 3 4 7 8

2 O-ring 6 Lip-seal
The lipseal (6) fitted to the cover prevents contaminants from entering the
shaft seal, respectively the compressor. Oil leaking through the shaft seal
is led to the outside of the compressor through a small bore drilled into the
cover. With the shaft seal working properly, the oil leakage should not ex-
ceed 35 drops per minute.
8.7.3 Connecting Rod Bearing

Besides the maintenance work specified in the maintenance plan, no spe-
cial maintenance of the connecting rod is required. The connecting rod
bolts must be tightened to a certain elongation (Fig. 8-25). For applicable
tightening torque (elongation) see section Compressor in chapter 13 Ap-
pendix.
We recommend, checking the correct tightening of the connecting rod bolts
periodically, every 16000 operating hours. For safety reasons, the locking
plate of the connecting rod bolts (if applicable) should be checked at each
oil change.

Crankgear
WARNING
Loose connecting rod bolts!
After a liquid knock, the connecting rod bolts must be checked immediately
for tightness!
1 Connecting rod
1 2 Crosshead pin bearing
3 Crosshead pin
2
4 Circlip
3 5 Connecting rod bolt
7 Connecting rod cover
4 8 Locking plate
6
LA_M4_0004b_01
Fig. 8-25 Connecting rod bearing
Clearance Check of Turn crank to BDC and measure clearance between crankshaft journal and
Crankshaft Journal connecting rod lower bearing shell with a feeler gauge.
Connecting Rod Bearing
For applicable clearances: see section Compressor in chapter 13 Ap-
pendix.
8.7.4 Crosshead
Checking of Clearances Press the crosshead in the crosshead bore of the frame to one side and
measure the clearance with the feeler gauge at various points.
pendix.
The crossheads often rubs slightly in the upper section. This is often
caused by starting in winter with a warm crosshead and a very cold coolant
directly after stopping the compressor (oil acts as an isolator). We recom-
mend waiting at least half an hour until starting with a cold coolant or im-
mediately shutting off coolant.)

Crankgear
The crosshead need not to be replaced as long as the crosshead clearance

in the lower half is tolerable. Should doubts arise about the admissibility of
the measured clearance, consult our Customer Support Service, address
see section 1.3 Contact Address.
8.7.5 Crosshead Pin Bearing

The crosshead pin is fitted to the crosshead and secured by circlips. The
crosshead pin bearing is fitted to the connecting rod small end with a tight
fit. It is secured by circlips. A pin prevents its rotation in the connecting rod.
LA_M3_0008b_01
10
Fig. 8-26 Crosshead pin bearing
1 Piston rod 6 Crosshead pin bearing

2 Crosshead 7 Crosshead pin
3 Wedges 8 Circlip
4 Locking screw 9 Pin
5 Circlip 10 Connecting rod
Bring crank to TDC and measure clearance with a dial gauge by lifting the
crosshead. Pay attention to measure only the crosshead pin bearing clear-
ance! If in doubt, eliminate the connecting rod bearing clearance and the
crankshaft bearing clearance by fitting and blocking the connecting rod
from the bottom side.
pendix.

Crankgear
8.7.6 Guide Bearing
1 2 3 4
LK_M5_0003b_01
Fig. 8-27 Typical view of a guide bearing

Guide Bearing Clearance Before dismantling the piston rod, the clearance between guide bearing
Check and rod must be checked with a feeler gauge. If the diametrical clearance
between bush and piston rod exceeds the value given at the clearance
table, the bush must be replaced.
Should doubts arise about the admissibility of the measured clearance,
consult our Customer Support Service, address see section 1.3 Contact
Address.
pendix.
For bearing replacement, please see section 9.16 Guide Bearing.
Crosshead Piston Rod Connection, please see section 9.18 Crosshead
and Connecting Rod.
Checks after Liquid Knock Check tightness of crosshead-piston rod connection immediately after a
liquid knock! (tightness of crosshead wedges).
Removal of Piston Rod and For removal of piston rod and oil scrapers please see section 9.10 Piston
Oil Scraper Rings and Piston Rod and 9.14 Oil Scraper.

Cylinder
8.8 Cylinder
8.8.1 Piston Rod

Check piston rod for any surface defects.
Sometimes it is possible to overhaul replaced piston rods. To assure oper-

ational safety of an overhauled piston rod, only perform overhauls after
consultation with our Customer Support Service.
8.8.2 Piston Rod Gland

The gland rings must be inspected every year or two by dismantling the
piston and piston rod. Inspections at shorter intervals are recommended in
case there are the following indications that the rings are badly worn:
leakage of process gas into the distance piece below the glands,
reduced discharge rate,
changes in the intermediate pressure,
increase of gland temperature, etc.
The piston rod gland is equipped with 1-piece gland rings.

The gland rings are to be handled with great care. In particular the labyrinth
combs and the faces are to be free of damage. The same applies to the
surface quality of the piston rod in the area where it enters the gland.
To prevent contamination of the rings when fitting them in their chambers,
the area of the piston rod which enters the gland must be clean and com-
pletely free of oil.
Take care that the diametrical clearance (see section 9.12 Piston Rod
Gland) between the gland rings and the piston rod is not too small.
WARNING
Wrongly modified or non-genuine spare parts.
Operational safety may be impaired!
Do neither modify parts nor spare parts.
Do not influence clearances on compressor.
Exchange worn parts.

Cylinder
8.8.3 Piston
Check the Pretension of Piston Crowns:

1. The pretension of the piston crowns to the piston skirt are measured
when a piston part is replaced or after the interval indicated on the
maintenance list. This applies also, if a piston nut came loose.
Pretension is the value by which the piston crowns are bent inwards
when the piston nut is tightened, thereby clamping the piston skirt.
Measure distance A as shown in Fig. 8-28 with the piston crowns
clamped together without the piston skirt.
1 2 3 4
A B
LA_C1_0004b_01
5
Fig. 8-28 Check pretension of piston crowns
1 Piston crown
2 Piston nut
3 Key
4 Piston skirt
5 Piston rod
2K158-2D_1 Diameter Pretension

Piston 1st stage 415mm 0.36mm to 0.40mm
Piston 2nd stage 260mm 0.16mm to 0.20mm
WARNING
Risk of piston seizure or loose piston skirt!
The measured values must be within the tolerances given above.
Tighten piston nut in accordance with section 8.8.4 Piston Nut SUPER-
BOLT
2. When installing a new piston skirt, it must be match-marked with the top
piston crown. It is important to define the position of the piston parts by
reference marking during assembly. In case a piston is disassembled
for inspection purposes, with or without replacing parts (i.e. checking of
piston pretension). During reassembly of the parts, these markings will
facilitate to have the identical position of the piston skirt in relation to
the cylinder.
Such marking shall be punch-marked or engraved only. In the assem-
bled and installed position of a piston, the marking shall always be on
the V-side (name plate side) of the compressor (see Fig. 8-29).

Cylinder
1 Upper piston crown

1 2
2 Piston skirt
xx*
: *xx
S/NoV *x*
V *x*
LA_C1_0005b_01
Fig. 8-29 Marking of piston crown and
skirt
Prior to measuring, clean all measuring tools, according to chapter 10

Clean and Degrease Plant and Compressor Components.
Measure piston clearance:

3. The piston clearance of each individual stage must be measured in the
TDC (Top Dead Center) as well as in the BDC (Bottom Dead Center)
position.
Always measure simultaneously with two opposite feeler gauges (see
Fig. 8-30).
Record measured values in the compressor check list of section 8.6.3
Clearance Measurement.
The clearance measured at the same place in the BDC and TDC must
be practically the same. Should doubts arise concerning measurement,
please contact our Customer Support Service.

Cylinder
1 2 3 4
7 6 5
1 5
4 3 8 7
LA_C1_0006b_01
2 6
Fig. 8-30 Measure piston clearance
1 Feeler gauge no. 1 5 Measuring point BDC

2 Feeler gauge no. 2 6 Piston rod
3 Piston 7 Measuring point TDC
4 Cylinder
4. Check cylinder clearances and record it.
5. Check the Bottom Dead Center (BDC) cylinder clearance with a feeler
gauge through the valve openings (see Fig. 8-31).
Repeat this procedure in the Top Dead Center (TDC).

Cylinder
a min. = 2.00 mm
A
a
a max. = 2.50 mm
b min. = 1.50 mm
b max. = 2.00 mm
LA_C0_0002b_01
b
a + b shall not exceed 4.50 mm

Fig. 8-31 Measure cylinder clearance
A Piston diameter
a Top dead center (TDC)
b Bottom dead center (BDC)
WARNING
Use of wrong lead wire or feeler gauge
Wrongly measured or adjusted cylinder clearances can cause major com-
pressor failure.
Use lead wire of appropriate thickness or use a feeler gauge.
Using too thick lead wire can lead to wrong measurement of cylinder
clearance.
If the values are not within the given tolerances there might be a mix-up of
parts (e.g. wedges, piston rods or crosshead).
If there is no mix-up with the assembly, the cylinder clearance must be ad-
justed with distance washers of 0.5 mm thickness between the lower piston
crown and piston rod (Fig. 8-32).
In case the piston must be removed, mark skirt, upper and lower crown.
1 Piston skirt
1 2 3
2 Piston rod
4 Lower piston crown
5 Washer 0.5 mm
4
5
LA_C0_0008b_01
Fig. 8-32 3-piece piston
Failures and Repairs on Gas loss between cylinder and piston influences the intermediate pres-
Cylinder and Piston sures as well as the outlet temperatures on the corresponding cylinders
(suction and final pressures maintained).
Inadequate pistons are defined as follows:

Cylinder
Piston with Excessive Diameter Clearance, but Labyrinth OK

Possible causes:
excessive vibrations at the foundation/compressor,
piston rod gland in bad condition,
excessive clearance between piston rod and guide bearing,
excessive clearance of crosshead,
insufficient clearance of dead space,
liquid knock due to leaky cooler/condensate,
pretension of piston too small, i.e. piston skirt rotates.
Piston Seizure, i.e. Piston Entirely or Partially with Flattened Laby-

rinth
Piston seizure often leaves piston residues in the cylinder. They are visible
as smooth spots on the labyrinth.
Possible causes:
rapid temperature increase, e.g. due to:
valve defect,
failure of cylinder cooling.
Impurities inside gas piping and/or plant accessories getting into the
cylinder.
Broken valve parts getting into the cylinder.
Liquid knock, e.g. leaky cooler during start-up/condensate.
Following maintenance and/or repair work:

rapid pressure increase during running-in of a new piston,
insufficient clearance between guide bearing and piston rod,
inadequate concentricity of guide bearing/guide bearing sleeve,
insufficient clearance between piston rod and piston rod gland ring,
excessive pretension of piston.
Insufficient Pretension of Piston

Insufficient pretension of piston leads to a loose piston skirt noticeable by
a clear knocking of the compressor. Piston parts may be remachined.
Having any questions, please get in touch with our Customer Support Ser-
vice (see 1.3 Contact Address).
Failed Piston Failed pistons and/or pistons with excessive clearance must be replaced.
If the clearance is still excessive, the cylinder must be rebored and over-
sized pistons have to be installed.
For further instructions, contact our Customer Support Service.

Cylinder
8.8.4 Piston Nut SUPERBOLT

Piston nuts SUPERBOLT do not loose their preload force even after sev-
eral years in service providing that they are correctly tightened. Neverthe-
less, we recommend to check the preload force during each revision. Use
a torque wrench adjusted to 100 % of the permitted tightening torque.
Should some pressure screws unexpectedly have lost some of the preload
force the following procedure is recommended:
1. Relieve tension of the piston nut slightly by loosening the pressure

screws (1/4 turn only) according to following subsection Loosening
Procedure. Thus, the nut remains tensioned.
2. Now tense according to following aubsection Tightening Procedure,
i.e. tighten in circular sequence with full tightening torque, until all pres-
sure screws are tightened.
Preventive Maintenance i.e. removal for maintenance purposes
1. Relieve according to following subsection Loosening Procedure.

2. Treat thread and end of pressure screws with admitted lubricant.
3. Hardened washer may be reused despite indentations, simply by
turning over. Depressions of a few 1/100 mm are normal.
4. Tighten again according to following subsection Tightening Proce-
dure
Loosening Procedure Loosening requires an exact procedure. The pressure screws must be re-
lieved stepwise!
Under no circumstances relieve single screws completely. The remaining
screws would have to carry the entire load and, a fact that makes it difficult
to loosen them. In extreme cases the pressure screws could jolt and make
loosening impossible!
1. Starting with No. 1 loosen every pressure screw in circular sequence

maximal 1/4 turn. Do not loosen beyond break loose point. After the
first round, pressure screw No. 1 will again be tightened, however, on
a lower level of loading.

Cylinder
1. In a 2nd round, repeat step 1.

2. In a 3rd round, repeat step 1.
3. Relieve pressure screws com-
pletely. Now the piston nut can
be removed by hand or with the
piston nut wrench.
Due to dirt or a pretensioned piston

the piston nut can still not be loos-
ened. Use the piston nut wrench
carefully to loose the nut.
XA_T9_0023a_01
Fig. 8-33 Loosening of pressure
screws
Follow subsection Trouble Shooting in this section before reusing the

pressure screws!
Tightening Procedure Required Tools

Piston nut wrench
Torque wrench
Socket
Extension for sockets
Lubricant Burckhardt Lubrication Grease BLG05
The stamped tightening torque is the maximum permitted value. For appli-
cable tightening torques: see section Compressor in chapter 13 Ap-
pendix.
Preparation
Make sure that:
pressure screws do not protrude from the nut,
pressure screws are well lubricated.

Cylinder
Procedure
1. Clean main thread and contact areas.

2. Lubricate main thread and contact areas with admitted lubricant.
3. For one-piece, solid pistons firmly tighten the piston nut manually.
9
5 4
6 3 10
2
7 1
1 7
2
3 6
XA_T9_0014b_01
4 5
Fig. 8-34 Piston nut wrench for piston nut SUPERBOLT (position 17 = SUPER-
BOLT size)
1 G 1" 6 G 2 1/2"
2 G 1 1/4" 7 G 3"
3 G 1 1/2" 8 Piston nut wrench
4 G 1 3/4" 9 Pin (dia. 6 mm/dia. 8 mm)
5 G 2" 10 Hexagon 22 mm

Cylinder
4. If the piston is multi-part, tighten the nut to eliminate the pretension of

the piston halves:
Screw the pins (9) into the piston nut wrench (8) at the position
which corresponds with the SUPERBOLT size.
Pin with diameter 6 mm, up to SUPERBOLT size G 2"
Pin with diameter 8 mm, from SUPERBOLT size G 2 1/2"
Attach piston nut wrench.
Tighten the piston nut with the piston nut wrench.
X
LA_T9_0025b_01
6 5 4 3
Fig. 8-35 X = Gap approx. 1 mm
1 Groove for O-ring 4 Piston rod

(with contaminated gas) 5 Pressure screw
2 Piston nut SUPERBOLT 6 Piston
3 Hardened washer
Afterwards turn back approx. 1/4 turn. Depending on the piston size
the gap X will be approx. 1 mm. If a small piston is used the pre-
tension may be eliminated.

Cylinder
Tightening of Piston Nuts The tightening must take place gradually:

Having 8 Pressure Screws
1. Tighten 4 pressure screws crosswise with 25 % of the recommended
tightening torque.
2. Tighten the same 4 pressure screws crosswise with 50 %.
XA_T9_0019a_01
XA_T9_0020a_1
Fig. 8-36 Tighten 4 pressure screws Fig. 8-37 Tighten all pressure
screws
4. Tighten the remaining pressure screws crosswise with 50 % of the rec-

ommended tightening torque.
5. Repeat step 4 with 100 %.
6. Now change to circular tightening and tighten all pressure screws with
100 % until all pressure screws are equally tightened.

Cylinder
Tightening of Piston Nuts 1. Tighten 3 pressure screws with 25 % of the recommended tightening
Having 6 Pressure Screws torque.
2. Tighten the same 3 pressure screws with 50 %.
1 1
6 2
XA_T9_0021a_01
XA_T9_0022a_01
3 2 5 3
Fig. 8-38 Tighten 3 pressure screws 4
Fig. 8-39 Tighten all pressure

screws
4. Tighten the remaining pressure screws with 50 % of the recommended

tightening torque.
5. Repeat step 4 with 100 %.
6. Now change to circular tightening and tighten all pressure screws with
100 % until all pressure screws are equally tightened.
Trouble Shooting Pressure Screws Cannot Be Loosened
1. Remove possibly existing dirt from the piston and SUPERBOLT

piston nut.
2. In case of heavy contamination, apply anti seizing or anti corrosion
spray to the SUPERBOLT piston nut and wait approx. 12 hours until
this agent has penetrated into the dirt.
3. Try to free at least one pressure screw.
4. Turn the loosened pressure screw back as far as possible and apply a
lubrication penetrating agent/spray.
5. Tighten this pressure bolt with 110% of the nominal torque
6. The two neighboring pressure screws should become free.
7. Turn this two pressure screws back as far as possible and apply a lu-
brication penetrating agent/spray.
8. Retighten this two pressing screws with 110 % of the nominal torque.
9. The next neighboring screws should now become free.
10. For loosening the rest of the pressure screws proceed in the same
manner as mentioned above (paragraphs 4 to 8).
11. For finally loosening of all pressure screws proceed according to sec-
tion Loosening Procedure.

Hardened Washers Are Damaged, i.e. after a Long Time in Service

Exchange against original (OEM) hardened washers SUPERBOLT.
Pressure Screws Are Damaged or Missing

Exchange against original (OEM) pressure screws SUPERBOLT.
CAUTION
Do not use commercial screws because they are not suitable for such high
loads!
Piston Nut Cannot Be Loosened Manually

Residue caused by dirty process gases can obstruct the nut despite the
pressure screws are loosen. Thus, use the piston nut wrench to loose the
piston nut carefully.
Other Problems?
Please contact our Customer Support Service (address see section 1.3
Contact Address).
8.9.1 Valve Maintenance

Since the compressor valves are among the most delicate components of
the compressor, they should be inspected every 60008000 hours of ser-
vice at normal conditions i.e. continuous operation.
If the compressor is not running continuously and/or with different gases,
the valves must be inspected at shorter intervals.
The intervals must be adjusted according operating experience and/or in
cooperation with our specialists.
Some process gases (propylene etc.) tend to polymerize. This may lead to
blocked valves.
Valve Service
CAUTION
We strongly recommend having valve overhauls carried out by our special-
ists at site or in one of our Burckhardt Compression AG licensed Service
Centers. We assume no liability for damage caused by inexpert valve over-
hauls. We also reject liability for wrongly assembled valves, or when non-
genuine spare parts are used.

WARNING
Wrongly modified or non-genuine spare parts.
Operational safety may be impaired!
Do neither modify parts nor spare parts.
Do not influence clearances on compressor.
Valves can be sent to the nearest Burckhardt Compression AG Service

Center to be reconditioned at a competitive price.
Contact Address
Service Center
Im Link 5
P.O. Box 65
CH-8404 Winterthur
Switzerland
Tel. +41 (0)52 262 60 03 Fax +41 (0)52 262 00 86
For the address of your nearest Service Center see www.burckhardtcom-

pression.com, Your Contacts Worldwide, Service Centers Worldwide.
For dismantling and assembling of valves see section 9.5 Suction Valves
and Discharge Valves.
8.9.2 Valve Failures (Malfunction)

If uniform service conditions are accompanied by pronounced fluctuations
of the interstage pressure, this may indicate broken or clogged valve discs.
The temperature fluctuations which follow a broken valve disc may lead to
dangerous failures (malfunction) on the compressor. Therefore, defective
valve components should be replaced as soon as they occur.
If repeated valve failure (malfunction) occurs, the lift of the valves can be
reduced or stronger springs be fitted. Such modifications are to be carried
out with Burckhardt Compression consent only. Since computer pro-
grammes can simulate valve behaviour on a specific operating point within
the operating range, therefore a set of readings (temperatures and pres-
sures) is needed in order to determine the necessary modification
(Fig. 8-40).

1 2
XA_CX_0014b_01
5
6 6
Fig. 8-40 Valve computation
1 Inadequate matching 4 Damper disc lift

2 Trouble-free valve 5 Valve disc lift
3 Cylinder pressure 6 Crankshaft (position)
Possible Causes of Valve Dirt in the process gas lines

Failures (Malfunction) Broken valve springs
Broken parts of piston rod gland
Gas pulsations
Clogged valves by Polymers

Controlled suction valve is blocked
Incorrect valve assembly:

Loose pressure screws loose valve lantern (broken valve guard)
Loose nut of center bolt
Oblique of center cut does not coincide
Valve seat has been remachined too much pinhole has not suf-
ficient depth (see section 9.5 Suction Valves and Discharge Valves
in subsection Repair of Valve Seats)
Valve springs not fitted according to Fig. 8-41.
1 Valve disc
1 2 3 4 5 6
2 Wrong position
3 Valve guard
4 Spring
5 Correct position
6 Damper disc
XA_CX_0028b_01
Fig. 8-41 Correct position of valve

springs

8.9.3 Maintenance of Controlled Suction Valves

To assemble the control mechanism of the controlled suction valves, see
Fig. 8-42.
Z
1
11
3
Y
GH
10
5
9
X 7
8
LA_C3_0010b_01
Standard Synthetic
Fig. 8-42 Controlled suction valve
1 Pressure sleeve 9 Valve disc metal

2 Cap nut 10 Valve seat
3 Center bolt 11 Finger unloader
4 Compression spring X Clearance X
5 NORD-LOCK washer pair Y Clearance Y
6 Valve guard Z Clearance Z
7 Valve disc synthetic GH Overall length
8 Damper disc

The clearance X (Fig. 8-42) between the tips of the finger unloader and
the valve disc must be checked every time before fitting a valve. The fin-
gers of the finger unloader should be adjusted to move freely through the
gaps of the valve seat.
Instructions Regarding Blocked suction valves on multi-stage compressors are bound to lead to
Failures (Malfunction) on changes in the interstage pressure and hence to dangerous temperature
Controlled Suction Valves increases and overloading of the properly working stage. All moving valve
components are to be given a light application of a process gas compatible
grease.
The purpose of the following is to indicate the faults which may occur, par-
ticularly in the case of the controlled suction valves. The measures to be
taken to resolve them are also described briefly.
1. Irregular knocking (hammering) of the piston against the cylinder wall

may be the result of the controlled suction valves not operating in the
correct manner. This can lead to increased piston wear. This is associ-
ated, in particular, with compressors with large piston diameters and a
high pressure ratio.
Dismantle the valves and check their compliance with the assembly in-
struction in this section.
2. Nitrogen supply pressure too low.
3. Even though the control device operate in a uniform manner, the suc-
tion valve does not change to the no load position when the control me-
dium pressure is off:
Too much clearance X between the tips of the finger unloader and the
valve disc, or too much clearance Z between pressure pin and pres-
sure sleeve.
Replace finger unloader and/or pressure pin or pressure sleeve.
4. One of the suction valves is blocked, i.e. the pressure pin does not
move.
Dismantle the control device and the nipple and check pressure pin for
ease of movement. Check guiding band and the stepseal. Replace it if
needed.
5. After overhauls: Wrong valve assembly!
Wrong control device and/or pressure pin fitted. Check number and
correct dimensions of springs (F) and check correct assembly mode of
actuator piston K.
Even though the controlled suction valve components are assembled
correctly and control medium pressure is correct, they do not switch
from no load to load position or vice versa.
This symptom could occur when the complete built length (total as-
sembly) in installed condition is not correct (Distance Z). Check for the
correct thickness of the valve gasket, the correct length of the pins (see
table Tab. 9-2 Valve dimensions in chapter 9.5 Suction Valves and Dis-
charge Valves, as well as pressure sleeve. It is advisable to assemble
the complete control valve set, valve, lantern, gasket and actuator in a
suitable compression device (i.e. press, large vice etc.). Use nitrogen
or air to operate the servo motor to verify the function of the controlled
valve set.

Dismantle and Assemble Compressor Components
9 Dismantle and Assemble Compressor

Components
Dismantling Overview This chapter follows a step by step philosophy to explain the complete dis-
mantling or assembling, respectively. It starts with the procedure to switch
off the compressor and ends up with the dismantling of the crankshaft as
the last unit.
The following table lists all steps sequentially and guides you to the desired
instruction. Each part is broken up in these 6 sections:
1. Status: which steps have to be done before this action can take place?
2. Special Tools: these tools are needed to perform the step.
3. Dismantle: steps to dismantle the given part.
4. Required checks: checks to perform after dismantle or before as-
semble the part, respectively.
5. Assemble new or used parts: steps to assemble the given part using
new or the already used pieces.
6. Final Checks: checks to perform after assembling.
Prerequisites before Before you start any inspection or repair activity take all safety measures
Dismantling according to section 8.2 Prerequisites for Maintenance.
DANGER
Before beginning any inspection or repair, turn the current off at the
Step Cross-reference to dismantling and assembling activities

1 9.1 Switch Off Compressor on page 3
2 9.2 Switch Off Cooling System on page 3
3 9.3 Non-Return Valve on page 4
4 9.4 Controlled Suction Valve on page 7
5 9.5 Suction Valves and Discharge Valves on page 10
6 9.6 Cylinder Cover on page 22
7 9.7 Frame Covers on page 23
8 9.8 Drain Lubricating Oil on page 24
9 9.9 Oil Strainer on page 26
10 9.10 Piston and Piston Rod on page 27
11 9.11 Internal Gas Leakage Pipes on page 39
12 9.12 Piston Rod Gland on page 39
13 9.13 Cylinder on page 41
14 9.14 Oil Scraper on page 43
15 9.15 Guide Bearing Bush on page 46
16 9.16 Guide Bearing on page 46

Step Cross-reference to dismantling and assembling activities

17 9.17 Connecting Rod Bearing on page 48
18 9.18 Crosshead and Connecting Rod on page 50
19 9.19 Crosshead Pin Bearing (with Cylinder Removal) on page 51
20 9.20 Gear Oil Pump on page 52
21 9.21 Electric Motor on page 54
22 9.22 Coupling on page 54
23 9.23 Flywheel on page 55
24 9.24 Oil Trap and Crankshaft Seal on page 57
25 9.25 Bearing Bracket and Main Bearing on page 58
26 9.26 Dismantle Crankshaft Sidewards on page 59
Prerequisites before
Assembly
CAUTION

Switch Off Compressor
9.1 Switch Off Compressor

Status Completed activities: none
Special Tools none
Switch Off 1. Switch off the compressor.

2. Before you start any maintenance or trouble shooting activity take all
safety measures according to section 8.2 Prerequisites for Mainte-
nance.
Required Checks Make sure, that:

the compressor and the surrounding plant components are in good
condition,
all compressor parts are fixed correctly and
no personel is staying within danger zones.
Switch On 1. Start the compressor according to section 6.2.2 Handling.
9.2 Switch Off Cooling System

Status Completed activities: 9.1
Special Tools none
Switch Off 1. Switch off the cooling system by turning the main switch to off position.
The compressor is now switched off and ready for maintenance
2. If the dismantling of the cooling pipes is required, then drain the
coolant.
Please remember to collect the glycol mixture if used in you cooling
system!
Switch On and Please see section 5.12.2 Coolant System

Final Checks

Non-Return Valve
9.3 Non-Return Valve

Special Tools none
Dismantle Dismantle the non-return valve according to following figure:
XA_L2_0003a_01
Fig. 9-1 Non-return valve
Contrary to the assembly of Burckhardt Compression plate valves installed

in the compressor, the non-return valve is assembled without springs (elim-
ination of whistling noises).

Non-Return Valve
Required Checks Check the marking X5:
1 Valve guard
1
2 Damper disc
3 Valve disc
HS 1
4 Valve seat
HS 2
2 5 Marking X5
HS 3 HS Distance discs
3
XA_CX_0027b_01
HS
Fig. 9-2 X5 Marking
Assemble New
or Used Parts 1 Correct position
1 2
2 Wrong position
XA_CX_0030b_01
Fig. 9-3 Positioning of damper disc

and valve disc

Non-Return Valve
7 XA_L2_0006b_01
Fig. 9-4 Components of non-return valve
1 Nut 5 Valve disc

2 Washer 6 Valve seat
3 Valve guard 7 Center bolt
4 Damper disc 8 Distance ring
Thread diameter Ma [Nm]
mm min max
12 36 45
16 90 110
20 180 220
24 300 350
Tab. 9-1 Tightening Torques, only valid if Burckhardt Lubrication Grease BLG05
is used

9.4 Controlled Suction Valve

Dismantle and Assemble Suction Valve Actuator 1st and 2nd Stage
1 2 3 4 5
LT LV
13 9
Z
12
10
11
LA_C3_0009c_01
Fig. 9-5 Controlled suction valve with actuator (with leak gas outlet)
LT Total length of pressure pin 6 Valve cover

LV Reference dimension 7 Leak gas outlet
Z Clearance 8 Pressure pin
1 Threaded bolt 9 Lantern
2 Cover for actuator piston 10 Controlled suction valve
3 Spring F 11 Cylinder
4 Diaphragm actuator piston 12 Flat copper gasket
5 Control medium inlet 13 Flat copper gasket
Required Checks Check for correct dimensions of springs F (3) and for correct assembly of
diaphragm actuator piston as follows:

Z
1
11
3
Y
GH
10
5
9
X 7
LA_C3_0010b_01
Standard Synthetic
Fig. 9-6 Controlled suction valve
1 Pressure sleeve 9 Valve disc metal

2 Cap nut 10 Valve seat
3 Center bolt 11 Finger unloader
4 Compression spring X Clearance X
5 NORD-LOCK washer pair Y Clearance Y
6 Valve guard Z Clearance Z
7 Valve disc synthetic GH Overall length
8 Damper disc

1st Stage [mm] 2nd Stage [mm]

Item Code Dimension Code Dimension
Spring F C31445 6.5x53x105 C32445 6.5x53x105
Overall GH
length
Pressure Pin LT C31421 Dia. 14x226 C32421 Dia. 14x156

Pressure Pin LV C31421 Dia. 14x88 C32421 Dia. 14x18
Design Tolerance Design Tolerance
Clearance X 2.0 0.52.5 2.0 0.52.5
Clearance Z 1.5 1.53.0 1.5 1.53.0
Clearance Y 0.5 0.30.8 0.5 0.30.8
Tab. 9-2 Valve dimensions
LT Total lenght of pressure pin (pin dismantled)

LV Pressure pin protrusion and control device disassembled (piston posi-
tion with a.m. springs)
Clearance X, Y, Z see Fig. 9-5 and .Fig. 9-6
Dismantle Procedure:
1. Disconnect piping of control medium and leak gas.
2. Remove valve actuator from cylinder.
3. Remove cover for actuator piston (2) from valve cover (6).
4. Dismount diaphragm actuator piston (4).
Required Checks 1. Check for correct dimension of spring F (3) see Tab. 9-2.
2. Check flat copper gaskets (12/13) and replace them if necessary.
3. Check diaphragm actuator piston for damage.
4. Check pressure pin protrusion, see Tab. 9-2.
Assemble New
or Used Parts
CAUTION
Lubricants solidify when in contact with low temperature.
Pressure pin gets jammed.
Do not use any lubricant on components of the suction valve actuator!

1. Fit spring F.
2. Fit diaphragm actuator piston with flat copper gaskets.
3. Fit cover for actuator piston to valve cover.
4. Connect piping of control medium and leak gas.

Status Completed activities: 9.1, 9.4
Tools
1 2 3
LA_T9_0027c_01
Fig. 9-7 Valve dismantling and assembling device
1 Cylinder
2 Valve
3 Dismantling and assembling device
Removal of Valves
1. Remove valve cover nuts.

2. Remove valve cover.
3. Remove gasket.
4. Remove lantern.
5. Remove valve possibly using removal and assembling device ac-
cording to Fig. 9-7.

Disassembly of Valves
Fig. 1 Fig. 2 Fig. 3
XA_C3_0027a_01
Fig. 9-8 Fixing the valve
1. To properly hold a valve in place for disassembly or assembly, a device

as shown in Fig. 9-8 should be used. If such device is not available, a
simple device as shown in Fig. 9-8 should be made and used for
holding the valves during disassembly and assembly.
2. Clean the center bolt before you loosen the locking nut.
XA_T9_0028a_01
Fig. 9-9 Correct handling
In order to prevent the locating pin in the valve from sheering off, it is ad-
visable to hold the valve seat and valve guard respectively while loosening
or tightening the nut, see Fig. 9-9.

Fig. 5 Fig. 6
Fig. 7 Fig. 8
XA_T9_0029a_01
Fig. 9-10 Incorrect handling
Valves should never be clamped in a vise to disassemble or to loosen the

locking nut from the center bolt, see Fig. 9-10. Do not hammer on the
wrench when loosening or tightening the nut.
3. With the locking nut removed, separate the seat from the guard. Keep
the seat and sealing elements the way they came apart
Required Checks 1. Clean all components. Use a cleaning fluid and a soft brush, taking par-
ticular care to free the ports of the seat and the guard from all foreign
matter to ensure full seat area in operation. Never use wire brushes or
tools with sharp edges to clean the seats and plates.
2. Check the valves, inspect individual components for damage and wear
and replace them, if necessary.
3. Inspect lanterns, they shall not be cracked or have any damage to the
seating faces.
4. Generally, the valve gaskets should be replaced.
5. If the locking nuts do not lock anymore (after several tightening proce-
dures) replace them.

If valve components are only inspected but not replaced, they must be re-
assembled with the same valve seat and installed in the same location as
before removal.
Repair of Valve Seats

If the accurately machined surfaces of the seal ridges on the valve seat be-
come damaged due to hammering, etc., they can be machined on a lathe
according to Tab. 9-3 Remachining limitsand Fig. 9-11.
C
B
A
3
N6
Min.
D
0.5 mm
1 2 3 4
0.5 mm
XA_CX_0043b_01
8 5
0.5 mm
0.5 mm
3 7 1 6
Fig. 9-11 Valve seat
1 Pinhole 5 Discharge valve seat with tapped

2 Tapped hole blind hole (old design)
3 Seal ridge 6 Suction valve seat
4 Discharge valve seat with tapped 7 Through boring
hole (new design) 8 Tapped blind hole

Valve Plate A B C Min.

Diameter [mm] [mm] [mm] [mm]
[mm]
60196 4.00 4.50 5.50 2.50
212266 5.00 5.50 7.00 3.50
310 6.50 7.00 9.00 4.50
D = Re-machining of surface is not permitted
Tab. 9-3 Remachining limits
Re-machining quality of surface (3): N6 fine machined. Check pinhole (1)

for sufficient depth, drill deeper if necessary.
For controlled suction valves only: check clearance X according to

Tab. 9-2 in section 9.4 Controlled Suction Valve.
Repair of Valve and Damper Discs
Neither valve nor damper discs may be reworked, e.g. by grinding.

Only lapping-in with the associated valve seat is possible.
Assemble New The proper functioning of the valves depends largely on the correct as-
or Used Parts sembly. The most important factors are the lift of the valve and the hard-
ness of the valve springs.
WARNING
All components coming into contact with process gas must be clean and
free of oil or grease.
The valve configuration is simulated by a computer program and optimized

for each compressor/application (see Fig. 9-12).
The configuration of the valve components is dictated by its application.
Therefore, it is not advisable to change parts and configuration without con-
sultation of our Customer Support Service.

1 2
XA_CX_0014b_01
5
6 6
Fig. 9-12 Result of optimized valve configuration
1 Inadequate matching
2 Trouble-free valve
3 Cylinder pressure
4 Damper disc lift
5 Valve disc lift
6 Crankshaft (position)
Always install the springs starting from the outermost circle of spring holes
(1) and proceed towards the center. Always complete a circle first before
starting with the next one (see Fig. 9-13).
It may be necessary, that not a full set of springs is installed.
2 1
XA_CX_0018b_01
Fig. 9-13 Placing of springs
1 Outermost circle
2 Inner circle
Key to Valve Type Example:

Designations
XA_CX_0008b_01
122.YYY.YYY.200 CSV 202 - 100 - BC - X - S - 80 - 32 - 300 - T
1 2 3 4 5 6 7 8 9 10 11
Fig. 9-14 Valve type designation
1 Drawing number 6 Valve plate material

2 Valve type Controlled Suction 7 Type of damper disc Standard,
Valve, Konical, O-without
Suction Valve, Discharge Valve 8 Diam. spring wire (in 1/100 mm)
3 Valve size 9 Number of springs
4 Pressure class 10 Lift (in 1/100 mm)
5 Valve type (Company) 11 Special design
Low Temperature, Special

The valves shall be fitted with the following distance rings and springs:
Number Valve Type Distance Ring Spring Wire Dia.
per Stage Piece x [mm] Piece [mm]

1st Stage
Suction 4 161-8-16 3x0.45 16 0.6
Discharge 4 161-8-16 3x0.45 16 0.8
2nd Stage
Suction 2 161-25-50 3x0.45 16 0.8
Discharge 2 161-25-50 3x0.45 16 0.8
Tab. 9-4 Valve design
If failures (malfunction) occur repeatedly, the lift can be reduced or stronger

springs fitted. Such modifications are only to be carried out with our ap-
proval. Please contact our Customer Support Service, address see 1.3
Contact Address
Assembly Procedure
It is essential, that valve parts are always assembled in accordance with
the following instructions:
Tab. 9-5 For tightening torques
Fig. 9-18 For fitting of the valve springs
The nuts must be tightened thoroughly.
The center slanting cuts on valve and damper discs must coincide (see
Fig. 9-15).
1 Correct position
1 2
2 Wrong position
XA_CX_0030b_01
Fig. 9-15 Positioning of damper disc

and valve disc

1 3 2
XA_CX_0022b_01
Fig. 9-16 Valve assembly
1 Suction valve
2 Discharge valve
3 Nut
4 NORD-LOCK washer pair
Required Checks Check the marking X5:
1 Valve guard
1
2 Damper disc
3 Valve disc
HS 1
4 Valve seat
HS 2
2 5 Marking X5
HS 3 HS Distance discs
3
4
XA_CX_0027b_01
HS
Fig. 9-17 X5 Marking

Thread diameter Ma [Nm]
mm min max
12 30 35
16 70 90
20 160 180
24 230 280
Tab. 9-5 Tightening Torques, only valid if Burckhardt Lubrication Grease BLG05
is used
Clean all parts according to chapter 10 Clean and Degrease Plant and
Compressor Components.
To prevent the valve springs from rotating around their longitudinal axis
during operation, they seat flush in the valve guard. Usually, these springs
must be slightly pressed in when fitting into the appropriate spring guide.
The simplest way to do this is by turning the springs counter clockwise
while fitting them. Refer to the following fitting instruction.
Instruction for Fitting of Valve Springs

The springs must be adjusted vertically in the cylindrical part of the guide
of the valve guard. Take care that they do not interfere with damper disc.
For assembly, push the springs in a counterclockwise motion into the guide
of the valve guard.
1 Valve disc
1 2 3 4 5 6
2 Wrong position
3 Valve guard
4 Spring
5 Correct position
6 Damper disc
XA_CX_0028b_01
Fig. 9-18 Correct position of valve

springs
Fit Valves into Cylinder

The sealing surfaces between the valves and the cylinders are lapped in.
Avoid damages of the sealing surfaces during installation of valves. The
lanterns on the suction side are shorter than those on the discharge side.

1. Insert valves with their lanterns

00.1 mm
into the correct valve ports (use
eye bolts). Valves and lanterns
must show an overlap at the cyl-
inder of 00.1 mm in the fitted
position (Fig. 9-19). The in-
serted lantern must fit properly.
LA_CX_0011a_01
Fig. 9-19 Overlap
CAUTION
Lantern too short
A difference of only 0.1 mm in length is sufficient to cause the affected lan-
tern to shift axially.This will successively increase the axial clearance and
leads to damage to the valves and especially the valve guards.
Lanterns which are too short can be rectified by welding-up or by fitting thin
rings of non ferrous metal or stainless steel disc.
STOP
XA_CX_0031a_01
2. Lubricate bolts and nuts.

3. Put valve cover and gasket on cylinder and tighten the nuts slightly.
4. Tighten the nuts diagonally, applying specified torque. For applicable
tightening torques: see section Compressor in chapter 13 Appendix.

A B
8
9 10
11 12
13
14
15
16
12 17
LA_CX_0012b_01
18 19
Fig. 9-20 Valve components
1 Valve cover 12 Valve spring

2 Gasket 13 Damper disc, discharge side
3 14 Distance ring
4 Lantern 15 Center bolt
5 Suction valve 16 Damper disc, suction side
6 Discharge valve 17 Valve disc, discharge side
7 Nut 18 Valve guard, suction side
8 NORD-LOCK washer pair 19 Valve seat, discharge side
9 Valve seat, suction side A Installed suction valve
10 Valve guard, discharge side B Installed discharge valve
11 Valve disc, suction side

Cylinder Cover
9.6 Cylinder Cover

Tools
LA_T9_0009a_01
Fig. 9-21 Eye bolt
Dismantle and Checks 1. Dismantle one of the upper and one of the lower valves.
The cylinder clearance is now accessible
a min. = 2.00 mm
A
a
a max. = 2.50 mm
b min. = 1.50 mm
b max. = 2.00 mm
LA_C0_0002b_01
b

A Piston diameter
WARNING
pressor failure.
clearance.

Frame Covers
3. Remove all nuts of the cylinder cover.

4. Fit eyebolts to cylinder cover.
5. Remove cylinder cover.
Required Checks 1. Check cylinder cover surface for cleanliness.

2. Check if the O-ring is in perfect condition.
Assemble New 1. Replace O-ring if required.

or Used Parts
Installation takes place in reverse order to dismantling.
9.7 Frame Covers

Special Tools none
Dismantle and Assemble 1. Remove all screws at the margin of the covers.
2. Lift off the covers according to following figure and stow them away.
LK_M0_0009a_01
Fig. 9-23 Frame cover removal

Drain Lubricating Oil
9.8 Drain Lubricating Oil

Special Tools none
Drain 1. Drain the oil from the oil sump.

2. Drain the piping of the lubrication system.
3. Remove and clean the oil strainer of the compressor (see section 9.9
Oil Strainer).
4. Clean the crankcase with a sponge (do not use fibrous textile).
5. Clean the duplex oil filter in accordance with the manufacturers in-
structions (see Technical Documentation).
6
LK_M2_0007b_01
Fig. 9-24 Gear oil pump
1 Gauge for crankcase pressure 4 Oil strainer

2 Gauge for lubricating oil pressure 5 Oil drain
3 Gear oil pump 6 Oil sight glass
Refill The required oil quantity for the compressor crankgear is about 64 litres.
The oil is contained in the crankgear. The oil level can be checked through
the oil sight glass. When the compressor is at standstill, 3/4 of the oil sight
glass must be covered.

Drain Lubricating Oil
3/4
LA_M2_0008b_01
2
Fig. 9-25 Oil level
1 Oil sight glass

2 Oil
3 Frame
Refill as follows:
1. Shut oil outlets.
2. Refit oil strainer, filter, etc.
3. Fill the compressor with fresh oil.

Oil Strainer
9.9 Oil Strainer

Special Tools none
Dismantle and Assemble The oil strainer is located in the crankgear:
LA_M0_0006_c_01
Fig. 9-26 Position of oil strainer within crankgear

Piston and Piston Rod

Status Completed activities: 9.1, 9.2, 9.5, 9.6, 9.7
Tools
LA_T9_0009a_01
Fig. 9-27 Eye bolt
Dismantle 1. Check piston clearance in cylinder (see Fig. 9-33).

2. Check clearance between guide bearing bush and piston rod.
3. Disconnect the piston rod from the crosshead, proceeding as follows:
Turn crosshead to top dead point.
Loosen safety device and knockout wedges.
Apply lube oil to the sliding faces and insert the cotter key.
Drive in the middle wedge until the piston rod is forced out, a dull
sound can be heard.
1 2 3
LA_T9_0022b_01
Fig. 9-28 Cotter key T97010
1 Crosshead
2 Piston rod
3 Cotter key

Confirm that the two rounded parts of the cotter key are inserted as shown
in the figure above.
Make sure to allow the tapered centre wedge to work properly (tapered
opening between rounded pieces). Working order is correct, when the
stamped-on numbers of the three parts are facing to the same side.
4. Remove cotter key.

5. Carefully lift piston rod paying attention that piston rod gland, oil
scraper rings and the guide bearing will not get damaged.
6. Loosen guide bearing cover, the spring plate and remove the oil
scraper rings.
Details regarding oil scraper rings, see section 9.14 Oil Scraper.
In case the guide bearing clearances is out of tolerance, proceed according

to section 9.15 Guide Bearing Bush.
Required Checks Observe numbering of individual parts (see section 8.6.2 Marking of Com-
pressor Components).
1. Check the items to be fitted (piston, piston rod, oil scraper rings, oil
shield, guide bearing cover, spring plate and garter springs) for pos-
sible damage.
2. Check if the piston rod surface is in perfect condition. Should a piston
rod be damaged, contact our after Customer Support Service.
Assemble New If you insert a new piston rod, please note the last part in this section: Fur-
or Used Parts ther Steps for Piston Rod Replacement.
1. Bring crosshead to TDC (Top Dead Centre).

2. Fit eye bolt into the piston rod. Lift piston rod and piston with the hoist.
free of grease and oil.
When using solvents, observe manufacturers safety precautions.
3. Lower the oil-free piston rod through the gland to approximately 50 mm

above the guide bearing housing.
4. Fit the following parts onto the dry piston rod:
Oil shield without garter spring (1)
Guide bearing cover (2)
Spring plate (3)

1 2
LK_M5_0003c_01
Fig. 9-29 Guide bearing
1 Oil shield
2 Guide bearing cover
3 Spring plate
4 Oil scrapers
Proceed as follows:
5. Hold these parts in the uppermost possible position and oil the piston
rod underneath.
6. Oil the scraper rings (4) with compressor oil on the inside and slide
them with fitted garter springs onto the piston rod (see section 9.14 Oil
Scraper).
7. Put the spring plate and the guide bearing cover on top of the scraper
rings.
8. While lowering the piston rod through the oiled guide bearing, move the
dry oil shield up along the piston rod. Make sure that the portion of the
piston rod below the oil shield always gets some oil before it moves
through the scraper rings.
9. As soon as the piston rod is positioned in the guide bearing, the guide
bearing cover (2) can be hand tightened.
If you insert a new piston rod proceed with instructions in part Further
Steps for Piston Rod Replacement at the end of this section.
10. Lower the piston rod and continue to move up the oil shield on the
piston rod until it sits in its groove on the piston rod. At the same time
clean off excess oil on the piston rod taper and crosshead. Then install
the garter spring on the oil shield.

X
5 4
LA_M3_0003b_01
Fig. 9-30 Crossheadpiston rod connection
1 Piston rod
2 Wedges for piston rod
3 X = Minimum clearance 0.5 mm
4 Crosshead
5 Fitting bolt
Proceed as follows:
11. Lower the piston rod completely. Apply some oil to all sliding surfaces
and fit the wedges according to the drawing, make sure the number on
the wedges corresponds with the crosshead and piston rod. Force the
wedges firmly into its slot by hand, now use a copper punch and a
hammer and knock in the lower wedge approx. 15 mm from this posi-
tion (see Fig. 9-30).
12. Secure the wedges with the safety device according to the drawing.
Required Checks For detailed information about piston nut SUPERBOLT see 8.8.4 Piston
Nut SUPERBOLT.

Check the Pretension of Piston Crowns:

1. The pretension of the piston crowns to the piston skirt are measured
when a piston part is replaced or after the interval indicated on the
maintenance list. This applies also, if a piston nut came loose.
Pretension is the value by which the piston crowns are bent inwards
when the piston nut is tightened, thereby clamping the piston skirt.
Measure distance A as shown in Fig. 9-31 with the piston crowns
clamped together without the piston skirt.
1 2 3 4
A B
LA_C1_0004b_01
5
Fig. 9-31 Check pretension of piston crowns
1 Piston crown
2 Piston nut
3 Key
4 Piston skirt
5 Piston rod
2K158-2D_1 Diameter Pretension

Piston 1st stage 415mm 0.36mm to 0.40mm
Piston 2nd stage 260mm 0.16mm to 0.20mm
WARNING
Risk of piston seizure or loose piston skirt!
The measured values must be within the tolerances given above.
Tighten piston nut in accordance with section 8.5.4 Tightening Torques
and Method.
2. When installing a new piston skirt, it must be match-marked with the top
piston crown. It is important to define the position of the piston parts by
reference marking during assembly. In case a piston is disassembled
for inspection purposes, with or without replacing parts (i.e. checking of
piston pretension). During reassembly of the parts, these markings will
facilitate to have the identical position of the piston skirt in relation to
the cylinder.
Such marking shall be punch-marked or engraved only. In the assem-
bled and installed position of a piston, the marking shall always be on
the V-side (name plate side) of the compressor (see Fig. 9-32).


1 2
2 Piston skirt
xx*
: *xx
S/NoV *x*
V *x*
LA_C1_0005b_01
Fig. 9-32 Marking of piston crown and
skirt
Prior to measuring, clean all measuring tools, according to chapter 10

Clean and Degrease Plant and Compressor Components.
Measure piston clearance:

3. The piston clearance of each individual stage must be measured in the
TDC (Top Dead Center) as well as in the BDC (Bottom Dead Center)
position.
Always measure simultaneously with two opposite feeler gauges (see
Fig. 9-33).
Record measured values in the compressor check list of section 8.6.3
Clearance Measurement.
The clearance measured at the same place in the BDC and TDC must
be practically the same. Should doubts arise concerning measurement,
please contact our Customer Support Service.

1 2 3 4
7 6 5
1 5
4 3 8 7
LA_C1_0006b_01
2 6
Fig. 9-33 Measure piston clearance
1 Feeler gauge no. 1 5 Measuring point BDC

2 Feeler gauge no. 2 6 Piston rod
3 Piston 7 Measuring point TDC
4 Cylinder
4. Check cylinder clearances and record it.

a min. = 2.00 mm
A
a
a max. = 2.50 mm
b min. = 1.50 mm
b max. = 2.00 mm
LA_C0_0002b_01
b

A Piston diameter
WARNING
pressor failure.
clearance.
If the values are not within the given tolerances there might be a mix-up of
parts (e.g. wedges, piston rods or crosshead).
If there is no mix-up with the assembly, the cylinder clearance must be ad-
justed with distance washers of 0.5 mm thickness between the lower piston
crown and piston rod (Fig. 9-35).
In case the piston must be removed, mark skirt, upper and lower crown.
1 Piston skirt
1 2 3
2 Piston rod
4 Lower piston crown
5 Washer 0.5 mm
4
5
LA_C0_0008b_01
Fig. 9-35 3-piece piston
Further Steps for Piston In general, proceed as mentioned within this section in part Assemble New
Rod Replacement or Used Parts, sequence 1 through 10.

Because new parts have to be fitted, the contact pattern of the tapered seat
(piston rod and crosshead) and of the wedges must be checked. The posi-
tion of the piston in the cylinder must also be checked. Proceed as follows:
1. Lower the piston rod and continue to move up the oil shield on the
piston rod until it sits in its groove on the piston rod. At the same time
clean off any oil on the piston rod taper and cross head seat with a sol-
vent. Apply some blue ink for a dye check.
2. Lower the piston rod and check the blue pattern, the cone should be
matching at its whole surface area (check contact pattern and run-out).
3. Apply some oil to the contact faces, between the wedges only, apply
blue ink to the outside (rounded side) and firmly force wedges by hand
into crosshead slot, now use a copper punch to hammer the lower
wedge in approx. 10 mm from this position. Check the clearances of the
piston to the cylinder. (Compare clearances with the piston clearances
taken with the old piston rod. Clearances should not change.
4. Remove the wedges and compare the contact faces to its counter part,
i.e. the top wedge to the corresponding part of the crosshead and the
lower wedge to the corresponding part of the piston rod. File off the high
points on the wedges only, with a fine file. Repeat this procedure 3 and
4 until the wedges get contact along the entire seat-engaging surface.
5. Finally force wedges by hand firmly into crosshead slot, now use a
copper punch to hammer the lower wedge in approx. 15 mm from this
position. The piston rod must drop about 0.4 mm into the tapered bore
during this procedure. The piston rod has to have a min. of 0.5 mm
clearance measured between the lower wedge and the lowest point of
the crosshead slot. Mark the position for the locking device hole. Dis-
mantle the wedges and drill the holes for the applicable locking device
(probably the old hole has to be closed first). Fit the wedges securely
with the safety device according to the drawing (Fig. 9-30).
6. Check piston clearances and compare them with the previous mea-
surements and record them as described in this section at the begin-
ning.
7. Verify the proper tightening torque of the piston nut. Install the cylinder
cover and tighten the nuts (see part Final Checks in this section).
8. Check dead space clearances according to previous instructions and
adjust if necessary with washers (Fig. 9-35).
Adjusting of Asymmetric Crosshead Wedges

Piston rod (3) and crosshead (1) are connected with two asymmetric
wedges (2). Cotter keys allow to loose the wedging. After mounting of
piston rod and crosshead, the crossheads run-out with reference to the
piston rod has to be minimal. The contact patterns at the taper part of the
piston rod and at the back of the wedges (4) have to be even.

4
3
LA_M3_0007b_01
5 4
Fig. 9-36 Adjustment of wedges
1 Crosshead
2 Wedges
3 Piston rod
4 Back of wedges
5 Sliding faces

Assembly of Crosshead and Piston Rod
1. Fit the taper part of the piston rod (3) into the tapered bore of the cross-
head (1) (check the contact pattern and run-out, touch up by blue ink).
2. Fit the wedges (2) into the slot (make it move freely).
3. Knock the large wedge in slightly, check run-out of crosshead, adjust
rounded backs of wedges.
4. Apply lube oil to the sliding faces (5) and force the wedge by hand
firmly into its slot and knock it in approx. 10 mm from this position.
Check the run-out.
5. Knock out lower wedge (2) with a mandrel, disassemble wedges and
adjust backs of wedges.
6. Place cotter keys according to following figure in the way, that the flat
key (7) lays between the two rounded ones (6 and 8):
6
1
LA_T9_0022c_01
8
Fig. 9-37 Cotter keys
1 Crosshead
3 Piston rod
6 Upper cotter key
7 Middle cotter key
8 Lower cotter key

The cotter keys are placed in correct order, when the stamped-on numbers
are facing to the same side
Force out piston rod (3) from crosshead (1) by driving in the middle
cotter key (7); a dull sound can be heard. Remove cotter keys.
7. Apply lube oil to the sliding faces (5). Force the wedges (2) again by
hand firmly into its slot and knock it in 15 mm from this position. The
piston rod must consequently enter into the tapered bore by approx. 0.4
mm.
15 mm
0.4 mm
11
10
5
9
LA_M3_0003c_01
Fig. 9-38 Position of wedges
5 Sliding faces
9 Locking plates
10 Fitting bolt
11 Overlapping end
8. Check contact pattern of the wedges back and run-out of crosshead.

9. Dismantle the piston rod again, adjust the contact patterns of the taper
end and the wedges back.
10. Repeat points 7 to 9 until run-out and contact patterns are in order.
11. Short the large wedge on the two ends (11) in case it overlaps the
crosshead.

Internal Gas Leakage Pipes
Make sure that the wedge is forced into the slot by 15 mm and the piston
rod has entered the tapered bore by at least 0.4 mm.
12. Drill the fitting bolt bore (10) in the wedge in closest position to the
crosshead neck when positioning the locking plates (9). The bore in the
locking plates are excentric in order to allow 4 different positions for
clearance-free adjustment.
9.11 Internal Gas Leakage Pipes

Special Tools none
Dismantle and Assemble Dismantle and assemble the internal gas leakage pipes according to
Fig. 9-39.
1 2
LA_C5_0011b_01
Fig. 9-39 Piston rod gland gas leakage pipes (typical view)
1 Gas leakage pipes

2 Piston rod gland
9.12 Piston Rod Gland

Status Completed activities: 9.1, 9.2, 9.5, 9.6, 9.10, 9.11
Special Tools none
Dismantle 1. Unfasten gland flange and carefully lower the complete piston rod
gland.
The gland flange cannot be taken out through the lower ports of the cyl-
inder. Whenever a gland flange must be replaced, removal of cylinder
is required.
2. Dismantle piston rod gland and clean individual parts.
Required Checks 1. Inspect individual parts for possible damage. Grooves and front faces
must not be damaged.
2. Measure the radial clearance of the one-piece rings on the piston rod
(on oil scraper area).

Piston Rod Gland
Measured piston rod gland ring clearance:

75 + 0.05 to 0.07 mm
Assemble New
or Used Parts
free of grease and oil.
When using solvents, observe manufacturers safety precautions.
8 1
2
7
4
6
5 LK_C5_0002b_01
Fig. 9-40 Piston rod gland
1 Gland chamber (top) 5 Nipple

2 Gland chamber (middle) 6 Gasket
3 Intermediate ring 7 Gland ring
4 Gland flange 8 Spring

Cylinder
Procedure:
1. Place gland flange (4) with bottom gland ring (7) on top of guide
bearing.
2. Place intermediate ring (3) on top of the gland flange.
3. Build a stack with following sequence:
2 gland chambers (2) with gland rings and springs
1 gland chamber (1) with gland ring and springs
4. Place this stack on top of the intermediate ring.
5. Tighten flange slightly.With flange tightened, the gland rings must be
movable radially.
6. Install piston, see section 9.10 Piston and Piston Rod.
7. Turn the flywheel several times manually in running direction.Verify that
everything is in proper mechanical condition.
8. Tighten flange with the mandatory tightening torque.
For mandatory tightening torques: see section Compressor in chapter 13

Appendix.
9. Fit the gas leakage lines.
9.13 Cylinder
Tools
XA_T9_0007a_01
Fig. 9-41 Flogging spanner
Dismantle 1. Remove cooling pipes from cylinder.

2. Loosen the nuts of the threaded bolts.

Cylinder
DANGER
Suspended loads!
3. Attach carrying ropes in the safe manner, described and illustrated in

section 5.4 Lifting Procedure.
4. Lift off the cylinder. Be careful that the threaded bolts do not touch the
bores in the frame.
Assemble New
or Used Parts
CAUTION
All components coming into contact with process gas must be clean (oil-
free and free of grease).
When using solvents, observe the safety precautions of the manufacturer.
1. Degrease gas leakage pipes of piston rod glands according to chapter

10 Clean and Degrease Plant and Compressor Components.
2. Place them on the frame inside the distance piece.
DANGER
Suspended loads!
3. Attach carrying ropes in the safe manner, described and illustrated in

section 5.4 Lifting Procedure.
4. When lowering the cylinder onto the frame, be careful that the threaded
bolts do not touch the bores in the frame.
5. Pay attention that the centering pins fit properly into the corresponding
bores in the cylinder.

Oil Scraper
1 Plug
1 2 3 4 5
2 Cylinder
3 Centering pin
4 Epoxy resin
5 Frame
LA_C0_0003b_01
Fig. 9-42 Centering pin
6. Tighten the nuts of the threaded bolts with the mandatory tightening
torque.
9.14 Oil Scraper

Special Tools none
Required Checks The rings shall not show any sign of damage and must lie snug against the
piston rod on their whole circumference. The height of the ring surface on
the piston rod (running surface) should be 1 mm to max. 2 mm. The
scraping edge must be as sharp as possible and must end in a pointed

Oil Scraper
angle. The rings must have a slight pretension when pushed onto the
piston rod, even without the garter spring. With the garter spring fitted, they
must not slide off the piston rod when in a vertical position.
2 1
1,5 - 2,0
LA_M5_0004b_01
- H6
3 4
Fig. 9-43
1 Top
2 Funnelshaped mouth
3 Scraping edge
4 Bottom
Assemble New Please take care about the following:

or Used Parts Mount the scraper rings in the correct order: top, middle and bottom
ring. Make sure that the inclined cuts of the scraper rings are offset
120 to each other (they must form a triangle when viewed from above
(see figures below).
Another indication of proper assembly are the positioning marks (black
vertical notch on each scraper ring). They line up, one on top of the
other, as long as a bottom, middle and top ring are used. Bottom,
middle and top scraper rings have different article numbers (Figures
below).
The two upper scraper rings have one brad each. The brads prevent
the rings to rotate against each other.
Never tilt the scraper rings on the piston rod.

Oil Scraper
2 1 2 3 2
LA_M5_0011b_01
Fig. 9-44 Oil scrapers without garter spring
1 Brad (upper rings)

2 Gap: 120 staggered
3 Marking
2 1 2 3 LA_M5_0006b_01
Fig. 9-45 Oil scrapers with garter spring
1 Brad (upper rings)

2 Gap: 120 staggered
3 Marking

Guide Bearing Bush
9.15 Guide Bearing Bush

Status Completed activities: 9.1, 9.2, 9.5, 9.6, 9.7, 9.10, 9.14
Special Tools Dismouting device for bush (see Fig. 9-46)
Dismantle If the diametrical clearance between bush and piston rod exceed the Dia.
B (for applicable clearances see section Compressor in chapter 13 Ap-
pendix), replace the bush with the device to be made at site as shown in
Fig. 9-46.
1 2 3 4
LA_M5_0026b_01
Fig. 9-46 Dismantle guide bearing bush
1 Guide bearing
2 Bearing bush
3 Dismounting device
4 Crosshead
Required Checks Before fitting the new bush, check the clearance between the bush and rod.
9.16 Guide Bearing

Status Completed activities: 9.1, 9.2, 9.5, 9.6, 9.7, 9.10, 9.13
Special Tools none
Dismantle Before removal and inspection, the guide bearing clearance must be mea-
sured.
Measure the clearance with a feeler gauge.

Guide Bearing
For applicable clearances see Table of Clearances in section Com-

pressor in chapter 13 Appendix.
Should doubts arise about acceptance of measured clearance, contact our

Customer Support Service that will gladly assist you.
1. Loosen the screws and remove the guide bearing according to

Fig. 9-47
1 2 3 4
LK_M5_0003b_01
Fig. 9-47 Guide bearing


9.17 Connecting Rod Bearing

Special Tools none
Tools
Dismantle
1 Connecting rod
1 2 Crosshead pin bearing
3 Crosshead pin
2
4 Circlip for crosshead pin bearing
3 5 Connecting rod bolt
7 Connecting rod bearing cover
4 8 Locking plate
6
LA_M4_0004b_01
Fig. 9-48 Connecting rod bearing
1. Measure bearing clearance and record it (see section Required

Checks).
2. Remove bolt locking device.
3. Slacken bolts.
4. Turn respective crank to TDC (Top Dead Centre).
5. Lower connecting rod bearing cover by unscrewing the bolts.
Required Checks Turn crank to BDC and measure clearance between crankshaft journal and
connecting rod lower bearing shell with a feeler gauge.
For applicable clearances see section Compressor in chapter 13 Ap-
pendix.
Assemble After removal for inspection, refitting of bearing is generally carried out in
reverse sequence to removal.

1. Turn respective crank to TDC.

2. Fit connecting rod bearing cover with bearing shell.
3. Tighten bolts according to the following instruction.
LA_M4_0005b_01
4
Fig. 9-49 Instructions for fitting of connecting rod bolts.
1 Connecting rod bolt

2 Locking plate
3 Bearing shell
4 Connecting rod bearing cover
L: Length of bolt before tightening

L1: Length of bolt when tightened
The bolt is properly tightened when:

L1 L = + 0.28 mm (min.) up to + 0.34 mm (max.)
For applicable clearances see section Compressor in chapter 13 Ap-
pendix.
4. Measure bearing clearance.

5. Only if necessary, re-punch marks on the connecting rod.
6. Fit locking plate (2).

Crosshead and Connecting Rod
9.18 Crosshead and Connecting Rod

Status Completed activities: 9.1, 9.2, 9.5, 9.6, 9.8, 9.7, 9.10, 9.13, 9.16, 9.17
Tools
XA_T9_0003a_01
XA_T9_0004a_01
Fig. 9-50 Circlip pliers
Dismantle The crosshead may be removed through the bore of the guide bearing.
1. Lift crosshead with hoist.Take care that the connecting rod is hanging
freely, i.e. not damaging the crosshead guide while lifting.
2. Remove crosshead pin.
Assemble New Installation takes place in reverse order to dismantling.

or Used Parts

Crosshead Pin Bearing (with Cylinder Removal)
9.19 Crosshead Pin Bearing (with Cylinder Removal)

Status Completed activities: 9.1, 9.2, 9.6, 9.8, 9.7, 9.10, 9.11, 9.13, 9.16, 9.17,
9.18
Special Tools Press, Freezer, Oven
Dismantle Push the used crosshead pin bearing out of the connecting rod bore with a
press.
Assemble New or Used 1. Clean the connecting rod bore and the crosshead pin.
Parts
2. Check the crosshead pin and the crosshead pin bearing diameter. The
diameter of the crosshead pin and the crosshead pin bearing must cor-
respond to the set values given in the table of clearances, see section
Compressor in chapter 13 Appendix.
3. The crosshead pin bearing must be cooled down to approximately
-20C before it can be installed. Therefore, cool it in a freezer for about
12 hours.
4. The connecting rod must be heated-up in hot oil to 60C80C. Never
use a burner or a blower for heating-up. Risk of connecting rod defor-
mation!
5. Insert the new crosshead pin bearing quickly. Make sure that the posi-
tioning pin in the bearing and the groove of the connecting rod are in
line.
Due to thermal expansion of the crosshead pin bearing, thermal
shrinkage of the connecting rod the position of the crosshead pin
bearing cannot be corrected anymore after a few seconds!
Final Checks Check the diameter of the crosshead pin bearing when the crosshead pin
bearing and the connecting rod have reached ambient temperature. Table
of clearances, see section Compressor in chapter 13 Appendix.

Gear Oil Pump
9.20 Gear Oil Pump

Tools
LA_T9_0009a_01
Fig. 9-51 Eye bolt
Dismantle 1. Remove external oil pipes.

2. Dismantle the oil pump according to figure Fig. 9-52 and Fig. 9-53.
LK_M2_0008a_01
Fig. 9-52 Dismantled gear oil pump (typical view)

Gear Oil Pump
12
11
10
LK_M2_0005b_01
3 2 1
Fig. 9-53 Crankshaft driven gear oil pump
1 Crankshaft 7 Throttling valve

2 Bearing bracket 8 Driving flange
3 O-ring 9 Nylon bush
4 Housing 10 Crankcase pressure
5 Driven gearwheel 11 Gear oil pump outlet pressure
6 Driving gearwheel 12 Frame
The gear oil pump is fitted to the frame (12) at the non-drive end of the com-
pressor. Bearing bracket (2) and housing (4) are sealed with O-rings (3).
The gear oil pump consists of a driven gearwheel (5) and a driving gear-
wheel (6) attached to the driving flange (8), which is driven by the crank-
shaft (1). The two gearwheels are of the same size and fit snugly in the
pump body. The lubricating oil is carried from the inlet to the delivery side
of the pump by both gearwheels.
Assemble New Assemble the gear oil pump in reverse order of dismanting procedure.
or Used Parts

Electric Motor
9.21 Electric Motor

Special Tools none
Dismantle 1. Remove flywheel guard.

2. Release electric motor from coupling.
Assemble New For detailed assembly instructions see chapter 5.7 Install Electric Motor
or Used Parts and Coupling.
9.22 Coupling
Special Tools none
Dismantle and Assemble 1. Dismantle (or assemble) the coupling according to Fig. 9-54:
1 2 3
LA_L1_0020b_01
Fig. 9-54 Coupling
1 Electric motor
2 Coupling
3 Flywheel
For details about assemble the coupling see 5.7.3 Install Coupling.
For further information about coupling details see manufacturers docu-
mentation Coupling in chapter 13 Appendix.

Flywheel
9.23 Flywheel
Tools
1 2 3
LA_T9_0023b_01
1 Crankshaft
2 Flywheel
3 Pull-of device
Transport and Lifting of For transport and lifting of flywheel, take care to avoid any damage; please
Flywheel refer to section 5.2.1 Safety of Transport.
DANGER
Suspended loads!
Lift flywheel only in the correct manner as described and illustrated in

Flywheel
LA_XX_0044c_01
Fig. 9-56 Transport and lifting of flywheel
Dismantle 1. Dismount coupling.

2. Attach flywheel in the safe manner as described and illustrated in this
Instruction Manual to a lifting device, strapping carefully the ropes.
3. Drain the lube oil from the seal housing through the drain plug before
opening the bearing bracket.
Assemble New For detailed assembly instructions see chapter 5.6.2 Flywheel.
or Used Parts
Final Checks 1. Check radial and face runout as illustrated in Fig. 9-57.
1 2 3 4 5 6 LA_L1_0001b_01
Fig. 9-57 Radial and face runout

2 Flywheel 5 Washer
3 Measuring head 6 Castellated nut for crankshaft

Oil Trap and Crankshaft Seal
Tolerance of radial and face runout must not exceed 0.04 mm.
When checking the face runout, push the crankshaft to one side up to its
stop. The axial clearance of the crankshaft must be eliminated.
9.24 Oil Trap and Crankshaft Seal

Status Completed activities: 9.1, 9.22, 9.23
Special Tools none
Dismantle and Assemble Dismantle or assemble the oil trap and crankshaft seal according to
Fig. 9-58.
1 2 5 1 6
LA_M1_0013b_01
8 7 3 4 7 8

2 O-ring 6 Lip-seal

Bearing Bracket and Main Bearing
Required Checks 1. Check the diametrical clearance between running rings (1) and shaft.
Required clearance: 0.4 - 0.5mm
2. Check the diametrical clearance between spring guide rings (3, 4) and
running rings.
Required clearance: 0.4 - 0.5mm
3. Check the crankshaft surface.
The surface must be in perfect condition in the area where the shaft
seal is fitted.
4. Check the distance between the two spring gruide rings.
The distance must be at least 1.5mm.
5. Check the oil leakage.
Oil leakage should no exceed 3 -5 drops per minute.
9.25 Bearing Bracket and Main Bearing

Special Tools none
Dismantle and Assemble Dismantle or assemble the bearing bracket and main bearing according to
Fig. 9-59.
1 2 3 4 5
LA_M1_0019b_01
Fig. 9-59 Removal of bearing bracket
1 Crankgear
2 Crankshaft
3 Main bearing
4 Bearing bracket
5 Oil trap

Dismantle Crankshaft Sidewards
Required Checks Measure clearance with feeler gauge at the upper circumference between
crankshaft and main bearing.
pendix.
9.26 Dismantle Crankshaft Sidewards

Status Completed activities: 9.1, 9.2, 9.6, 9.7, 9.8, 9.9, 9.11, 9.21, 9.22, 9.23,
9.24,
Special Tools Lifting/balancing device
Dismantle 1. Dismantle connecting rod bearing covers and bearings according to

section 9.17 Connecting Rod Bearing.
2. Lift and secure pistons according to Fig. 9-60.
LK_M1_0009a_01
Fig. 9-60 Lifting of pistons
3. Dismantle gear oil pump according to section 9.20 Gear Oil Pump.
4. Fix bearing bracket non-drive end according to Fig. 9-61.

LK_M1_0006a_01
Fig. 9-61 Fixation of bearing bracket non-drive end
5. Dismantle bearing bracket and main bearing according to section 9.25

Bearing Bracket and Main Bearing.
6. Attach a rope to the crankshaft.
7. Attach a lifting/balancing device to the crankshaft, see Fig. 9-62.
LK_M1_0007a_01
Fig. 9-62 Attach lifting/balancing device

8. Loosen set screw of center bearing (if applicable).

9. Dismantle crankshaft sidewards according to Fig. 9-63.
LK_M1_0008a_01
Fig. 9-63 Dismantle crankshaft sidewards
Required Checks 1. Measure the clearance between the bearing and bearing journal.
Replace bearing if clearance is out of tolerance.
2. Check crankshaft for any damage on bearing journal surface.
Sometimes it is possible to overhaul crankshafts in case of dam-
aged bearing journal surface.
3. Check counterweights (if applicable) for perfect seating and fixation.
Retighten nuts if required.
Assemble New Installation takes place in reverse order to dismantling.

or Used Parts


Clean and Degrease Plant and Compressor Components
10 Clean and Degrease Plant and Compressor

Components
10.1 Cleaning Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 3

10.1.1 Scope and Purpose . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 3
10.1.2 Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 3
10.1.3 Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 4
10.1.4 Safety Measures. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 4
10.1.5 Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 4
10.2 Working Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 5
10.2.1 Workplace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 5
10.2.2 Tools and Facility . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 6
10.3 Select Cleansing Agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 6
10.4 Cleaning Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 8
10.4.1 Mechanical Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 10 - 9
10.4.2 Chemical Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 9
10.4.3 Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 10
10.4.4 Immersion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 10
10.4.5 Wiping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 10
10.4.6 Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 10
10.4.7 Degreasing with Solvent Vapor . . . . . . . . . . . . . . . 10 - 10
10.4.8 Ultrasonic Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 10 - 11
10.5 Conservation of Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 11


Cleaning Specification
10.1 Cleaning Specification
10.1.1 Scope and Purpose

This chapter deals with the cleaning of plant components and compressor
parts to assure that all parts and surfaces exposed to process gas are
cleaned to the required level of cleanliness.
Applicability The cleaning specification is applicable during manufacturing, installation

of the compressor plant on site as well as during preventive maintenance
or repair. It also applies to gas pipes made and/or adapted on site.
cleanliness.
CAUTION
Existing company-internal cleaning instructions must be taken into account

too.
10.1.2 Terms
Significant Surface Any surface which is exposed to process gas.

Cleaning Specification
10.1.3 Principles
Adapt cleaning process to type and extent of contaminant present.
Accomplish adequate cleaning whilst manufacturing, installation and

testing in order to avoid residual contamination and the subsequent re-
contamination of cleaned components.
Prevent risk and dangers by careful selection of cleansing agents.
Use only solvents which have been declared acceptable by national
authorities.
Use effective facilities for checking the level of cleanliness.
Provide effective measures to keep the cleaned component parts clean
until they are used.
10.1.4 Safety Measures

Personnel who use cleansing agents must take safety precautions ac-
cording to the Material Safety Data Sheets (MSDS) when working with
such materials. For general information refer to section 2.3.9 Handling
Chemicals.
DANGER
Health hazard and fire hazard!
Chemicals can be toxic, caustic, flammable and explosive.
Do not eat, drink or smoke in the proximity to chemicals!
Before handling any chemicals,
pay attention to the warning symbols, peril indications and safety
advice on the label of the storage container,
familiarize yourself with procedures in the event of contamination,
poisoning, corrosion, spilling, leakage of unknown substance.
10.1.5 Responsibility
Hazards The superior authority is obliged to inform the personnel handling chemi-
cals about possible dangers to humans and the environment.
flash point,
toxicity,
The superior authority is obliged to instruct personnel using cleansing

agents about their safe use. He must ensure that all necessary precautions
have been are taken when using such chemicals.

Working Environment
Our field supervisor will inform customer personnel about the risks involved
when using cleansing agents. He must be supported by the clients per-
sonnel in charge to ensure safe use and handling.
Training The personnel must be fully trained by the superior authority to carry out
the correct cleaning methods and their attention must be drawn to the se-
rious consequences of faulty cleaning.
The personnel shall take special notice of:
classification and properties of the cleansing agent,
possible dangers (explosion and/or fire risks and other health con-
cerns),
safety precautions for handling cleansing agents,
dealing with an incident,
manufacturers instructions,
appropriate cleaning methods,
disposal procedures.
10.2 Working Environment

Technical aspects to be considered:
Location where cleaning is carried out:
in the workshop,
on installation site.
Period when cleaning is carried out:

during manufacturing,
installation,
pre-commissioning,
maintenance/repair.
State of equipment to be cleaned:

assembled,
disassembled.
Complexity:
big or elongated (pipes) parts,
complicated/dead ends, crevices.
10.2.1 Workplace
The workplace for cleaning and installation has to be clean and as far from
heavy manufacturing and machine tools as possible. Its arrangement shall
make an inadvertent mix-up of cleaned and uncleaned components as well
as the utilization of non-approved material for assembly impossible. The
cleanliness of the workplace must correspond to the commonly accepted
work place for light assembly and testing.

Select Cleansing Agent
Harmless cleaning agents should preferably be applied. The use of harmful

cleaning agents must be limited to a minimum. Components cleaning must
be carried out in closed facilities.
DANGER
Health hazard!
Cleansing agents may impair your health.
Avoid concentrations higher than the MAC-value (Maximum Allowable
Concentration for working area).
Provide adequate ventilation in areas where cleaning operations are
performed.
DANGER
Fire hazard!
Flammable organic solvents, acids or lyes.
Provide adequate ventilation in areas where cleaning operations are
performed.
No open fire.
No smoking.
10.2.2 Tools and Facility

Tools and equipment used for cleaning must either be stored cleanly and
separate from other tools and installations or be cleaned carefully before
each use. This also applies to testing equipment which is used on the
cleaned component parts.
Working surfaces must be cleaned before use and covered with clean,
strong packing paper or polyethylene sheeting.
10.3 Select Cleansing Agent

Special care shall be given to the properties of the cleansing agent re-
garding compatibility with process gas, flammability, toxicity, corrosion ef-
fect, and environmental impact.
Personnel who use cleansing agents must take safety precautions ac-
cording to the Material Safety Data Sheets (MSDS) when working with
such materials. For general information refer to section 2.3.9 Handling
Chemicals.
Health Aspects The ideal agent is non-toxic or at least has a low toxicity. The main factors
to take into consideration are inhalation effects, skin effects and eye ef-
fects.
Environmental Aspects There are four main issues concerning the environment: emission to water,
waste disposal, emission to air and energy.

Select Cleansing Agent
Emission to Water
Contamination of water arises from improper waste disposal, inadequate
waste water treatment or in case of solvents, accidental spillage caused by
improper handling or storage.
Waste Disposal
Degreasing with solvents gives rise to a residue containing oils and
greases. The solvent content can easily be reduced by distillation either in
house or by licensed recycler, thus recovering useful quantities of solvent.
The residue a highly concentrated final waste should be disposed by a
licensed contractor, meeting local regulations.
Cleaning in an aqueous system generates effluent containing chemical
products necessary for the cleaning process and may be contaminated
with oils and greases. This residue must be treated in a waste water treat-
ment plant.
Emission to Air
The limit values of emissions to air due to organic solvents are given in na-
tional regulations.
Energy
When a drying stage is required aqueous cleaning processes can be more
energy intensive than those using solvents.
Organic Solvents The increasingly stringent environment regulations of the last years, regu-
lations including the phasing out of most chlorofluorocarbons (CFC), re-
strictions in the use and banning of some volatile organic compounds
(VOC) led to the necessity to develop alternatives.
CFCs contribute to the depletion of the ozone layer, VOCs are a major
source of photochemical smog and ground level ozone that have harmful
effects on human health and the environment.
Potential users should determine whether the solvent has been declared
acceptable by national authorities.
Acetone
For the cleaning of significant surfaces, we recommend the use of acetone.
Clean parts with a paint brush or a clean, lint-free cleaning tissue
soaked in acetone.
Completely remove liquid and vapors after cleaning.
Purge cleaned spaces with oil-free compressed air till no trace of the
solvent can be detected.

Cleaning Methods
WARNING
Fire and health hazard!
Acetone is flammable. Vapor my cause flash fire. Harmful if swallowed or
inhaled. Causes irritation to skin, eyes and respiratory tract. Affects central
nervous system.
Restrict the use of acetone to a minimum.
No open fire.
No smoking.
Cleansing Agent BLG05

Use Cleansing Agent BLG05 to remove Burckhardt Lubrication Grease
BLG05.
Other cleansing agents can be used for surfaces that are not exposed to
process gas.
Water Soluble Cleansing The manufacturers specification for application of the cleansing agent
Agents shall be strictly observed.
After cleaning using water soluble cleansing agents (e.g. alkaline deter-
gents), thorough rinsing and drying of all components is essential.
Air and Nitrogen Air and nitrogen used for purging, drying or testing after final cleaning (=
cleaning with acetone or other cleansing agents) must be clean, dry (dew
point 29 C or lower) and oil-free. Compressed air can be used. Careful
control of the filter system is vital.
Water Water used for making solutions or for flushing must be tap water or of
equivalent quality. Any inorganic corrosion inhibitor may be used to mini-
mize rusting of ferrous items.
Corrosion Inhibitors Any inorganic corrosion inhibitor may be used in the hydrostatic pressure
test or rinse water to minimize rusting of ferrous items. Sodium nitrite (ap-
proximately 0.5 % by weight) or borax (approximately 1.5 % by weight) is
recommended. The use of these substances must be limited to the specific
applications.
10.4 Cleaning Methods

cleanliness.

Cleaning Methods
CAUTION
Principles Each or a combination of the cleaning methods listed below can be

used depending on the facilities available, size and shape of item, na-
ture of the contamination, accessibility, etc.
Sandblasting is the preferred method to achieve grey, metallic surfaces
for carbon steel items such as gas piping, vessels etc. Except for thor-
oughly removing particles by blowing out, wiping or vacuum cleaning,
no further cleaning is required. The term sandblasting includes shot,
bead, and grit blasting.
Large objects such as long pipes must be cleaned and degreased be-
fore welding together. Open ends of the pipes must be covered with a
temporary leak proof cover to prevent ingress of foreign matter.
Do not clean parts just for better appearance.
The result of the cleaning must meet the requirements of section 10.1.3
Principles.
Select the appropriate method of cleaning according to required level of

cleanliness.
10.4.1 Mechanical Cleaning

For example wire brushing, blast cleaning, scraping or other physical re-
moval of contaminants from equipment. It is generally used as a prelimi-
nary cleaning method or in combination with other methods.
This method is not used for accurately dimensioned components as the
method can cause uneven material loss.
10.4.2 Chemical Cleaning

Normally a preliminary cleaning operation for piping and vessels. This in-
cludes acid pickling (descaling), passivation, derusting, bright dipping, al-
kaline cleaning, etc. Conventional chemical solutions are acceptable
providing they do not leave a residue or are followed by final cleaning.
The manufacturers specification for application of the cleansing agent and
necessary safety precautions must be strictly observed.

Cleaning Methods
10.4.3 Flushing
With this method, the equipment to be cleaned is filled with a flowing sol-
vent or heated detergent solution which is agitated if possible. Thorough
rinsing with clean water and subsequent drying with oil-free dry air or ni-
trogen is required if a detergent is used. If a solvent is used, the vessel
must be thoroughly purged with oil-free, dry air or nitrogen.
10.4.4 Immersion
With this method, the equipment to be cleaned is submerged in a solvent
or detergent solution and scrubbed, if possible. When many parts are to be
cleaned, use two baths, the first to remove most of the contaminants and
the second to remove the remaining contaminants. When the first bath be-
comes dirty, it is discarded and the second becomes the first and a new,
clean, final bath is provided. Briefly immerse non-metallic parts or wipe with
a tissue as described below.
10.4.5 Wiping
Components with readily accessible surfaces may be cleaned with this
method using a solvent or detergent solution. Typical examples are vessels
that can be entered (using only detergent solutions and observing all appli-
cable safety procedures). Non-metallic parts that cannot be immersed be-
cause the solvent causes them to swell, may be cleaned by wiping with a
clean tissue moistened with solvent or detergent solution.
10.4.6 Spraying
The cleansing agent solvent or detergent is discharged at high velocity
through nozzles specially chosen for particular applications. This method is
frequently used on large equipment or piping.
10.4.7 Degreasing with Solvent Vapor

With this method, cleaning is carried out by the flushing action of solvent
vapor which condenses on the cool surface of the component being
cleaned. It has the advantage of continually distilling the solvent so that
only pure solvent contacts the surface. Components must be positioned to
ensure complete drainage. Components with dead ends or pockets from
which condensate cannot be drained should be cleaned with an alternative
method.
Do not vapor degrease non-metallic materials. Limit to brief immersion or
wipe with a tissue moistened with a solvent or detergent solution.

Conservation of Cleanliness
10.4.8 Ultrasonic Cleaning

The cleaning solution is agitated with high frequency by the use of an ultra-
sonic generator, so that contaminants will be detached and thin layers will
lacerate. Especially effective for cleaning of small parts with dead ends or
pockets and crevices.
10.5 Conservation of Cleanliness

Freshly cleaned component parts, which are not immediately installed,
must be protected against re-contamination during transportation and
storing by covering them with polyethylene sheeting, clean strong packing
paper or rust preventing paper. The packing shall not be opened until the
equipment is ready to be installed.
Cleaned components must be stored until installation in a suitable dedi-
cated area free from contamination and always separate from uncleaned
parts to avoid accidental mix-up.
Prior to installation, the cleanliness must be checked again to ensure that
the required level of cleanliness has been maintained.

Conservation of Cleanliness

Decommissioning or Dispose Plant
11 Decommissioning or Dispose Plant
11.1 Preserve Compressor Plant . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 3

11.2 Maintain Plant during Decommissioning. . . . . . . . . . . . . . . . . 11 - 4
11.3 Recommission Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 5
11.4 Dispose Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 5


Preserve Compressor Plant
11.1 Preserve Compressor Plant

Period of Standstill If the standstill period of a compressor plant exceeds 2 month, the com-
Exceeds 2 Month pressor and its auxiliary equipment must be protected against possible
standstill damage by taking appropriate measures for the respective period
of time.
CAUTION
Standstill damage possible!
Due to the numerous possibilities of installation and employment of our
compressors, instructions on preservation depend on application.
General Procedure The following procedure is intended to provide general advice. Depending
on your application, our instructions on preservation are liable to amend-
ment or supplement at any time.
2. Fill crankgear with lubricating oil.

A special corrosion protecting oil from a reputable supplier may be
used during the standstill period.
3. Oil the piston rods well by hand up to the oil shield. Turn the flywheel a
number of times.
Generally, the gas conducting compressor and plant components should

not be protected by oil or grease (leave surfaces dry and untreated).
4. Fill the compressor or the entire compressor system with dry, oil-free
nitrogen.
During the whole standstill period, the plant/compressor should be flushed

continuously through with nitrogen, respectively kept under a slight over-
pressure of 0.20 bar g.
DANGER
Plant/compressor under nitrogen pressure.
system.

Maintain Plant during Decommissioning
DANGER
Health hazard!
symptoms.
5. To prevent corrosion in the vicinity of the cylinder and down to the guide
bearings, insert moisture absorbent agent e.g. VCI mats (Volatile
Corrosion Inhibitor) in the cylinder, valve spaces and distance piece.
Experience has shown that in the area of the lubricated crankgear, ab-
sorbent agents are not necessary.
CAUTION
Forgotten absorbent agent mats can damage the compressor!
Record number and location of absorbent agent packs/mats in the
compressor.
Make sure the flywheel can still be turned manually.
11.2 Maintain Plant during Decommissioning

1. Check condition of moisture absorbent agent every six month and re-
place if necessary.
2. To protect the bearings, turn the flywheel for a few minutes by hand
every week (approximately 10 rotations).
Be careful about absorbent agent packs/mats in the cylinders!
3. Large difference between day and night temperatures can lead to con-
densation in the electric motor. Due attention should be given to this oc-
currence during the standstill period and before putting into operation
again (dry out, heat, ventilate, check insulation resistance, etc.).
4. Annually conduct an condition check of the complete compressor

system.

Recommission Plant
11.3 Recommission Plant

Carefully check the complete compressor system before recommissioning.
In particular, the functionality and operation of the mechanical and elec-
trical safety devices.
Perform a hydrostatic pressure test of all the cooling chambers, using
the specified pressure test data.
We advise customers to arrange for one of our specialists to be present

when this work is carried out.
11.4 Dispose Components

Compressor Components At the end of its lifetime, the compressor components must be disposed ac-
cording to all applicable regulations. We recommend to contact a company
specializing in recycling and waste disposal.
Lubricants Oils must be recycled, return them to the supplier.

Take care of the environment: dispose of lubricants according to na-
tional regulations.
It is strictly forbidden to dispose of lubricants in toilets, cleaning rooms,
water drains or to discharge to the ground or waste containers etc.
Chemicals Take care of the environment: dispose of chemicals according to na-

tional regulations.
It is strictly forbidden to dispose of chemicals in toilets, cleaning rooms,
water drains, into the ground or waste containers etc.
Cleansing Agents Degreasing with solvents gives rise to a residue containing oils and
greases. The solvent content can easily be reduced by distillation either in
house or by licensed recycler, thus recovering useful quantities of solvent.
The residue a highly concentrated final waste should be disposed by a
licensed contractor, meeting local regulations.
Cleaning in an aqueous system generates effluent containing chemical
products necessary for the cleaning process and may be contaminated
with oils and greases. This residue must be treated in a waste water treat-
ment plant.

Dispose Components

Spare Parts
12 Spare Parts
12.1 Order Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 3

12.1.1 Order Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 3
12.1.2 Original Spare Parts Only! . . . . . . . . . . . . . . . . . . . . 12 - 3
12.1.3 Importance of Spares Inventory . . . . . . . . . . . . . . . . 12 - 4
12.1.4 Spare Parts Recommendation . . . . . . . . . . . . . . . . . 12 - 5
12.2 Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 8
12.3 Spare Parts Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 17

Spare Parts

Spare Parts
Order Spare Parts
12.1 Order Spare Parts

Required Data When ordering spare parts, always provide the following data:
Compressor type: 2K158-2D_1
Compressor serial no.: 100822 or 100823
Spare part designation
Code no. Example: code no. for a 1st stage discharge valve is C41200
Approach 1. Find the demanded spare part on respective spare parts drawing in
section 12.3 Spare Parts Drawings and note the corresponding code
no.
Bold printed code no. on spare parts drawings refer to detail drawing of the
respective spare part.
2. Consult the spare parts list in section 12.2 Spare Parts List and look up
the related spare part designation.
3. Order spare parts (address see section 12.1.1 Order Address) pro-
viding compressor type and serial no.
12.1.1 Order Address
Spare Parts
Im Link 5
P.O. Box 65
CH-8404 Winterthur
Tel. +41 (0)52 262 55 00 Fax +41 (0)52 262 00 53
For the address of your nearest Agent see www.burckhardtcompres-

sion.com, Your Contacts Worldwide, Agents Worldwide.
12.1.2 Original Spare Parts Only!

We only assume liability for original spare parts which have been supplied
by Burckhardt Compression AG. Spare parts and plant accessories which
have not been delivered by us may not correspond to the original or modi-
fied design.

Spare Parts
Order Spare Parts
CAUTION
Increased risk!
components and/or their operational safety may be impaired.
Do not modify parts/spare parts.
Only use original spare parts.
Never use unsuitable material.
Please note that specific fabrication and supply specifications often exist
for parts supplied by Burckhardt Compression AG as well as by sub-sup-
pliers. We can always offer you spare parts which correspond to the latest
technical standards and comply with the newest legal regulations.
12.1.3 Importance of Spares Inventory

A stock of the most important replacement and wear parts at the com-
pressor site is a vitally factor for the on-going operation and service avail-
ability of the compressor.
A distinction must be made between different kind of spare parts on stock:
Commissioning spare parts.
Wear parts for 2 years operation (section 12.1.4 Spare Parts Recom-
mendation, column W).
Capital spare parts for break down situations (section 12.1.4 Spare
Parts Recommendation, column C). These parts are not always avail-
able in stock. We therefore advise you to have your own stock-keeping.
Our Customer Support Service will be glad to provide you a corresponding

tender for wear parts and/or capital spare parts. Contact address see sec-
tion 12.1.1 Order Address.

Spare Parts
Order Spare Parts
12.1.4 Spare Parts Recommendation

We recommend keeping the following spare parts in the listed quantities in
stock:
(W = wear parts, C = capital spare parts)
Code No Bezeichnung Designation W C Qty

C01620 O-Ring zu Zylinderdeckel 1. Stufe O-ring for cylinder cover 1st stage X 1
C02620 O-Ring zu Zylinderdeckel 2. Stufe O-ring for cylinder cover X 1
2nd stage
C11110 Kolbenmantel 1. Stufe Piston skirt 1st stage X 1
C11500 Kolbenstange 1. Stufe Piston rod 1st stage X 0
C11520 Unterlegscheibe zu Kolbenstange Washer for piston rod 1st stage X 1
1. Stufe
C11610 O-Ring zu Spannmutter SUPER- O-ring for SUPERBOLT nut X 0
BOLT 1. Stufe 1st stage
C11700 lschirm zu Kolbenstange, Oil shield for piston rod, complete X 0
komplett 1. Stufe 1st stage
C12110 Kolbenmantel 2. Stufe Piston skirt 2nd stage X 1
C12500 Kolbenstange 2. Stufe Piston rod 2nd stage X 0
C12520 Unterlegscheibe zu Kolbenstange Washer for piston rod 2nd stage X 1
2. Stufe
C12610 O-Ring zu Spannmutter SUPER- O-ring for SUPERBOLT nut X 0
BOLT 2. Stufe 2nd stage
C12700 lschirm zu Kolbenstange, Oil shield for piston rod, complete X 0
komplett 2. Stufe 2nd stage
C21015 Dichtung zu Ventildeckel 1. Stufe Gasket for valve cover 1st stage X 8
C21200 Saugventil, komplett 1. Stufe Suction valve, complete 1st stage X 1
C21210 Ventilkit 1. Stufe Valve kit 1st stage X 0
C21330 Zentralschraube 1. Stufe Center bolt 1st stage X 2
C21370 Hubscheibe 1. Stufe Distance disc 1st stage X 6
C21380 Ventilplatte 1. Stufe Valve disc 1st stage X 2
C21390 Dmpferplatte 1. Stufe Damper disc 1st stage X 2
C21400 Ventilfeder zu Saugventil 1. Stufe Valve spring for suction valve X 32
1st stage
C22015 Dichtung zu Ventildeckel 2. Stufe Gasket for valve cover 2nd stage X 2
C22200 Saugventil, komplett 2. Stufe Suction valve, complete 2nd stage X 1
C22210 Ventilkit 2. Stufe Valve kit 2nd stage X 0
C22330 Zentralschraube 2. Stufe Center bolt 2nd stage X 1
C22370 Hubscheibe 2. Stufe Distance disc 2nd stage X 0
C22380 Ventilplatte 2. Stufe Valve disc 2nd stage X 1
C22390 Dmpferplatte 2. Stufe Damper disc 2nd stage X 1
C22400 Ventilfeder zu Saugventil 2. Stufe Valve spring for suction valve X 16
2nd stage

Spare Parts
Order Spare Parts

C31001 Gesteuertes Saugventil, komplett Controlled suction valve, X 1
1. Stufe complete 1st stage
C31030 Spezialmutter 1. Stufe Special nut 1st stage X 1
C31040 Spannstift 1. Stufe Spring dowel sleeve 1st stage X 1
C32001 Gesteuertes Saugventil, komplett Controlled suction valve, X 1
2. Stufe complete 2nd stage
C32030 Spezialmutter 2. Stufe Special nut 2nd stage X 1
C32040 Spannstift 2. Stufe Spring dowel sleeve 2nd stage X 1
C41015 Dichtung zu Ventildeckel 1. Stufe Gasket for valve cover 1st stage X 0
C41200 Druckventil, komplett 1. Stufe Discharge valve, complete X 1
1st stage
C41210 Ventilkit 1. Stufe Valve kit 1st stage X 0
C41330 Zentralschraube 1. Stufe Center bolt 1st stage X 2
C41350 Sicherungsscheibe 1. Stufe Locking disc 1st stage X 2
C41370 Hubscheibe 1. Stufe Distance disc 1st stage X 0
C41380 Ventilplatte 1. Stufe Valve disc 1st stage X 2
C41390 Dmpferplatte 1. Stufe Damper disc 1st stage X 2
C41400 Ventilfeder zu Druckventil 1. Stufe Valve spring for discharge valve X 32
1st stage
C42015 Dichtung zu Ventildeckel 2. Stufe Gasket for valve cover 2nd stage X 2
C42200 Druckventil, komplett 2. Stufe Discharge valve, complete X 1
2nd stage
C42210 Ventilkit 2. Stufe Valve kit 2nd stage X 0
C42330 Zentralschraube 2. Stufe Center bolt 2nd stage X 1
C42350 Sicherungsscheibe 2. Stufe Locking disc 2nd stage X 1
C42370 Hubscheibe 2. Stufe Distance disc 2nd stage X 0
C42380 Ventilplatte 2. Stufe Valve disc 2nd stage X 1
C42390 Dmpferplatte 2. Stufe Damper disc 2nd stage X 1
C42400 Ventilfeder zu Druckventil 2. Stufe Valve spring for discharge valve X 16
2nd stage
C51124 Stopfbchsring Nr. 1 1. Stufe Gland ring No. 1 1st stage X 0
C51134 Druckfeder zu Stopfbchsring Spring for gland ring 1st stage X 0
1. Stufe
C52124 Stopfbchsring Nr. 1 2. Stufe Gland ring No. 1 2nd stage X 0
C52134 Druckfeder zu Stopfbchsring Spring for gland ring 2nd stage X 0
2. Stufe
M00435 O-Ring zu Gestelldeckel, mittel- O-ring for medium-sized frame X 8
gross cover
M10200 Kurbelwellenlager Crankshaft bearing X 1
M10800 Wellendichtung, gasdicht Shaft seal, gastight X 1
M10805 Laufring zu Wellendichtung Running ring for shaft seal X 2
M10810 O-Ring zu Wellendichtung O-ring for shaft seal X 2

Spare Parts
Order Spare Parts

M10831 Lippendichtung zu Wellen- Lipseal for shaft seal M10800 X 1
dichtung M10800
M10835 Dichtring zu Wellendichtung Sealing ring for shaft seal X 2
M20805 Filtereinsatz, komplett Oil strainer, complete X 1
M20815 O-Ring zu lfilter O-ring for oil strainer X 1
M30600 Kreuzkopfzapfen Crosshead pin X 1
M30620 Sicherungsring zu Kreuzkopf- Circlip for crosshead pin X 0
zapfen
M40410 Kreuzkopfzapfenlager, komplett Crosshead pin bearing, complete X 1
M40420 Sicherungsring zu Kreuzkopf- Circlip for crosshead pin bearing X 2
zapfenlager
M50060 Lagerbchse Bearing bush X 1
M50510 labstreifring, oberer, komplett Oil scraper ring upper, complete X 2
M50515 labstreifring, mittlerer, komplett Oil scraper ring middle, complete X 2
M50520 labstreifring, unterer, komplett Oil scraper ring lower, complete X 2
M50545 Federplatte Spring plate X 2

Spare Parts
Spare Parts List
12.2 Spare Parts List
Code No Bezeichnung Designation W C

A0*400 Manometer Gasdruck Saugseite Pressure gauge, gas suction side
A0*410 Manometer Gasdruck Druckseite Pressure gauge, gas discharge side
A00210 Drosselventil zu Manometer, komplett Throttling valve for pressure gauge,
complete
A00215 Dichtung zu Manometerverschraub- Gasket for pressure gauge connection
ung
A00255 Distanzstck zu Manometerventil Distance piece for throttling valve
A00260 Rohranschluss zu Manometerventil Pipe union for throttling valve
A00265 Dichtung zu Rohranschluss Gasket for pipe union
A00270 Reduziernippel zu Manometerventil Reduction piece for throttling valve
A00300 Satz Manometer, Gasseite Set of pressure gauges, gas side
A00630 Satz Manometer zu lpumpe Set of pressure gauges for oil pump
A00700 Manometer fr Kurbelgehusedruck Pressure gauge, pressure in
crankgear
A00710 Manometer fr ldruck Pressure gauge, oil pressure
A01400 Manometer Gasdruck Saugseite Pressure gauge, gas suction side
1. Stufe 1st stage
A01410 Manometer Gasdruck Druckseite Pressure gauge, gas discharge side
1. Stufe 1st stage
A02410 Manometer Gasdruck Druckseite Pressure gauge, gas discharge side
2. Stufe 2nd stage
A20009 Rohranschluss, Splgaseintritt Pipe union, purge gas, inlet
A20012 Rohranschluss, Splgasaustritt, Pipe union, purge gas, outlet frame
Gestell
A20115 Rohranschluss mit Kugelkopf, Pipe union with spherical head,
komplett complete
A20120 Dichtung zu Rohranschluss mit Gasket for pipe union with spherical
Kugelkopf head
A20205 Rohranschluss zu lpumpe Pipe union for oil pump
A20310 Rohranschluss, komplett Pipe union, complete
A20325 Rohrleitung, komplett Pipe, complete
A20355 Rohranschluss, komplett Pipe union, complete
A20375 Verschlussschraube Screw plug
A20450 Rohranschluss, komplett zu Kreuz- Pipe union, complete for crosshead
kopfkhlung cooling
A20455 Dichtung zu Rohranschluss Kreuz- Gasket for pipe union, crosshead
kopfkhlung
A20480 Rohranschluss, komplett zu Pipe union, complete for thermal
Wrmekragen (Gestell) barrier (frame)

Spare Parts
Spare Parts List

A20501 Rohranschluss Nr. 1, komplett, Pipe union No. 1, complete cylinder
Zylinder
A20603 Verschraubung mit Nippel Pipe union with nipple
A20604 Dichtung zu Verschraubung A20603 Gasket for A 20603
A30200 Rohranschluss Leckgasaustritt Pipe union, gas leakage outlet
A40000 Satz Dichtungen & O-Ringe komplett Set of gaskets/O-rings, complete per
pro Kompressor compressor
C0*001 Zylinder Cylinder
C0*210 Gewindebolzen zu Zylinderdeckel Threaded bolts for cylinder cover
C0*215 6-kt Mutter zu Zylinderdeckel Hexagonal nut for cylinder cover
C0*220 Gewindebolzen zu Saugventildeckel Threaded bolts for suction valvecover
C0*225 Gewindebolzen zu Druckventildeckel Threaded bolts for discharge valve-
cover
C0*230 6-kt Mutter zu Ventildeckel Hexagonal nut for valve cover
C0*240 Gewindebolzen zu Kolbenstangen- Threaded bolts for piston rod gland
stopfbchse
C0*245 6-kt Mutter zu Kolbenstangen- Hexagonal nut for piston rod gland
stopfbchse
C00001 Zylinder Cylinder
C00200 Gewindebolzen zu Zylinder/Gestell Threaded bolts for cylinder/frame, dis-
(Distanzstck) tance piece
C00205 6-kt Mutter zu Zylinder/Gestell Hexagonal nut for cylinder/frame
C01001 Zylinder 1. Stufe Cylinder 1st stage
C01510 Rohranschluss, Saug-/Druckseite, Pipe union suction-/discharge
komplett 1. Stufe side,complete 1st stage
C01513 Anschweissstck, Saug-/Druckseite Stub end, suction-/discharge side
1. Stufe 1st stage
C01519 Dichtung zu Saug-/Druckleitung 1. Gasket for suction-/discharge pipe
Stufe 1st stage
C01520 Flansch zu Rohranschluss 1. Stufe Flange for pipe union 1st stage
C01605 Zylinderdeckel, komplett 1. Stufe Cylinder cover, complete 1st stage
C01620 O-Ring zu Zylinderdeckel 1. Stufe O-ring for cylinder cover 1st stage X
C01630 Putzdeckel 1. Stufe Cleaning cover 1st stage
C02001 Zylinder 2. Stufe Cylinder 2nd stage
C02170 Verschlussschraube Nr. 1, gross Screw plug No. 1, large 2nd stage
2. Stufe
C02175 Dichtung zu Verschlussschraube Nr.1, Gasket for large screw plug No. 1
gross 2. Stufe 2nd stage
C02510 Rohranschluss, Saug-/Druckseite, Pipe union suction-/discharge side,
komplett 2. Stufe complete 2nd stage
C02513 Anschweissstck, Saug-/Druckseite Stub end, suction-/discharge side
2. Stufe 2nd stage
C02519 Dichtung zu Saug-/Druckleitung Gasket for suction-/discharge pipe
2. Stufe 2nd stage

Spare Parts
Spare Parts List

C02520 Flansch zu Rohranschluss 2. Stufe Flange for pipe union 2nd stage
C02605 Zylinderdeckel, komplett 2. Stufe Cylinder cover, complete 2nd stage
C02620 O-Ring zu Zylinderdeckel 2. Stufe O-ring for cylinder cover 2nd stage X
C02630 Putzdeckel 2. Stufe Cleaning cover 2nd stage
C1*100 Kolben, komplett Piston, complete
C1*110 Kolbenmantel Piston skirt X
C1*120 Oberer Kolbenboden Upper piston crown
C1*130 Unterer Kolbenboden Lower piston crown
C1*500 Kolbenstange Piston rod X
C1*520 Unterlegscheibe zu Kolbenstange Washer for piston rod X
C1*530 Einlegfederkeil Sunk key
C1*550 Spannmutter SUPERBOLT zu SUPERBOLT nut for piston
Kolben
C1*610 O-Ring zu Spannmutter SUPER- O-ring for SUPERBOLT nut X
BOLT
C1*700 lschirm zu Kolbenstange, komplett Oil shield for piston rod, complete X
C11100 Kolben, komplett 1. Stufe Piston, complete 1st stage
C12100 Kolben, komplett 2. Stufe Piston, complete 2nd stage
C2*000 Saugventil, Einbau Installation of suction valve
C2*005 Ventildeckel, Saugventil ohne Stell- Valve cover, suction valve without
zylinder actuator
C2*010 Ventildeckel, Saugventil mit Stell- Valve cover, suction valve with
zylinder actuator
C2*015 Dichtung zu Ventildeckel Gasket for valve cover X
C2*020 Ventillaterne zu Saugventil Valve lantern for suction valve
C2*200 Saugventil, komplett Suction valve,complete X
C2*210 Ventilkit Valve kit X
C2*310 6-kt Mutter zu Saugventilkrper Hexagonal nut for suction valve body
C2*320 Saugventilsitz Suction valve seat
C2*330 Zentralschraube Center bolt X
C2*350 Sicherungsscheibe Locking disc
C2*360 Saugventilfnger Suction valve guard
C2*370 Hubscheibe Distance disc X
C2*380 Ventilplatte Valve disc X
C2*390 Dmpferplatte Damper disc X
C2*400 Ventilfeder zu Saugventil Valve spring for suction valve X
C2*430 Zylinderstift Cylindrical pin
C21000 Saugventil, Einbau 1. Stufe Installation of suction valve 1st stage
C22000 Saugventil, Einbau 2. Stufe Installation of suction valve 2nd stage
C3*001 Gesteuertes Saugventil, komplett Controlled suction valve, complete X

Spare Parts
Spare Parts List

C3*010 Abhebevorrichtung, komplett zu Unloader complete for suction valve
Saugventil
C3*020 Druckhlse Pressure sleeve
C3*030 Spezialmutter Special nut X
C3*040 Spannstift Spring dowel sleeve X
C3*060 Druckfeder Spring
C3*070 Greiferglocke, komplett Finger unloader, complete
C3*400 Stellzylinder zu gesteuertem Actuator for controlled suction valve
Saugventil
C3*410 Stellzylinder, komplett Actuator, complete
C3*413 Nippel Nipple
C3*421 Druckbolzen zu Stellzylinder Pressure pin, actuator
C3*422 Spannscheibe USIT Strain washer USIT
C3*423 Unterlegscheibe Washer
C3*424 6-kt Mutter, selbstsichernd Self locking hexagonal nut
C3*428 Fhrungsbchse Guide bush
C3*429 Dichtung zu Fhrungsbchse Gasket for guide bush
C3*433 Deckel zu Stellkolben Cover for actuator piston
C3*445 Druckfeder Nr. 3, Medium, zu Stellkol- Spring No. 3, Medium, for actuator
ben piston
C3*450 Membran Stellkolben, komplett Diaphragm actuator piston
C3*451 Dichtungen zu Stellkolben Gaskets for actuator piston
C31000 Frdermengen Regulierung 1.Stufe Flow control 1st stage
C31300 Gesteuertes Saugventil, komplett Controlled suction valve, complete
1. Stufe 1st stage
C31400 Stellzylinder zu gesteuertem Actuator for controlled suction valve
Saugventil 1. Stufe 1st stage
C32000 Frdermengen Regulierung 2.Stufe Flow control 2nd stage
C32300 Gesteuertes Saugventil, komplett Controlled suction valve, complete
2. Stufe 2nd stage
C32400 Stellzylinder zu gesteuertem Actuator for controlled suction valve
Saugventil 2. Stufe 2nd stage
C4*000 Druckventil, Einbau Installation of discharge valve
C4*005 Ventildeckel, Druckventil Valve cover, discharge valve
C4*015 Dichtung zu Ventildeckel Gasket for valve cover X
C4*020 Ventillaterne zu Druckventil Valve lantern for discharge valve
C4*200 Druckventil, komplett Discharge valve, complete X
C4*210 Ventilkit Valve kit X
C4*310 6-kt Mutter zu Druckventilkrper Hexagonal nut for valve body
C4*320 Druckventilsitz Discharge valve seat
C4*330 Zentralschraube Center bolt X
C4*350 Sicherungsscheibe Locking disc X

Spare Parts
Spare Parts List

C4*360 Druckventilfnger Discharge valve guard
C4*370 Hubscheibe Distance disc X
C4*380 Ventilplatte Valve disc X
C4*390 Dmpferplatte Damper disc X
C4*400 Ventilfeder zu Druckventil Valve spring for discharge valve X
C4*430 Zylinderstift Cylindrical pin
C41000 Druckventil, Einbau 1. Stufe Installation of discharge valve 1st
stage
C42000 Druckventil, Einbau 2. Stufe Installation of discharge valve 2nd
stage
C42200 Druckventil, komplett 2. Stufe Discharge valve, complete 2nd stage X
C5*000 Kolbenstangenstopfbchse Piston rod gland
C5*106 Stopfbchsflansch Gland flange
C5*108 Zwischenring Nr. 1 Intermediate ring No. 1
C5*115 Stopfbchskammer Nr. 1 Gland chamber No. 1
C5*116 Stopfbchskammer Nr. 2 Gland chamber No. 2
C5*124 Stopfbchsring Nr. 1 Gland ring No. 1 X
C5*134 Druckfeder zu Stopfbchsring Spring for gland ring X
C50905 Stopfbchsleckgasleitung, komplett Piston rod gland leakage return line,
complete
C50910 Rohranschluss Nr. 1, komplett zu Pipe union, No. 1, complete for gland
Stopfbchsflansch flange
C50911 Dichtung zu Rohranschluss C50910 Gasket for pipe union C50910
C52000 Kolbenstangenstopfbchse 2. Stufe Piston rod gland 2nd stage
L10010 Schwungrad Flywheel
L10120 Kupplungsschraube, komplett Coupling bolt, complete
L10310 Motorkupplung/Motorwelle Motor coupling/Motor shaft
L10330 Zwischenstck Intermediate piece
L2*001 Rckschlagventil, komplett Non-return valve, complete
L2*100 Gehuse zu L2_000, komplett Housing for L2_000, complete
L2*110 Ring Ring
L2*500 Druckventil, komplett zu NRV Discharge valve, complete for NRV
L2*510 Ventilsitz zu Rckschlagventil Valve seat for non-return valve
L2*520 Hubscheibe, Rckschlagventil Distance disc, non-return valve
L2*530 Ventilplatte, Rckschlagventil Valve disc, non-return valve
L2*550 Dmpferplatte, Rckschlagventil Damper disc for non-return valve
L2*560 Rckschlagventilfnger Non-return valve guard
L2*570 Zentralschraube zu Rckschlagventil Center screw for non-return valve
L2*580 6-kt Mutter, zu Rckschlagventil, Self locking hexagonal nut for NRV
selbstsichernd
L2*590 Unterlegscheibe zu Rckschlagventil Washer for non-return valve

Spare Parts
Spare Parts List

L2*600 Zylinderstift zu Rckschlagventil Cylindrical pin for non-return valve
M00015 Gestell Frame
M00200 Lagerschild, Nichtantriebseite Bearing bracket, non-drive end
M00205 O-Ring zu Lagerschild, Nichtantrieb- O-ring for bearing bracket, non-drive
seite end
M00260 Lagerschild, Antriebseite Bearing bracket, drive-end
M00265 O-Ring zu Lagerschild, Antriebseite O-ring for bearing bracket, drive-end
M00410 Gestelldeckel, gross Frame cover, large
M00420 O-Ring zu Gestelldeckel, gross O-ring for large-sized frame cover
M00425 Gestelldeckel, mittelgross Frame cover, medium-sized
M00435 O-Ring zu Gestelldeckel, mittelgross O-ring for medium-sized frame cover X
M00440 Gestelldeckel, klein Frame cover, small-sized
M00450 O-Ring zu Gestelldeckel, klein O-ring for small-sized frame cover
M00470 Putzdeckel zu Gestell Cleaning cover for frame
M00475 Dichtung zu Putzdeckel Gasket for cleaning cover
M00485 Gestelldeckel zu Steuerapparat Frame cover for control device
M00490 O-Ring zu Gestelldeckel-Steuer- O-ring for frame cover of control
apparat device
M00705 Deckel zu Wrmesperre Cover for thermal barrier
M00710 Dichtung zu Deckel, Wrmesperre Gasket for cover, thermal barrier
M00735 Verschlusschraube zu Wrmesperre Screw plug for thermal barrier
M00740 Dichtung zu Verschlusschraube, Gasket for screw plug, thermal barrier
Wrmesperre
M00810 O-Ring, gross zu Gestell/Zylinder O-ring, large-sized for frame/cylinder
M00820 O-Ring, klein zu Gestell/Zylinder- O-ring, small-sized for frame/cylinder-
bolzen bolt
M10010 Kurbelwelle mit Gegengewicht, ko- Crankshaft, complete with counter-
mplett weight
M10015 Kurbelwelle ohne Gegengewicht Crankshaft without counterweights,
complete
M10020 Einlegfederkeil zu Kurbelwelle Sunk key for crankshaft
M10025 U-scheibe zu Kurbelwelle Washer for crankshaft
M10030 6-kt Kronenmutter zu Kurbelwelle Castellated hexagonal nut for crank-
shaft
M10035 Splint zu Kurbelwelle Split pin for crankshaft
M10070 6-kt Kronenmutter zu Gegengewicht Castellated hexagonal nut for counter-
weight
M10071 6-kt Mutter zu Gegengewicht Hexagonal nut for counterweight
M10095 Positionsstift zu Kurbelwelle/ Cylindrical pin for crankshaft/counter-
Gegengewicht weight
M10100 Schraube zu Gegengewicht Screw for counterweight
M10105 Sicherungsdraht Looking wire

Spare Parts
Spare Parts List

M10106 NORD-LOCK-Sicherungsscheiben- NORD-LOCK washer pair for
paar zu M10100 M10100
M10200 Kurbelwellenlager Crankshaft bearing X
M10600 lfang & Wellendichtung Oil trap & shaft seal
M10610 lfang Oil trap
M10620 O-Ring zu lfang O-ring for oil trap
M10800 Wellendichtung, gasdicht Shaft seal, gastight X
M10805 Laufring zu Wellendichtung Running ring for shaft seal X
M10810 O-Ring zu Wellendichtung O-ring for shaft seal X
M10815 Federfhrungsring mit Zylinderstift Spring guide ring with cylindrical pin
M10820 Federfhrungsring Spring guide ring
M10825 Druckfeder zu Wellendichtung Spring for shaft seal
M10831 Lippendichtung zu Wellendichtung Lipseal for shaft seal M10800 X
M10800
M10835 Dichtring zu Wellendichtung Sealing ring for shaft seal X
M10840 Flachdichtung (Gummi) zu Wellen- Flat rubber gasket for shaft seal
dichtung
M20000 Zahnradlpumpe am Kompressor, Gear oil pump on compressor,
komplett complete
M20010 Gehuse zu M20000 Housing for M20000
M20030 O-Ring Nr. 1 zu lpumpe O-ring No. 1 for oil pump
M20040 Antriebsscheibe, komplett Driving flange, complete
M20060 Zahnrad, treibend Driving gearwheel
M20070 Einlegfederkeil Sunk key
M20080 Sicherungsring zu Zahnrad, treibend Circlip for driving gearwheel
M20090 Zahnrad, getrieben Driven gearwheel
M20100 Deckel zu M20000 Cover for M20000
M20120 O-Ring Nr. 2 zu lpumpe O-ring No. 2 for oil pump
M20210 Verschlussschraube EO Screw plug EO
M20400 Drosselventil zu Manometer, komplett Throttling valve for pressure gauge,
complete
M20401 Ventilgehuse Valve housing
M20402 O-Ring zu Drosselventil O-ring for throttling valve
M20403 Dichtung zu Drosselventil Gasket for throttling valve
M20404 Ventilspindel, komplett Valve spindle, complete
M20406 Druckring zu Drosselventil Pressure ring for throttling valve
M20407 Packungsring zu Drosselventil Packing ring for throttling valve
M20408 berwurfmutter zu M20400 Gland nut for M20400
M20409 Handrad zu Drosselventil Hand wheel for throttling valve
M20410 Manometerverschraubung 3-teilig zu Pressure gauge connection 3-pieces
M20400 for M20400

Spare Parts
Spare Parts List

M20411 Dichtung zu Manometerverschrau- Gasket for pressure gauge connection
bung
M20412 Dichtung zu Manometer Gasket for pressure gauge
M20417 Packungsring zu Drosselventil Packing ring for throttling valve
M20500 berstrmventil, komplett Relief valve, complete
M20505 Ventilgehuse Valve housing
M20535 Ventilkrper Valve body
M20540 Federfhrung Spring guide
M20545 Druckfeder Spring
M20550 Beilage zu Druckfeder (Dichtung) Washer for spring (gasket)
M20555 Ventilsitz Valve seat
M20560 Dichtung zu Ventilsitz, lberstrm- Gasket for valve seat relief valve
ventil
M20600 Filter im Gestell Filter element in frame
M20605 RASCHIG-Filter, komplett (separat) RASCHIG filter element, complete
(separately)
M20700 lschauglas, komplett Sight glass for oil level, complete
M20710 Schauglasfassung Sight glass holder
M20715 Schauglas Sight glass
M20720 Dichtung zu lschauglas Gasket for sight glass
M20725 O-Ring zu lschauglas O-ring for sight glass
M20800 lfilter im Kurbeltrieb Oil strainer in crankgear
M20805 Filtereinsatz, komplett Oil strainer, complete X
M20810 Deckel zu lfilter Cover for oil strainer
M20815 O-Ring zu lfilter O-ring for oil strainer X
M20900 lablass, komplett Oil drain, complete
M20905 Einschraubnippel Nipple
M20910 lablassschraube Oil drain screw
M20915 Verschlusskappe Cap
M20920 Dichtung zu lablass Gasket for oil drain
M20925 Dichtung zu lablass Gasket for oil drain
M20950 lfllventil, komplett Oil feeding valve, complete
M20955 Ventilgehuse zu M20950 Valve housing for M20950
M20960 Anschlag zu M20950 Stop for M20950
M20965 Kugel zu lfllventil Ball for oil feeding valve
M20970 Konische Druckfeder zu lfllventil Conical spring for oil feeding valve
M20975 Sicherungsring zu lfllventil Circlip for oil feeding valve
M20980 Dichtung zu lfllventil Gasket for oil feeding valve
M20985 Verschlussschraube EO zu lfllventil Screw plug EO for oil feeding valve
M3*005 Kreuzkopf, komplett Crosshead, complete
M3*065 Querkeile (Satz pro Kolbenstange) Set of wedges (set per piston rod)

Spare Parts
Spare Parts List

M3*080 Querkeil, oben Upper wedge
M3*085 Querkeil, unten Lower wedge
M3*090 Sicherungsplatte zu Querkeil Locking plate for wedges
M3*095 Passschraube zu Querkeil, komplett Dowl bolt for wedges, complete
M30000 Kreuzkopf-Kolbenstangenverbindung Crosshead-piston rod connection
M30065 Querkeile (Satz pro Kolbenstange) Set of wedges (set per piston rod)
M30600 Kreuzkopfzapfen Crosshead pin X
M30620 Sicherungsring zu Kreuzkopfzapfen Circlip for crosshead pin X
M40000 Schubstange, komplett, inklusive La- Connecting rod, complete with bear-
ger ings
M40010 Schubstange ohne Lager Connecting rod, without bearings
M40020 Gewindebolzen zu Schubstange Connecting rod bolt
M40060 Sicherung zu Schubstange Locking plate for connecting rod
M40300 Schubstangenlager Connecting rod bearing
M40410 Kreuzkopfzapfenlager, komplett Crosshead pin bearing, complete X
M40420 Sicherungsring zu Kreuzkopfzapfen- Circlip for crosshead pin bearing X
lager
M5*000 Fhrungslager & labstreifung Guide bearing & oil scraping
M50000 Fhrungslager & labstreifung Guide bearing & oil scraping
M50020 Fhrungslagergehuse mit Bchse Guide bearing casing with bush
M50060 Lagerbchse Bearing bush X
M50080 Kronenring Crown ring
M50090 Deckel zu labstreifer Cover for oil scraper
M50091 Deckel zu Deckel Cover for cover
M50100 O-Ring zu Deckel labstreifer O ring for cover oil scraper
M50110 Schutzdeckel Protection cover
M50120 USIT Ring zu 6-kt Schraube Strain washer USIT
M50130 Innen 6-kt-Schraube Allen screw
M50140 Schwerspannstift Rollpin (Heavy pattern spring dowel
sleeve)
M50510 labstreifring, oberer, komplett Oil scraper ring upper, complete X
M50515 labstreifring, mittlerer, komplett Oil scraper ring middle, complete X
M50520 labstreifring, unterer, komplett Oil scraper ring lower, complete X
M50545 Federplatte Spring plate X

Spare Parts
Spare Parts Drawings
12.3 Spare Parts Drawings
Bold printed code no. on spare parts drawings refer to detail drawing of the
respective spare part.
Overview
Title Drawing No.

Compressor layout 126000501
Compressor sectional view 126000500
Gas System
Title Drawing No.

Non-return valve 126000492
Lubricating System
Title Drawing No.

Gear oil pump 126000078
Pressure gauge and throttling 126000033
Details for oil system 126000036
Crankgear
Title Drawing No.

Crankgear with gear oil pump 126000077
Crankgear driven end 126000079
Crankshaft seal 126000020
Raschig filter element in fram 126000034
Crosshead keys 126000081
Guide bearing and oil scrapers 126000085
Cylinder
Title Drawing No.

Labyrinth piston 126000024
Installation of suction valve 126000066
Suction valve with actuator 126000183
Assembly of suction valve 126000087

Spare Parts
Spare Parts Drawings
Title Drawing No.

Controlled suction valve 126000088
Installation of discharge valv 126000067
Assembly of discharge valve 126000089
Piston rod packing 126000171
Throttling valve for pressure gauge 126000292

Kompressor Ansicht Compressor layout
Disposition du compresseur Disposizione del compressore
Vista del compresor Visto do compressor 2K158-2x
C42000 C21000
A20501
C00001 C02001 C01001

C42000
C31000
C31400 C21000
A20115
A20120 C31300
M00705
M00710
A20480 A30200 A02410

A01400
M00425 A20012
M00435 A01410 M00485
A00210 M00490
M00425 A20009 A00700

M00470 M00435 A00710
M00475
M00440 M00470
M00015 M00450 M00475 A20205
M00410 L10010 M20400

M00420
A20450 M20000
A20455
M00260
M10800
M20900
M00410
M00420
C32000 C22000 C41000

C02510 C01510
C02513 C01513
C02519 C01519
C02520 C01520
C02510
C02513 C01510
C02519 C01513
C01519
C42000 C21000 C31000
CO20/bk Original 122 846 015 12.07.2006 Rev. 0 126 000 501
Kompressor Schnitt Compressor sectional view
Coupe par le compresseur Sezione del compressore
Seccine del compresor Vista en corte do compressor 2K158-2x
C02605 C02630 C02170 C01630 C01605 C32300 C0*210 C42200

C02620 C02175 C01620 C0*215
C02001 C01001
C12100
C21000
C11100
C42000
C32000
C32400
M00735
M00740
C31000
C52000 C31400
M00705
M00810 M00710
M00820
A30200
C00200
C00205
C50905
C1*700
A00210 M20600
C1*500
M3*005
M50000 M00015
L10010
M30065
M40000
M10020
M40010
L10310
(L10330)
M20000 M10030
M10035
M10025
M40020
L10120
M40060
M20800 M10800
M00260
M10010
M10015
Rckschlagventil Non-return valve
Clapet de retenue Valvola di ritegno L2*000
Vlvula de retencin Vlvula de reteno L2*001
Nur ORIGINAL Dichtungen einbauen

Use only ORIGINAL gaskets
Utilisez que des joints ORIGINALES
Solo usar juntas ORIGINALES
L2*110 L2*100
L2*500
L2*570 L2*510 L2*560

L2*001
L2*550
L2*560
L2*530
L2*590
L2*510
L2*580
L2*600
L2*520
L2*570
* Kompressor-Stufe und/oder Tag Nr. angeben
L2*510 Compressor stage and/or Tag No. to be indicated
tage du compresseur et/ou Tag No. indiquer
(Example: L23100 3th stage / NRV-107 A/B)
CO20/NP Original 122 808 190 22.05.2006 Rev. 0 126 000 492
Zahnradlpumpe Gear oil pump
Pompe huile engrenage Pompa dolio ad ingranaggi
Bomba de engranajes Bomba de leo a engrenagens M20000
M20400
M00205
M00200
M20100
M20120
M20080
M20060
M20070
M20040 M10200
M20090
M20010
M20210
M20030
M20000
Manometer am lpumpengehuse Pressure gauges on oil pump casing
Manomtres infrieurs la pompe dhuile Manometro nel corpo della pompa di olio
Manmetros en la bomba de aceite Manmetros na carcaqa da bomba de leo M20400
A00700
A00710
(A00630)
M20412
M20410
M20411 M20400
M20401
M20406
M20409 M20404 M20408 M20417 M20403 M20402 M20010

M20407
Details zum lsystem Details for oil system
Details pour le systme d'huile Dettaglio per il systema di olio
Details para sistema de aceite Details para sistema de leo
M20700 lstand-Schauglas
Oil sight glass
Regard d'huile
Spia d'olio
M20710
Visor nivel aceite
M20715 Visor do nivel de leo
M20720
M20725
M20920 M20905 M20925 M20910 M20915 M20900 lablass

Oil drain
Vidange d'huile
Scarico d'olio
Purga de aceite
Purga de leo
M20500 berstrmventil
[4K165 6 006 178 (ex 6 005 940)
Relief valve
11
Soupape de decharge
M20535 M20555 M20560 M00265
Valvola di scarico
Vlvula de seguridad descarga
M00265
Vlvula de descarga
M20545
M20505
M20550
M20540
M20985 M20955 M20980 M20965 M20970 M20975 M20960 M20950 lnachspeiseventil

Oil feeding valve
Soupape d'alimentation d'huile
Valvola d'alimentazione d'olio
Vlvula de alimentacion de aceite
Vlvula para alimentaao de leo
ersetzt 6 005 333
CO20/bk/SR 14.07.2004 Rev. 0 126 000 036

Kurbeltrieb und lpumpe Crankgear with gear oil pump
Attelage et pompe dhuile Manovellismo e pompa dolio
Cigueal biela y bomba de aceite Cruzeta biela e eixo - manivela
C1*500
M3*065
M3*005 M40420
M40410
M30600
M30620
M40000
M40010
M20400
M40300
A20205
M40060
M40020
M20000
M10095
M10200 M10100
M10070
M20805
M10105
M20810
M20815
Option
M10106
M10071
Kurbeltrieb Antriebseite Crankgear driven end
Attelage ct d'entrainement Manovellismo lato volano
Lado de accionamiento Lado de accionamento M10000
M20500 M10610 M10620 A20355

A20360
Optional
A20375
A20360
M10030
M10020
M10035
M10025
M10800
A20310
A20315
A20325
M10200 M00265 M00260
Kurbelwellendichtung Crankshaft seal
Presse-toupe de vilebrequin Guarnizioni dell albero a gomiti
Sello del cigeal Slo rotativo do eixo-manivela M10800
M10800
M10810 M10825
M10805 M10805
M10831
M10840 M10840
M10835 M10835
M10815 M10820
CO20/NP 11.05.2007 Rev. 3 126 000 020

RASCHIG Filter im Gestell RASCHIG Filter element in frame
RASCHIG Filtre dans le bti RASCHIG Filtro nell'incastellatura
RASCHIG Filtro del carter RASCHIG Filtro no carter M20600
M20605
Raschig Ringe
Anneaux Raschig
Anillos Raschig
Raschig rings
Anelli Raschig
Aneis Raschig
ersetzt 6 006 128
Kreuzkopf-Querkeile Crosshead keys
Jeux de clavettes pour crosse Chiavette per testa a croce
Cuas para cruceta Chaveta para cruzetta M3*065
Kompressorstufe angeben / Compressor stage to be indicated

* = tage du compresseur indiquer / Stadio del compressore da indicare
Indicar etapa del compresor / Indicar estgio del compresor
(Example: M31080 1st stage)
C1*500
M3*005
M3*080
M3*085
M3*090 M3*095 M3*085

ersetzt 6 006 058/6 312 186
CO20/bk/WK Original 106 073 939 18.01.2005 Rev. 1 126 000 081
Fhrungslager und labstreifer Guide bearing and oil scrapers
Palier de guidage et racleurs dhuile Cuscinetto di guida e raschia olio
Cojinete de gua y rascador de aceite Mancal de guia e raspadores de leo M5*000
Kompressorstufe angeben / Compressor stage to be indicated

* = tage du compresseur indiquer / Stadio del compressore da indicare
Indicar etapa del compresor / Indicar estgio del compresor
(Example: C01001 1st stage)
C1*500
M50545
C1*700 M50090
M50100
M50020
M50510
M50515
M50520
M50080
M50060
M50140
Option
M50130
M50091 M50120
M50110
ersetzt 6 006 179
CO20/SR Original 122 842 021 07.02.2006 Rev. 2 126 000 085
Labyrinthkolben Labyrinth piston
Piston labyrinth Pistone a labirinto
Pistn a laberinto Embolo a labirinto C1*100
Stufe / tage
stage / fase * Code No. *
* entsprechende Stufe auswhlen,
1 C11100 z. B. Labyrinthkolben 1. Stufe C11100
2 C12100 select stage as applicable,

e.g.: Labyrint piston 1st stage C11100
3 C13100
4 C14100 choisir ltage correspondant,
p. ex.: Piston labyrinth 1er tage C11100
5 C15100
6 C16100 elejir etapa como aplicable,
p. es.: Pistn a laberinto 1a fase C11100
C1*530 C1*500 C1*550 (C1*610)

Optional
C1*120
C1*110
C1*100
C1*130
(C1*520)
U-Scheibe / Washer / Rondelle / Rondella / Arandela
nur fr Kolbenstange mit Kreuzkopf Querkeilverbindung
for compressors with crosshead wedges only
seulement pour compresseurs avec clavettes au crosse
solamente per compressori con chiavette a la testa croce
solamente para compresores con cunas al cruzeta
CO20/NP 21.03.2007 Rev. 6 126 000 024

Saugventil, Einbau Installation of suction valve
Installation du clapet d'aspiration Installaione vavola di aspirazione
Installatin del vlvula de aspriracin Instalao vlvula de aspirao C2*000
Stufe / tage
stage / fase * Code No. * * entsprechende Stufe auswhlen,
z.B. Saugventil 2. Stufe C22000
select stage as applicable,

1 C21000 e.g.: Suction valve 2nd stage C22000
2 C22000
choisir ltage correspondant,
3 C23000 p. ex.: Clapet daspiration 2me tage C22000
4 C24000
elejir etapa como aplicable,
5 C25000 p. es.: Vlvula de aspiracin 2a fase C22000
6 C26000
C0*220
C0*230
C2*005
C2*015
C0*001
C2*020
C2*200
CO20/bk 26.04.2007 Rev. 3 126 000 066

Saugventil mit Stellzylinder Suction valve with actuator
Clapet daspiration avec Valvola di aspirazione con azionatore
unit de commande
Vlvula de aspirao comandada C2*000
Vlvula de admisin con accionador con dispositivo de regulao C3*400
Stufe / tage
stage / fase * Code No. * * entsprechende Stufe auswhlen,
z. B Stellzylinder 1. Stufe C31400

1 C31400 e.g.: Control unit 1st stage C31400
2 C32400
3 C33400 p. ex.: Dispositif de rglage 1er tage C31400
4 C34400
5 C35400 p. es.: Dispositivo di regolazione 1a fase C31400
6 C36400
C3*433 C3*422 C3*423 C3*424 C3*445 A20603

A20604
C3*410
C2*010
C3*450
C3*428
C0*220
C3*429
C0*230
A20603
A20604
C3*451
C2*015
C3*421
C2*020
C3*413
C3*001
Saugventil, Zusammenbau Assembly of suction valve
Assemblage clapet d'aspiration Assemblaggio valvola di aspirazione
Ensablaje vlvula de aspiracon Montagem vlvula de aspirao C2*200
Stufe / tage
C2*200
1 C21200
2 C22200
3 C23200
4 C24200
5 C25200
6 C26200

z.B. Saugventil 2. Stufe C22200

e.g.: Suction valve 2nd stage C22200

p. ex.: Clapet daspiration 2me tage C22200

p. es.: Vlvula de aspiracin 2a fase C22200
C2*330
C2*310
C2*350
C2*320
C2*380
C2*390
C2*400
C2*370 C2*430
C2*360
C2*210
CO20/bk 12.02.2007 Rev. 3 126 000 087

Gesteuertes Saugventil Controlled suction valve
Clapet daspiration command Valvola di aspirazione comandata
Vlvula de admisin regulable Vlvula de aspirao comandada C3*001
Stufe / tage
C3*010 C3*001
1 C31001
2 C32001
3 C33001
4 C34001
5 C35001
6 C36001

z.B. Gesteuertes Saugventil, komplett ,
2. Stufe C32001

e.g.: Controlled suction valve, complete,
2nd stage C32001
choisir l'tage correspondant,

p. ex.: Clapet d'aspiration command, complet,
2me tage C32001

p. es.: Vlvula de aspiracin controlada, completo,
2a fase C32001
C3*020
C3*040
C3*030
C3*070
C3*060
C2*210
CO20/bk 13.02.2007 Rev. 4 126 000 088

Druckventil, Einbau Installation of discharge valve
Installation du clapet de refoulement Installatione valvola di mandata
Installatin del vlvula de impulsin Instalao vlvula de recalque C4*000
Stufe / tage * entsprechende Stufe auswhlen,

stage / fase * Code No. * z.B. Saugventil 2. Stufe C42000

1 C41000 e.g.: Suction valve 2nd stage C42000

p. ex.: Clapet daspiration 2me tage C42000
3 C43000
p. es.: Vlvula de aspiracin 2a fase C42000
5 C45000
6 C46000
C0*225
C4*005
C0*230
C4*015
C0*001
C4*020
C4*200
CO20/bk 27.04.2007 Rev. 2 126 000 067

Druckventil, Zusammenbau Assembly of discharge valve
Assemblage clapet de refoulement Assemblaggio valvola di mandata
Ensablaje vlvula de impulsin Montagem vlvula de aspiro C4*200
Stufe / tage
C4*200
1 C41200
2 C42200
3 C43200
4 C44200
5 C45200
6 C46200

z.B. Druckventil 2. Stufe C42200

e.g.: Discharge valve 2nd stage C42200
choisir l'tage correspondant,

p. ex.: Clapet de refoulement 2me tage C42200

p. es.: Valvola di mandata 2a fase C42200
C4*330
C4*310
C4*360
C4*350
C4*400
C4*390
C4*380
C4*320
C4*430 C4*370
C4*210
CO20/bk 12.02.2007 Rev. 3 126 000 089

Kolbenstangenstopfbchse Piston rod gland
Presse - toupe pour tige de piston Premistoppa dellasta del pistone
Prensa estopas del vastago del mbolo Gaxeta da haste do mbolo C5*000
Stufe / tage
z. B. Stopfbchsring 2. Stufe C52124
1 C51000
2 C52000 e.g.: Gland ring 2nd stage C52124
4 C54000 p. ex.: Bague de presse-toupe 2me tage C52124
6 C56000 p. es.: Anillo del prensaestopa 2a fase C52124
C0*001 C5*134
C5*115
C5*116 C5*124
C5*108
C5*106
C50911
C0*245
C50910
C0*240
Option
C5*134
C50911
C5*124
C50910
Drosselventil zu Manometer Throttling valve for pressure gauge
Vanne dtranglement pour manomtre Valvola strozzante per manometro
Vlvula de estrangulacin para manometro Vlvula do manmetro A00210
A00300
A0*400
A0*410
A00215
C0*001
A00210
A00255
A00270 A00260
A00215 A00265
Appendix
13 Appendix
P & I Diagram
Title Drawing No. Sheet No.

P & I DIAGRAM OIL SYSTEM 122824382 D01
P & I DIAGRAM CAPACITY CONTROL 122824383 E01
Technical Data

Sound Pressure Level 2013642-E01
Safety and Monitoring Set Points 2016500 E01
Summarysheet Operating Data 2013642_L01_00
Suction Strainer ANSI 8" 150lbs, R 122808184 200
Non-Return Valve ANSI 4" 300lbs, R 106105648 200
Drive System

Operating Instruction for VULKAN Cou- 1X34100379-
pling 701818
Lubricating System

Lubrication of BCA Piston Compressors VBCA546005
(VSB)
Lubrication of Closed (Pressure-Resis- 1001300 (VSB)
tant) Labyrinth Compressors
Crankgear Lubrication Mineral Oil 1001132 (VSB)
Lubricating Oils ISO VG 150 Categories 1001135 (VSB)
C/CL
Laby Polyalkylene Glycol Lubricants 1001301 (VSB)
Laby Polyalkylene Glycol Lubricants 1001302 (VSB)
Compressor

Compressor Disposition 122846553 D01
Sectional View 122846369 D01

Appendix

Table of Clearances 2K158-2D_1 2012787 D02
Tightening Torques 2K158-2D_1
(Drawing)
TIGHTENING TORQUES 2K158-2D_1 2013023 E01
(List)

RecipCalc
1.5 Sound pressure level

Valid for free field sound radiation at 1 m distance from compressor
and low basic noise at n = 595.0 rpm
According DIN 45635 - part 13
Lp = 85.6 dB(A)
Octave spectrum of sound pressure level
f [Hz] 63 125 250 500 1000 2000 4000 8000

Lp [dB] 77.1 82.1 85.6 81.6 81.1 78.6 74.6 67.6
f: frequency, Lp: sound pressure level
REV.INDEX: 0 DOK.NR.:
PREPARED 11.09.2006 DUEBI_R (TDO) 2013642-E01
APPROVED 11.09.2006 GROB_A PAGE 8
2000697-704_NORGAS_WZL-0601-4&ORDER RecipCalc V 03.00.00 OF 8
Safety and Monitoring set points
Safety Valves Set Points

1st stage discharge side to 1st stage suction side p 8.5 bar
1st stage discharge side to vent mast p 10.0 bar g
2nd stage discharge side to vent mast p 24.0 bar g
Gas Pressure Set Points

1st and 2nd stage suction pressure p min. 0.8 bar a
1st stage suction pressure:
LNG Cargoes p max. 2.0 bar g
1st stage differential pressure p max. 7.5 bar

1st stage discharge pressure p max. 9.0 bar g
2nd stage discharge pressure p max. 22.0 bar g
Lube Oil Pressure Set Point

Lube oil differential pressure p min. 3.0 bar
Gas Temperature Set Points

1st stage temperature discharge side t max. 100.0 C
2nd stage temperature discharge side t max. 130.0 C
Coolant Temperature Set Points

Coolant inlet temperature t min. 34.0 C
Coolant inlet temperature t max. 47.0 C
Lube Oil Temperatures

(usually no temperature switches provided)
Lube oil temperature t min. 15.0 C
Lube oil temperature t max. 70.0 C
Coolant Quantity
Required coolant quantity (each compressor) Q min. 6.0 m3/h
The maximum allowable gas pressure in the crankcase is 15.0 bar g

The maximum allowable pressure in the coolant cavities is 8.0 bar g
10.11.2006 2000697 Rev. 0 / J. Studer 100822 2K158-2D_1

NORGAS WZL 0601/0602/0603/0604
2K158-2D_1/LNG TDO_2013642_L01_00
2000697, 1 of 4
2000702-704 595
Summarysheet Operating data 0 08.09.2006 rd
Rev Date Sig

1st stage 2nd Stage
Medium Process Suction Saturat. Super- Suction Act Mass Disch. Disch. Suction Suction Suction Mass Disch. Disch. Cond. Power Recomm. Refrig.
Press. Temp. heat Temp. Suction Flow Press. Temp. Press. Temp. Volume Flow Press. Temp. Temp. Cons. Motor Capacity
Volume Power
bar abs C C C m/h kg/h bar abs C bar abs C m/h kg/h bar abs C C kW kW kW
1 Ethylene 1.02 -65 15bara FLSC FLASH LSC 1.02 -103 38 -65 860 1426 4.2 40.1 4.2 19.5 362 1798 15.0 109.1 -39 145.3 167.1 159.9
14 Ethylene 1.6 -65 16.2bara FLSC FLASH LSC 1.60 -95 30 -65 924 2435 5.9 30.0 5.9 14.7 412 2972 16.2 86.9 -37 193.5 222.5 263.3
11 Ethylene 1.6 -33 Start Up FLSC FLASH LSC 1.60 -95 125 30 944 1692 5.7 125.5 5.7 90.3 400 2152 18.0 161.6 -33 186.1 214.0 184.0
24 Ethylene 1.9 -65 -33 FLSC FLASH LSC 1.90 -92 27 -65 932 2934 6.9 28.8 6.9 13.9 422 3601 18.0 82.7 -33 221.9 255.2 310.4
95 1,3 Butadiene 1.02 38 OSO NIC 1.02 -4 6 2 1110 2757 4.1 58.0 38 72.7 83.6 250.6
96 1,3 Butadiene 1.12 40 OSO NIC 1.12 -2 7 5 1144 3092 4.4 59.7 40 78.7 90.5 279.4
97 1,3 Butadiene 1.5 40 OSO NIC 1.50 6 3 9 1381 4976 4.4 53.6 40 99.0 113.9 463.0
98 1,3 Butadiene 2st 1.02 28 NIC NIC 1.02 -4 6 2 1096 2721 2.4 40.2 2.4 40.2 518 2721 3.1 54.6 28 70.0 80.5 265.4
99 1,3 Butadiene 2st 1.02 33 NIC NIC 1.02 -4 6 2 1088 2701 2.5 42.2 2.5 42.2 506 2701 3.6 58.9 33 75.0 86.3 254.5
A0 1,3 Butadiene 2st 1.5 28 NIC NIC 1.50 6 3 9 1140 4109 3.2 45.7 3.2 45.7 593 4109 3.1 49.0 28 78.6 90.4 415.2
A1 1,3 Butadiene 2st 1.5 40 NIC NIC 1.50 6 3 9 1101 3967 3.5 46.6 3.5 46.6 520 3967 4.4 59.8 40 96.0 110.4 369.1
NORGAS WZL 0601/0602/0603/0604
2K158-2D_1/LNG TDO_2013642_L01_00
2000697, 2 of 4
2000702-704 595
Rev Date Sig

1st stage 2nd Stage
Volume Power
74 Ammonia 1.02 28 LSC LSC 1.02 -33 13 -20 949 787 3.5 93.2 3.5 2.3 382 1023 11.1 104.1 28 126.5 145.5 275.7
75 Ammonia 1.02 40 LSC LSC 1.02 -33 13 -20 887 733 3.9 107.8 3.9 5.2 340 1016 15.7 131.2 40 146.7 168.7 253.7
76 Ammonia 2.0 28 LSC LSC 2.00 -18 8 -10 1043 1655 5.7 84.9 5.7 16.0 464 1984 11.1 73.1 28 169.3 194.7 560.5
77 Ammonia 2.0 40 LSC LSC 2.00 -18 8 -10 997 1580 6.3 95.3 6.3 18.6 429 2009 15.7 98.2 40 204.5 235.2 528.9
78 Ammonia 3.0 28 LSC LSC 3.00 -9 6 -3 1088 2550 7.8 83.6 7.8 25.7 506 2906 11.1 57.3 28 193.6 222.6 841.5
79 Ammonia 3.0 40 LSC LSC 3.00 -9 6 -3 1049 2457 8.6 92.4 8.6 28.0 474 2962 15.7 81.2 40 241.3 277.5 801.1
90 Butylene 1.02 40 OSO NIC 1.02 -6 4 -2 988 2587 4.6 54.6 40 69.7 80.2 211.4
91 Butylene 2.0 40 OSO NIC 2.00 13 1 14 1532 7617 4.6 48.4 40 117.5 135.1 672.5
92 Butylene 2st. 1.02 40 NIC NIC 1.02 -6 4 -2 1063 2785 2.6 37.3 2.6 37.3 474 2785 4.6 60.1 40 82.6 95.0 227.6
93 Butylene 2st. 2.0 40 NIC NIC 2.00 13 1 14 1113 5530 4.4 49.6 4.4 49.6 544 5530 4.6 54.9 40 108.2 124.4 488.2
62 Comm Propane 5% 1.02 28 LSC LSC 1.02 -48 26 -22 772 1542 4.5 51.5 4.5 -3.1 296 2572 17.8 66.7 28 129.3 148.7 143.2
63 Comm Propane 5% 1.02 35 LSC LSC 1.02 -48 26 -22 715 1425 4.8 54.5 4.8 -0.7 273 2559 20.6 73.0 35 132.4 152.3 129.8
64 Comm Propane 5% 2.0 28 LSC LSC 2.00 -31 12 -19 944 3805 6.5 38.8 6.5 10.8 407 5181 16.6 58.1 28 195.2 224.5 336.5
65 Comm Propane 5% 2.0 35 LSC LSC 2.00 -31 12 -19 904 3643 7.0 41.8 7.0 12.9 388 5279 19.3 64.3 35 204.8 235.5 315.7
66 Comm Propane 5% NIC 2.0 28 NIC 2.00 -31 10 -21 1000 4066 5.9 33.0 5.9 33.0 394 4066 16.6 80.5 28 188.3 216.5 293.4
67 Comm Propane 5% NIC 2.0 35 NIC 2.00 -31 10 -21 976 3967 6.2 33.2 6.2 33.2 366 3967 19.3 87.2 35 195.7 225.1 261.5
52 Comm. Propane 2.5% 2.0 28 LSC LSC 2.00 -28 13 -15 976 4020 6.1 38.4 6.1 12.1 433 5327 13.7 52.3 28 181.7 209.0 357.3
54 Comm. Propane 2.5% NIC 2.0 28 NIC 2.00 -28 10 -18 1026 4282 5.6 32.2 5.6 32.2 422 4282 13.7 72.4 28 176.2 202.6 317.8
55 Comm. Propane 2.5% NIC 2.0 40 NIC 2.00 -28 10 -18 988 4118 6.0 33.5 6.0 33.5 377 4118 17.8 83.9 40 189.8 218.3 262.5
50 Comm. Propane 2.5% 1.02 28 LSC LSC 1.02 -45 26 -19 828 1709 4.1 45.9 4.1 -1.9 331 2727 14.4 59.0 28 122.9 141.3 159.7
26 Ethane 1.02 -33 FLSC FLASH LSC 1.02 -88 28 -60 940 1646 3.6 15.1 3.6 4.5 405 1944 9.8 65.1 -33 118.5 136.3 190.1
42 Propane 1.02 40 LSC LSC 1.02 -42 11 -31 807 1843 4.1 34.2 4.1 2.8 341 2973 13.9 59.2 40 121.8 140.1 168.7
43 Propane 2.0 40 LSC LSC 2.00 -25 15 -10 953 4015 6.4 42.9 6.4 17.0 435 5727 13.9 55.1 40 182.6 210.0 348.3
44 Propane 3.2 40 LSC LSC 3.20 -12 12 0 1031 6852 8.7 48.7 8.7 28.5 487 8685 13.9 53.6 40 231.0 265.7 564.0
45 Propane 3.2 40 NIC NIC 3.20 -12 12 0 1075 7141 8.0 43.5 8.0 43.5 476 7141 13.9 70.8 40 226.6 260.6 504.1
NORGAS WZL 0601/0602/0603/0604
2K158-2D_1/LNG TDO_2013642_L01_00
2000697, 3 of 4
2000702-704 595
Rev Date Sig

1st stage 2nd Stage
Volume Power
30 Propylene 1.02 28 LSC LSC 1.02 -47 17 -30 859 1861 3.9 39.1 3.9 -5.6 360 2882 12.5 55.6 28 123.0 141.5 182.9
31 Propylene 1.02 40 LSC LSC 1.02 -47 17 -30 774 1671 4.5 47.8 4.5 -1.6 319 2893 16.7 67.9 40 131.8 151.6 159.6
32 Propylene 2.0 28 LSC LSC 2.00 -31 10 -21 983 4122 6.1 37.5 6.1 8.8 449 5514 12.5 48.9 28 180.3 207.3 384.9
36 Propylene 3.8 40 NIC NIC 3.80 -14 -8 1069 8384 9.6 42.7 9.6 42.7 477 8384 16.7 73.8 40 272.7 313.6 607.1
83 VCM 1.5 41 NIC NIC 1.50 -4 0 -4 1053 4571 3.9 59.7 3.9 59.7 496 4571 6.0 88.7 41 119.3 137.2 346.1
B2 Butane 5%Ethane 1.25 40 NIC NIC 1.25 4 6 10 1069 3340 3.1 44.2 3.1 44.2 471 3340 5.6 64.7 40 97.1 111.7 276.7
85 i-Butane 1.02 40 OSO NIC 1.02 -11 4 -7 771 2135 5.3 51.9 40 61.9 71.2 146.1
86 i-Butane 2.0 40 OSO NIC 2.00 7 2 9 1410 7418 5.3 45.7 40 121.0 139.2 560.5
87 i-Butane 2st. 1.02 40 NIC NIC 1.02 -11 5 -6 1044 2881 2.6 30.0 2.6 30.0 450 2881 5.3 54.8 40 86.2 99.1 197.2
A3 n-Butane 1.02 28 OSO NIC 1.02 0 5 5 1444 3826 2.7 38.0 28 68.0 78.2 344.3
A4 n-Butane 1.02 40 OSO NIC 1.02 0 5 5 1158 3069 3.8 47.4 40 70.0 80.5 249.9
A5 n-Butane 2.0 28 OSO NIC 2.00 19 2 21 1804 9090 2.7 37.2 28 80.6 92.7 888.8
A6 n-Butane 2.0 40 OSO NIC 2.00 19 3 22 1639 8224 3.8 48.1 40 106.1 122.0 733.8
A8 n-Butane 2st 1.02 40 NIC NIC 1.02 0 5 5 1081 2862 2.4 36.7 2.4 36.7 491 2862 3.8 54.6 40 76.1 87.5 233.1
B0 n-Butane 2st 2.0 40 NIC NIC 2.00 19 4 23 1155 5769 4.0 51.4 4.0 51.4 614 5769 3.8 53.9 40 96.5 111.0 514.8
NORGAS WZL 0601/0602/0603/0604
2K158-2D_1/LNG TDO_2013642_L01_00
2000697, 4 of 4
2000702-704 595
Rev Date Sig

1st stage 2nd Stage
Volume Power
B4 Methylchloride 1.02 28 LSC LSC 1.02 -23 8 -15 1014 2477 3.0 77.3 3.0 12.5 455 3055 6.2 73.2 28 104.2 119.8 264.4
C0 Methylchloride 1.5 28 NIC NIC 1.50 -14 4 -10 1054 3750 4.1 74.7 4.1 74.7 505 3750 6.2 107.7 28 122.5 140.9 375.3
C1 Methane 1 19 NIC NIC 1.00 -161 20 -141 835 1198 4.5 -44.3 4.5 -44.3 313 1198 19.0 84.6 -109 170.3 195.8 101.4
C4 Methane 1 22 NIC NIC 1.00 -161 20 -141 808 1153 4.7 -39.3 4.7 -39.3 293 1153 22.0 101.9 -105 179.8 206.8 90.9
C2 Methane 2.5 19 NIC NIC 2.50 -149 20 -129 980 3366 8.5 -51.8 8.5 -51.8 434 3366 19.0 13.1 -109 268.5 308.8 303.2
C5 Methane 2.5 22 NIC NIC 2.50 -149 20 -129 964 3305 8.8 -49.3 8.8 -49.3 417 3305 22.0 24.8 -105 289.0 332.4 278.4
C3 Methane 2.8 19 NIC NIC 2.80 -147 20 -127 993 3787 9.3 -51.0 9.3 -51.0 447 3787 19.0 7.2 -109 281.8 324.1 343.7
C6 Methane 2.8 22 NIC NIC 2.80 -147 20 -127 978 3724 9.6 -48.6 9.6 -48.6 431 3724 22.0 18.5 -105 304.3 349.9 316.3
D1 Methane + N2 1 19 NIC NIC 1.00 -163 21 -142 838 1310 4.5 -44.2 4.5 -44.2 316 1310 19.0 86.8 -122 172.0 197.8 111.9
D4 Methane + N2 1 22 NIC NIC 1.00 -163 21 -142 811 1262 4.7 -39.1 4.7 -39.1 296 1262 22.0 104.5 -118 181.6 208.8 100.8
D2 Methane + N2 2.5 19 NIC NIC 2.50 -151 21 -130 979 3655 8.6 -51.4 8.6 -51.4 435 3655 19.0 14.5 -122 271.7 312.5 329.9
E1 Commercial Methane 1 19 NIC NIC 1.00 -162 21 -141 839 1309 4.5 -43.0 4.5 -43.0 316 1309 19.0 88.3 -123 172.0 197.8 112.3
E4 Commercial Methane 1 22 NIC NIC 1.00 -162 21 -141 811 1261 4.7 -37.3 4.7 -37.3 297 1261 22.0 106.8 -119 181.5 208.7 101.3
E2 Commercial Methane 2.5 19 NIC NIC 2.50 -149 21 -128 980 3518 8.6 -49.3 8.6 -49.3 435 3518 19.0 16.6 -118 270.3 310.8 321.5
Methane + N2 : 89mol% Methane in gasphase

Commercial Methane: Liquid phase mol% N2 0.4, C2H6 6.5, C3H8 1.0, C4H10 0.3, C4H10 0.3, CH4 91.5
Suction Strainer ANSI 8" 150lbs, RF
Description: Suction strainer suitable for fitting between flanges according ANSI B 16.5
- Flange size, DN 8"
- Flange rating 150 lbs
- Flange facing RF
Dimensions: D1 = 277 mm L = 836 mm

D2 = 190 mm
D3 = 60 mm Wire = 0.2 mm
B = 19 mm Mesh size = 0.315 mm
Free flow 500 cm ( > 1.5 x pipe cross section )
Material: Flange, perforated plate and cap 1.4435 ( 316L )

Wire cloth 1.4401 ( 316 )
Total weight: 7 kg
BCA Material No.: 122.808.184.200
REV. INDEX
ERSTELLT / PREPARED 10.04.2007 STUDER_J
DOK.-No. 122808184
GEPRUEFT / REVIEWED SEITE / PAGE 1
FREIGABE DVS / RELEASE DVS 11.04.2007 STUDER_J VON / OF 1
Non return valve ANSI 4" 300lbs, RF
Description: Non Return Valve suitable for fitting between flanges according ANSI B 16.5
- Flange size, DN 4"
- Flange rating 300 lbs
- Flange facing RF
Dimensions: D1 = 178 mm D3 = 124 mm

D2 = 104 mm L = 90 mm
Valve description: BCA NRV plate valve type 110 K24 a

Valve flow section 30.7 cm
Maximum allowable pressure PS 32 bar
Maximum allowable temperature TS 200 C
Instructions: For ease instalation the pipe arrangement

shall be as per sketch adjoining.
Use only gaskets of 2.4 mm thickness with I.D and O.D according
to ANSI B 16.21. Otherwise malfunction and/or damage may result.
Material: Housing and Ring 1.4435 ( 316L )

Valve Sainless steel
Total weight: 42 kg
BCA Material No.: 106.105.648.200
REV. INDEX
ERSTELLT / PREPARED 24.05.2007 STUDER_J
DOK.-No. 106105648
GEPRUEFT / REVIEWED SEITE / PAGE 1
FREIGABE DVS / RELEASE DVS 24.05.2007 STUDER_J VON / OF 1
Commission 310701818, ...2875, ...76, ...77
Drawing no. 1X34100379-701818
Installation and Operating Instruction for VULKAN

VULASTIK-L couplings
Series 2800, 2801, 2810, 2811, 2830, 2831
Table of contents:
1 General safety instructions ......................................................................................................................... 2
1.1 Symbol for industrial safety.......................................................................................................................2
1.2 Attention remark........................................................................................................................................2
1.3 Safety Regulations ....................................................................................................................................2
2 Generalities................................................................................................................................................. 2
3 Technical Data............................................................................................................................................ 2
4 Series and executions ................................................................................................................................ 3
4.1 Series 2800 and 2801...............................................................................................................................3
4.2 Series 2810 and 2811...............................................................................................................................4
4.3 Series 2830 and 2831...............................................................................................................................5
4.4 Design with clamping set ..........................................................................................................................6
5 Torsional limit device .................................................................................................................................. 7
6 Assembly of the coupling............................................................................................................................ 7
6.1 Assembly of bell-housing applications, series 2800 a. 2801 ....................................................................7
6.2 Assembly of free-standing applications ....................................................................................................7
6.2.1 Assembly of series 2810, sizes 1410-1910 .......................................................................................7
6.2.2 Assembly of series 2810 u. 2811, sizes 2210-4310 ..........................................................................8
6.2.3 Assembly of series 2830 a. 2831.......................................................................................................8
6.2.4 Assembly of design with clamping set...............................................................................................9
7 Couplings with hubs for an oil-pressure unit .............................................................................................. 9
7.1 Mounting of the hub ..................................................................................................................................9
7.2 Disassembly of the hub...........................................................................................................................10
8 Alignment of the coupling ......................................................................................................................... 10
9 Commissioning and Safety Regulations................................................................................................... 11
10 Replacement of the VULASTIK-L elements ............................................................................................. 11
10.1 Replacement of the element in bell-housing applications, series 2800 a. 2801 .................................11
10.2 Replacement of the element in free-standing applications .................................................................11
10.2.1 Replacement of the element, series 2810, sizes 1410-1910 ..........................................................12
10.2.2 Replacement of the element, series 2810 a. 2811, sizes 2210-4310 .............................................12
10.2.3 Replacement of the element, series 2830 a. 2831 ..........................................................................12
11 Guarantee................................................................................................................................................. 12
12 Maintenance ............................................................................................................................................. 12
VULKAN Kupplungs- und Getriebebau

B. Hackforth GmbH & Co. KG
Postfach 200462, 44634 Herne / Germany
Heerstrae 66, 44653 Herne / Germany
Tel. ++49-2325/922-0
Fax ++49-2325/71110
E-Mail: info.vkg@vulkan24.com
http://www.vulkan24.com
Titel Installation and Operating Instruction Theme Vulastik-L 2800,-01,-10,-11,-30,-31

Responsibility Authoring Checked and released Document E&W Vulastik-L 2800, 2801, 2810,
2811, 2830, 2831, Spannsatz englisch-
02.03.2006 16.03.2006 Version: 004
TB 20 S.Prbner H. Brenienek Page: 1/13
1 General safety instructions
1.1 Symbol for industrial safety

This symbol is added to all passages of this documentation concerning industrial
safety and including a risk to people's life and limb. Please follow these instructions
and handle with the utmost caution in these situations. Hand over all industrial safety
instructions to other users as well.
1.2 Attention remark

This "Attention!" remark is added to passages in this documentation which
should be specially noted in order to stick to the guidelines, regulations,
instructions and correct flow of work and to prevent any damages or de-
struction of the coupling.
1.3 Safety Regulations

A coupling shield has to be provided, according to the accident prevention regulations. According to EN 292,
part 1 Safety of Machines, a shield against mechanical movements of machine parts (protection against acci-
dental contact) is permissible, if a usage according to the regulations is guaranteed during all working con-
ditions. At the same time a good ventilation of the coupling has to be ensured (use of perforated plates). If the
possibility of exceeding the permissible speed of the coupling, nkmax, cannot be excluded completely, e. g. in
case of an incident or because of a failure of the over-speed-trip in the system, the coupling shield has to be so
designed that possible coupling fragments cannot escape to the surrounding environment. For coupling appli-
cations in fast ships (Dynamically Supported Craft), the safety regulations of publication A373 of IMO (Inter-
national Maritime Organisation) are valid. Dependant on the construction, these machine arrangements contain
components with a high rotating energy. When the coupling runs outside of a casing, an external protecting
device has to be provided to keep off possible coupling fragments in any case.
2 Generalities
The highly-flexible VULASTIK-L coupling is a torsionally flexible rubber coupling compensating radial, axial and
angular displacements of the connected machines.
The torque transmission is guaranteed by the ring-shaped rubber elements which are loaded with turning thrust.
The VULASTIK-L coupling series 2800 is especially suitable for the installation in gearbox bell housings or ge-
nerator bell housings.
The coupling should be protected against the permanent effect of oil and against the radiation of heat.
The VULASTIK-L element is designed for use at ambient temperatures between -45 C up to +90 C (silicone
elements from 45 up to +120C).
To reach a long service life, a sufficient ventilation cross section should be guaranteed. This especially refers to
bell housing installations.
Basically, the connection surfaces of the coupling and the finish bores are preserved by Tectyl. Prior to instal-
lation of the coupling, these surfaces should be cleaned with conventional solvents.
Pay attention to wear protective clothes (gloves, safety glasses etc.) while working with solvents.
When the cleaned surfaces are completely dry, they must be greased slightly.
To guarantee faultless function and optimum use of the highly-flexible VULASTIK-L coupling, certain installation
instructions have to be observed. First of all this means to tighten all screwed connections participating in the
transmission of the torque with a torque spanner. The permissible tightening torques for the corresponding ma-
terial quality are given by the manufacturers of the screws and are not allowed to be exceeded. The tightening
torques for the fastening screws of the flexible elements (7) are given in the respective general drawing of the
coupling.
3 Technical Data
For the valid technical data please look into the actual product information from catalogues or Internet-pages.

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4 Series and executions
VULASTIK-L couplings can be supplied in the following executions:
4.1 Series 2800 and 2801

for connection of a SAE-flywheel with a shaft
element replacement with displacement of the connected units
series 2800 without torsional limit device
series 2801 like 2800, however, with torsional limit device
figure 1 figure 2
2800 2801
figure 3
2800 dual

02.03.2006 16.03.2006 Version: 004
4.2 Series 2810 and 2811
element replacement without displacement of the connected units
figure 4 figure 5 figure 6

2810 (sizes 14 19) 2810 (sizes 22-43) 2811
figure 7 figure 8
2810 dual 2811 dual

02.03.2006 16.03.2006 Version: 004
4.3 Series 2830 and 2831
for connection of two shafts
element replacement without displacement of the connected units
figure 9 figure 10
2830 2831
figure 11 figure 12
2830 dual 2831 dual

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4.4 Design with clamping set
for connection of two shafts

Abbildung 13 Abbildung 14
SAE shaft design shaft shaft design

02.03.2006 16.03.2006 Version: 004
5 Torsional limit device
The VULASTK-L coupling series 2801, 2811, 2831 is delivered with
a torsional limit device. This torsional limit device allows emergency
operation up to 25% of the engine nominal torque.
During emergency operation the system has to run under conditions
that no hammering should occur between the emergency-run cams.
The elements should be replaced as soon as possible.
After a break of the VULASTIK-L element and installation of a tor-
sional limit device it is required to replace the element as well as the
cam ring, the limit ring and the fastening screws.
With respect to the assembly of the torsional limit

device, special attention should be paid that the cams are stag-
gered by 90 towards each other. figure 13
6 Assembly of the coupling
During transportation, please pay attention to a sufficient carrying force of the lifting devices. Only use
approved transportation elements. Fix the transportation elements thoroughly.
While lifting the flexible element, pay attention not to damage the flexible element and the add-
on pieces.
The VULASTIK-L coupling is dispatched by VULKAN in the assembled condition (executions with oil-fitted hubs
in the preassembled condition).
6.1 Assembly of bell-housing applications, series 2800 a. 2801

Sequence of operations (please refer to figure 1, figure 2, figure 3):
Remove the housing (1) from the coupling and attach it to the engine flywheel using suitable
connection elements and the washers noted in the drawing.
The tightening torque required for the chosen screw quality is to be kept.
Series 2801: Place the limit ring (8) between housing (1) and engine flywheel.
Release the connecting elements (7) and pull the flexible element (6) for dual couplings (5, 6)
from the hub.
Series 2801: Remove the cam ring (9) as well.
Push the hub (4) onto the shaft end using a method meeting a modern engineering practice.
The assembly of the hub with oil-pressure unit is described separately.
Screw up the flexible element (6) for dual couplings (5, 6) with the hub (4) using the connecting
elements (7). The tightening torque required for the chosen screw quality is given on the drawing.
Series 2801: Place the cam ring (9) against the flexible element (6) on the face.
Join engine and machine and attach them to the engine housing using suitable connecting
elements, so that the element toothing (6) is in alignment with the toothing gaps of the housing (1).
Concerning series 2801: In addition, please pay attention that the cams are stag-
gered by 90 towards each other (please refer to paragraph 5 Torsional limit device).
6.2 Assembly of free-standing applications
6.2.1 Assembly of series 2810, sizes 1410-1910

Sequence of operations (please refer to figure 4):
Remove housing (1) and spacer ring (12) from the coupling.
Release the connecting elements (7) and pull the flexible element (6) and if required the spacer
ring (19) from the hub.
Push the hub (4) onto the shaft end using a method meeting modern engineering practice.
Deposit the housing (1) on the hub (4).

02.03.2006 16.03.2006 Version: 004
The alignment of the system and the alignment control are described separately.
The assembly of the hub with oi-pressure unit is described separately.
Insert the flexible element (6) and spacer ring (19) between hub (4) and engine flywheel and screw
up these parts with the hub (4) using the connecting elements (7). The tightening torque required for
the chosen screw quality is given on the drawing.
Take the housing (1) and the spacer ring (12) from the hub (4) and fix them to the engine flywheel
using appropriate connecting elements and the washers noted in the drawing.
6.2.2 Assembly of series 2810 u. 2811, sizes 2210-4310

Sequence of operations (please refer to figure 5 figure 6, figure 7, figure 8):
Remove the housing (1) from the coupling.
Series 2811: Remove the limit ring (8) as well.
Release the connecting elements (7) and pull the flexible element (6) for dual coupling (5, 6)
from the hub.
Deposit the housing (1) with respect to series 2811 the limit ring (8) as well on the hub (4).
Insert the flexible element (6) for dual couplings (5, 6) - between hub (4) and engine flywheel and
screw up these parts with the hub (4) using the connecting elements (7). The tightening torque
required for the chosen screw quality is given on the drawing.
Series 2811: Place the cam ring (19) between hub (4) and flexible element (6).
Take the housing (1) from the hub (4) and fix these parts to the engine flywheel using appropriate
connecting elements and the washers noted in the drawing.
Concerning series 2811: Place the limit ring (8) against the housing (1) on the face.
In addition, please pay attention that the cams are displaced by 90 towards each other (please
refer to paragraph 5 Torsional limit device).
6.2.3 Assembly of series 2830 a. 2831

Sequence of operations (please refer to figure 9, figure 10, figure 11, figure 12):
Release connecting elements (15, 16, 17).
Remove the housing (1) from the coupling.
Series 2831: Remove the limit ring (8) as well.
Release connecting elements (7) and pull the flexible element (6) for dual couplings (5, 6) from
the hub.
Deposit the housing (1) with respect to series 2831 the limit ring (8) as well on the hub (4).
Release the connecting elements (14) and separate the plate flange (12) from the hub (13).
Assemble the plate flange (12) to the hub (13) using the connecting elements (14).
Insert the flexible element (6) for dual couplings (5, 6) - between hub (4) and plate flange (12) and
screw it up with the hub (4) using the connecting elements (7) and with the plate flange (12) using
the connecting elements (15, 16, 17). The tightening torque required for the chosen screw quality is
given on the drawing.
Series 2831: Place the cam ring (19) between hub (4) and flexible element (6).
Take the housing (1) from the hub (4) and fix them to the engine flywheel using appropriate connec-
ting elements and the washers noted on the drawing.

02.03.2006 16.03.2006 Version: 004
Concerning series 2831: Place the limit ring (8) against the housing (1) on the face.
In addition, please pay attention that the cams are displaced by 90 towards each other (please
refer to paragraph 5 Torsional limit device).
6.2.4 Assembly of design with clamping set

Procedure (please refer to figure 13, figure 14):
Basically, the assembly of couplings equipped with a clamping set has to be carried out according to the
corresponding coupling series (please refer to 6.2.1 6.2.3).
The hub (item 13) has to be mounted onto the shaft end using a method according to the best available
technology.
Before mounting the hub (item 13), the clamping ring (item 20) has to be put down on
the shaft.
Then the clamping ring (item 20) has to be mounted via the male taper up to the stop by means of the
clamping screws (item 11). The tightening torque required for the chosen screw quality is to be kept.
7 Couplings with hubs for an oil-pressure unit
7.1 Mounting of the hub

Before the assembly it is required to check the interfaces from the
cone surfaces and the oil keyways with respect to edges. The
fitting can be controlled by applying a thin layer of blue grease and
by pressing the parts together.
Then clean and dry the cone surface.
In order to determine the push-up distance, the hub must be
pushed onto the shaft.
Do not assemble the parts firmly. The push-up distance is calcu-
lated from the point where the conical surfaces are closely con-
tiguous without exerting any pressure.
In order to determine the reference dimension, the edge of the
hub and the hydraulic nut are used.
In order to determine the reference dimension, the edge of the hub and the hydraulic nut are used.
Before the installation, the cone surface is coated with SAE-10 oil (viscosity approx. 20 cSt at 50C).
After having attached the hydraulic nut, the hydraulic supply can be connected. The push-up dimension inclu-
ding tolerance is marked on the front surface of the hub.
After the connection to the hydraulic supply, pressure is given on connection A in order to push-up the hub and
on connection B in order to expand the hub.
The hub should be positioned without any interruption. The push-up pressure (connection A) for
the hydraulic nut depends on the hubs diameter of the part to be pressed on.
After having pressed the part in the correct position, the expanding pressure has to be reduced slowly, whereas
the push-up pressure has to be kept in order to get the oil distributed (approx. 30 minutes).
The push-up pressure has to be maintained all the time, while the expanding pressure is redu-
cing, so that the part will keep its position.
A waiting time of 24 hours is required before the oil-pressure unit can be loaded with the full nominal speed of
the engine.
This is necessary to ensure that the oil has completely dropped off from the mounted hub.

02.03.2006 16.03.2006 Version: 004
Oil under high pressure can cause injuries. While working with high-pressure oil systems, take care for
an adequate protection equipment. High-pressure oil should not come in contact with the skin.
After the hub has been installed, the alignment control can be carried out:
7.2 Disassembly of the hub

The hydraulic nut is installed same as for the assembly and put under pressure. The nut thread has to be com-
pletely screwed on the shaft journal.
The mounted parts are under high pressure and can cause injuries when pulling them off. The hy-
draulic nut serves as stop to hold the part to be disassembled. For the disassembly, the hub has to be ex-
panded, i. e. oil-pressure has to be given on connection B.
The hub releases abruptly from the shaft journal by oil-pressure on connection B and simultaneous reduction of
the oil-pressure at connection A.
The part to be removed releases suddenly, if the oil-pressure at connection A is reduced down to zero.
Therefore pay attention to the correct assembly of the hydraulic nut.
In case that the hub does not release, the disassembly process has to be repeated with the following changes:
increase the oil-pressure at connection B
let the hub remain under pressure for an hour
heat the hub
use a disassembly device
8 Alignment of the coupling

Before starting the coupling assembly, the drive system has to be aligned. Only couplings in free-standing appli-
cation must be aligned. The more exact the system is aligned, the more reserves are given for the coupling to
compensate displacements during operation.
For the alignment of the system the following alignment tolerances are to be kept.
radial alignment axial angular
tolerance alignment tolerance alignment tolerance
Kr= Ka= Kw=

size 14 19: 1 0.05
0,1 [mm] [mm] []
size 22 34:
0,2 [mm]
size 40 43:
0,35 [mm]
The permissible gap X resulting from the angle
is to be calculated from the angle tolerances
Kw and the reference diameter D:
D
X= tan( K )
2
w
The alignement tolerances must be suitable for the warmed up application

under running conditions.
After the coupling has been installed into the system according to the installation and operating instruction de-
livered with the coupling, we recommend to check the alignment by measuring with a dial gauge over one revo-
lution in order to determine the radial and angular deviations.

02.03.2006 16.03.2006 Version: 004
With respect to series 2800, 2801, 2810,
2811 a machined surface at the flywheel or
at the flywheel housing serves as reference
surface.
Concerning series 2830, 2831 it is mea-

sured from hub to hub (please refer to the
figure).
9 Commissioning and Safety Regulations

After completion of the assembly, the drive system is ready for operation, as far as the coupling is concerned.
We would like to point out that before first operation you have to make sure that all installation
aid devices have been removed from the VULASTIK-L coupling.
10 Replacement of the VULASTIK-L elements
In case of a replacement of the elements, only original VULKAN elements with coordinated
technical data, approved by the classification societies, must be used!
10.1 Replacement of the element in bell-housing applications, series 2800 a. 2801

The VULASTIK-L element can be exchanged by displacing the units.
Sequence of operations (please refer to figure 1, figure 2, figure 3):
Release the screwed connection of the system components and separate the units
Release connecting elements (7).
Pull the flexible element (6) for dual couplings (5, 6) from the hub (4).
Installation of a new element in the reversed order (please refer to chapter 6.1 Assembly of bell-
housing applications, series 2800 a. 2801)
10.2 Replacement of the element in free-standing applications

The VULASTIK-L element can be replaced without having to displace the units.

02.03.2006 16.03.2006 Version: 004
10.2.1 Replacement of the element, series 2810, sizes 1410-1910
Sequence of operations (please refer to figure 4):
Release the connecting elements to the engine flywheel.
Remove housing (1) and spacer ring (12) from the flywheel and deposit them on the hub (4).
Press the element (6) from the flywheel.
Remove the spacer ring (19).
Remove the element (6).
Release connecting elements (11) and remove the intermediate ring (10) from the element (6) and
attach it to the new element.
Installation of the new element in the reversed order (please refer to chapter 6.2.1 Assembly of
series 2810, sizes 1410-1910)
10.2.2 Replacement of the element, series 2810 a. 2811, sizes 2210-4310

Sequence of operations (please refer to figure 5 figure 6, figure 7, figure 8):
Release the connecting elements to the engine flywheel.
Remove housing (1) and spacer ring (12) from the flywheel and desposit them on the hub (4).
Series 2811: additionally deposit the limit ring (8).
Press the element (6) for dual couplings (5, 6) towards the flywheel and remove it.
Release the connecting elements (11) as well and remove the intermediate ring (10) from the ele-
ment and fix it to the new element. This is not applicable for dual couplings of series 2830.
Concerning dual couplings of series 2831: Release connecting elements (18) and remove the
spacer ring (10) from the element (5). and fix it to the new element.
series 2810 u. 2811, sizes 2210-4310)
10.2.3 Replacement of the element, series 2830 a. 2831

Sequence of operations (please refer to figure 9, figure 10, figure 11, figure 12):
Release connecting elements (15, 16, 17) .
Remove the housing (1) from the plate flange (12) and deposit it on the hub.
Series 2831: additionally deposit the limit ring (8).
Press the element (6) for dual couplings (5, 6) towards the plate flange (12) and remove it.
Series 2831: additionally remove the cam ring (19).
Release connecting elements (11) and remove the intermediate ring (10) from the element (6) and
attach it to the new element. This is not applicable for series 2830.
Concerning dual couplings of series 2831: Release connecting elements (18) and remove the
spacer ring (10) from the element (5) and attach it to the new element.
series 2830 a. 2831)
11 Guarantee
On behalf of the international approval bodies, we wish to state the following for classified couplings:
The torsional vibration behaviour of the driving system has been checked and approved by the classification
society. The expected and satisfactory behaviour is guaranteed only, provided that all components comply to
the values, the torsional vibration calculation is based upon. With respect to the coupling, this means to exactly
keep to the dynamic stiffness and damping. In case of a replacement of the elements, only original VULKAN
elements with coordinated technical data, approved by the classification societies, must be used!
12 Maintenance
Under normal circumstances, the highly-flexible VULASTIK-L coupling does not require maintenance. In many
cases, however, the highly-flexible VULASTIK-L coupling is an indicator for malfunctions in the system. In case
02.03.2006 16.03.2006 Version: 004
of unusual events, e. g. propeller contact, misfiring operation, short circuit, faulty synchronization or emergency
shutdown, we recommend a check of the flexible element.
In addition, an annual check of the flexible part and for free-standing applications a alignment control should be
carried out.
If cracks should be found during the visual inspection at the VULASTIK-L element, the element has to be re-
moved.
The element should be replaced after approx. 15000 operating hours or 10 years resp.

02.03.2006 16.03.2006 Version: 004
VULKAN: PRODUCTION Partslist
Manuf.Product: 1X34120379-B Date: 26.03.2007

VULASTIK-L Page: 1
Drawing: 1X34100379 Printed by: WALLBAUM
Item Quant Part Number Description Dimensions Material Remark DM
1 1 3X3400020M-B HOUSING FM 580X 476 X109 G-AlSi7Mg-T64
4 1 4X3420115M-B HUB FM 290X 130 X 250 C45+N
6 1 2X3412A004 VUL-L-ELEMENT 3412
7 16 7000020100-C HEXAGON BOLT M 20 X100 8.8 931M
10 1 3X3411000M-B INTERMEDIATE RING FM 290X 205 X 22 C45E+N
11 2 7010012040 SOCK HD SCREW M 12 X 40 8.8 912M
12 1 3X3416000M-B ADAPTER PLATE FM 580X 205 X 27 C45+N
13 1 4X3431013M-B CONN.FLANGE FM 380 X 150 X 256 C45+N
14 16 7001020055-C HEXAGON BOLT M 20 X 55 8.8 933M
15 12 7000016150 HEXAGON BOLT M 16 X150 8.8 931M
16 12 7020016000 HEX NUT M 16 8 934
17 12 7032016000 WAVE WASHER B 16 55SI7 137
18 16 7033620000 DISC 20 42CrMo4+QT EN 10083-1

Gilt fr / Valid for BCA
Verteiler / Distribution Intranet: Qualitaet / VBCA
Lubricating Oil Specifications
Lubrication of BCA Piston Compressors
Scope of Application
This specification applies to the lubrication of BCA secondary (hyper) compressors, process gas compressors and open/closed

(pressure resistant) labyrinth compressors (Laby ).
General
In the case of the above mentioned compressors, the compressed gas does not come into contact with the crankgear oil.
However, the cylinder lubricating oil of the process gas compressors with lubricated cylinders comes into contact with the
compressed gas and is partially carried over to the process downstream.
a) Crankgear Lubrication
a1) For the lubrication of the crankgear, mineral oil according to the Lubricating Oil Specification (VSB) 1001132 is used.
Exception: Labyrinth compressors (pressure resistant).
a2) For the lubrication of the crankgear of closed (pressure resistant) labyrinth compressors, oil according the Allocation
Table Crankgear Lubrication (VSB) 1001300 must be used
For mineral oil, see Lubricating Oil Specification (VSB) 1001132.
For polyalkylene glycols (PAG), see Lubrication Oil Specification (VSB) 1001301.
b) Cylinder Lubrication
b1) In most cases, mineral oil according to the Lubricating Oil Specification (VSB) 1001133 is used for cylinder lubrication
of BCA process gas compressors.
Exceptions:
Primary compressors for LDPE production: As a rule, the cylinder lubricating oil is the same as in the secondary
compressor: see Lubricating Oil Specification (VSB) 1001134.
Compressors for NH3, corrosive gases etc.: Check with Burckhardt Compression.
b2) For the cylinder lubrication of BCA secondary compressors (hyper compressors), white oils and polyakylene glycols
(PAG) according to the Lubricating Oil Specification (VSB) 1001134 are used.
c) Cooling and Flushing Oil

For Cooling and Flushing Oil of secondary compressors (hyper compressors) the following qualities are admissible:
Technical or pharmaceutical white oil
Mineral oil categories C and CL according to Lubricating Oil Specification (VSB) 1001303.
Rev. Index A Dat. Sig. (VSB) VBCA546005

ausgestellt von / issued by 07.02.2005 KAUFMANN_W ersetzt / replaces VBCA546005
Seite / Page 1
berprft / reviewed 07.02.2005 STAEHELI_H Revision 0
Freigabe DVS 07.02.2005 KAISER_T vom / from 07.05.2004 von / of 1
Allocation Table Crankgear Lubrication
Lubrication of Closed (Pressure-Resistant) Labyrinth Compressors

Area of Application

This specification applies to the lubrication of closed BCA labyrinth compressors (Laby ).
General
Due to solubility and/or chemical reaction issues, certain gases necessitate the application of especially suited types of
lubricating oils. These interactions depend on the temperature and the pressure. For the temperature, a value of 4050 C
(typical oil sump temperature) is assumed, the usual pressures are covered by the allocation table below.
Allocation Table
MO Mineral oil according to Lubrication Oil Specification (VSB) 1001132.
PAG Polyalkylene glycol according to Lubrication Oil Specification (VSB) 1001301.
! Refer to Burckhardt Compression (Dept. CSS) .
X Not admissible
Suction pressure 1 2 3 4 6 10 Remarks

[bar a]
Gas
Methane CH4
MO MO MO MO MO MO
Ethane C2H6
PAG PAG PAG PAG PAG PAG
Ethylene C2H4
MO MO MO For refrigeration applications use special propane
Propane C3H8 PAG PAG PAG
PAG PAG PAG refrigeration oils
MO MO
Butane C4H10 PAG X X X
PAG PAG
MO MO MO MO
Propylene (Propene) C3H6 PAG PAG
PAG PAG PAG PAG
Butylene C4H8 PAG PAG X X X X
MO
Butadiene C4H6 PAG X X X X
PAG
MO
Vinyl chloride (VCM) PAG X X X X
PAG
Dimethyl ether (DME) MO MO
MO X X X No operation experience (02/2003)
(CH3)O(CH3) PAG PAG
Reacts with certain additives
Ammonia NH3 ! ! ! ! ! !
Check suitability of the product used
Carbon monoxide CO MO MO MO MO MO MO
Carbon dioxide CO2 MO MO MO MO MO MO
Air, nitrogen, noble gases MO MO MO MO MO MO
Sulphur dioxide SO2 ! ! ! ! ! !
Hydrogen sulphide H2S ! ! ! ! ! ! Special oils available (corrosion protection)
Chlorine Cl2 ! ! ! ! ! !
Helium He MO MO MO MO MO MO
Gases and pressures not listed: Check with Burckhardt Compression AG or oil manufacturers.
Rev. Index Dat. Sig. (VSB) 1001300

ausgestellt / issued 02.12.2004 KAUFMANN_W
Mitgeltende Unterlage zu Seite / Page 1
berprft / reviewed 07.02.2005 STAEHELI_H VBCA 546005
Freigabe DVS 07.02.2005 KAISER_T Applicable Dokument to von / of 1
Lubricating Oil Specification
Crankgear Lubrication Mineral Oil
This specification applies to BCA compressors with the crankgear lubricated with mineral oil.
Lubricating Oil Categories

Lubricating oil category C (according to DIN 51 517 Part 1): Ageing-resistant mineral oils without additives.
Lubricating oil category CL (according to DIN 51 517 Part 2): Mineral oils containing additives to increase
corrosion protection and aging resistance.
Note: There are no corresponding ISO standards to these categories.
Other lubricating oil categories (VBL, VCL, VDL, L-TD, HL according to DIN 51 502 or L-DAB, L-DAC, L-DAG, L-DAH, L-TSA,
L-TGA, L-TGB, L-HH, L-HL, L-HM, L-HR, L-HV according to ISO 6743-X) are admissible if they meet the following requirements
stated below.
Only lubricating oils FREE of zinc dialkyl dithiophosphate (ZDDP, ZDTP, ZDP) may be used!
Requirements
Parameter Value Unit DIN ISO

Viscosity class VG 150 (kin. Viscosity 150mm/s 10% at 40 C) * - 51 519 3448
Density at 15 C Report kg/m 51 757
The sump and/or inlet temperature must be between +5 C and +60 C.

The use of lubricating oils that differ in particular points from these requirements must be cleared with Burckhardt
Compression AG.
Burckhardt Compression AG does not assume any responsibility for the quality and properties of the used
lubricating oils.
Further relevant BCA specifications etc.:
MI-76en Safe Handling of Lubricants
VSB 1001135 Selection List
Rev. Index A Dat. Sig. (VSB) 1001132

berprft / reviewed 07.02.2005 STAEHELI_H VBCA546005
Selection List
Lubricating Oils ISO VG 150 Categories C / CL
General
This list contains a selection of lubricating oils of the viscosity class ISO VG 150 in the categories C (DIN 51 517 Part 1) and CL
(DIN 51 517 Part 2). The listing is in alphabetical order according to manufacturers and/or brand names. It is intended for the
use with Lubricating Oil Specifications (VSB) 1001132 and (VSB) 1001133.

Lubricating oil category C (according to DIN 51 517 Part 1): Ageing-resistant mineral oils without additives
Lubricating oil category CL (according to DIN 51 517 Part 2): Mineral oils with additives to increase corrosion
protection and ageing resistance.
This list contains only lubricating oils without zinc dialkyl dithiophosphate (ZDDP, ZDTP, ZDP) additive.
Category
Brand Name Name VG Remarks ISO
(DIN 51 517)
AGIP Radula 150 150 C

AGIP Acer 150 150 CL/HL
BP Amoco Energol CS 150 150 C
Castrol Magna 150 150 C
Chevron (Texaco) Regal R&O 150 150 CL
ExxonMobil DTE Excel 150 CL
ExxonMobil Mobil Vacuoline 128 150 C
Shell Vitrea 150 150 C
Shell Morlina 150 150 CL
Total Cirkan RO 150 150 CL
Total Dacnis P150 150 CL
Strub Vulcobase P 150 C
Burckhardt Compression AG does not assume any responsibility for the quality and properties of the used
lubricating oils.
Rev. Index B Dat. Sig. (VSB) 1001135

Lubricating Oil Specification
Laby Polyalkylene Glycol Lubricants

This specification applies to BCA labyrinth compressors (Laby ) that are lubricated with polyalkylene glycol (PAG) according
to Lubricating Oil Specifications (VSB) 1001300.
General
Hydrocarbons and other process gases dissolve to an appreciable degree in mineral oils. The resulting drop in viscosity and the
formation of foam with fluctuating suction pressures can cause operating failures. For polyalkylene glycol, the solubility is much
lower and, therefore, lubricating oils on polyalkylene glycol basis are preferably used to compress these gases.
Lubricant Category
Synthetic lubricating liquids on polyalkylene glycol basis (PAG, polyglycol), especially formulated for the use in gas
compressors.
Note: There are no DIN or ISO standard for these lubricants
Caution!
Gear lubricants on a polyalkylene glycol basis have different properties and must not be used in BCA gas compressors!
Polyalkylene glycol based lubricants are hygroscopic, i.e. they attract humidity from the air. Therefore, contact with ambient air
should be kept to a minimum.
Requirements
Parameter Value Unit DIN ISO

Viscosity at 40 C 120 200 mm/s 51 519 3448
Density at 15 C Report kg/m 51 757
The oil sump and gas inlet temperature must be between +5 C and +60 C.
The use of lubricating oils that differ in particular points form these requirements must be cleared with Burckhardt
Compression AG.
VSB 1001302 Selection List

Selection list
Laby Polyalkylene Glycol Lubricants
General
This list contains a selection of lubricants on polyalkylene glycol basis (PAG) for compressors. The order is according to
manufacturers and/or brand names. It is intended for the use with the Lubricating Oil Specification (VSB) 1001301.

Synthetic lubricants on polyalkylene glycol basis (PAG, polyglycol), especially formulated for the use in hydrocarbon
compressors, with additives to increase the corrosion protection and the aging resistance.
Note: There are no DIN or ISO standards for these lubricants
Kinemat.
Brand Name Remarks
viscosity
at 40 C
[mm/s]
BP Amoco Enersyn GCS 180 185

Castrol Aircol PG 185 185
Chevron/Texaco LPG Compressor Oil 185
Cognis Compressor Lubricant LPG9 185
ExxonMobil Gas Compressor Oil 185
Shell Madrela T 190
Total Orites 125 DS 126
Burckhardt Compression AG does not assume any responsibility for the quality and properties for the
used lubricating oils.

ausgestellt / issued 03.10.2005 KAISER_T
berprft / reviewed VBCA546005
KW- Lager Schubst.- Lager KK-Zapfenlager offen gasdicht druckfest **)
operation at site
clearance after
Stufe Alle Masse in mm
Dnnwandlager Stage All dimensions in mm
Dickwandlager Etage Position Toutes dimensions en mm
Stadio Tutte le dimensione en mm
Galvanisiertes Lager
Etapa Todas las dimenciones en mm
Gestell
Min. Max. Max.
A Total Total Allow.
a
1) I A2 415 0.415 0.568 1.20
1) II A1 260 0.260 0.362 0.80
-- -- -- -- -- --
-- -- -- -- -- --
C
*) B 75 0.050 0.089 0.15

*) C 100 0.110 0.162 0.22
*) D 250 0.070 0.128 0.19
b
*) E 140 0.098 0.177 0.22
2) a 2.00 2.50 --
2) b 1.50 2.00 --
c/2 c 0.100 0.185 0.25
c/2 e -- -- --
*) F 140 0.095 0.145 0.20
B
D *) G -- -- -- --
V1 V2 *) H 140 0.095 0.145 0.20
II I *) K -- -- -- --
f 0.70 1.30 --
g -- -- --
h 0 -- --
k -- -- --
1) - If pistons are not run-in in our shop
piston clearances can be less as follows:
A2 min. allow. = 0.27 mm
A1 min. allow. = 0.19 mm
- Max piston clearance after running
in procedure:
A2 max.allow. = 0.75 mm
A1 max.allow. = 0.45 mm
(material and discharge temp.considered)
2) Min. allow. for "b" = 1.40mm

and "a+b" shall not exceed 4.50mm
F
a,b = highest resp. lowest part is relevant

(pistone plate, skirt, rod, nut)
E
f h
*) Wenn Spiele mit Fhlerlehre gemessen, knnen obige Spiele wie folgt kleiner sein: Ausfhrung mit KK-Zapfenlager
min. < 0.1mm = 0.01mm und min. > 0.1mm = 0.015mm gem. Zeichnung 2-122.802.944
*) If clearances measured by feeler gauges, the above values can be less as follows:
min. < 0.1mm = 0.01mm and min. > 0.1mm = 0.015mm
Version with cross head pin bearing
**) Remarks and descriptions see chapter 6 of manual acc. drawing 2-122.802.944
Spieltabelle fr lfreie Laby-Kompressoren (Zeichnungsmasse)
Clerance table for oilfree laby-compressor (Dimensions on drawing)
Tableau des jeux de compresseur a piston sec (Dimensions du dessin)
Tavola dei giochi del compressore a pistone secco (Dimensioni di disegno)
Tabla de juegos del compresor de piston seco (medidas sequn dibujo)
Rev. Index A B C D E 2K158-2D_1

Erstellt von M.Heiri Typ
Datum 05.02.2007
Geprft von H.Stheli 2000697 / 100822-823
Datum 05.02.2007 Auftrag/Masch. Nr. TDO 2012787/D02
Anzugsdrehmomente Tightening torques
Serrage des couples Coppie di serraggio
Pares de apriete Apertando torques 2K158-2D_1
001-2 001-1
002-2 002-1
003-1
004
003-2
005
018
006 017-1
012
015 017-2
014
008
016 013 011
CO20/WK 19.06.2007 TIM-ID 1973 Rev. 001

TIGHTENING TORQUES 2K158-2D_1
Pos. Bolt / Location Dimension Material Method Torque Angle

001* Cylinder cover
st
-1 1 stage M30 x 113 A4-70 II 650 - 700 Nm 20 - 30
nd
-2 2 stage M30 x 113 A4-70 II 650 - 700 Nm 20 - 30
002* Pipe connection gas piping
st
-1 1 stage M24 x 114 A4-70 II 300 - 350 Nm
nd
-2 2 stage M30 x 148 A4-70 II 650 - 700 Nm
003* Valve cover
st
-1 1 stage M24 x 104 A4-70 II 300 - 350 Nm
nd
-2 2 stage M24 x 109 A4-70 II 300 - 350 Nm
004* Piston nut G1 3/4" 1.7225-B7 V 34 Nm
005* Piston rod packing M20 x 99 A4-70 II 180 - 210 Nm
006* Frame Cylinder M36 x 232 A4-70 II 1100 - 1300 Nm 20 - 30
007** Piston rod crosshead - - - -
008** Connecting rod M36x3 x 265 34CrNiMo6 IV l =0.28 0.34mm
009** Main bearing cover - - - -
010** Frame base plate - - - -
011** Foundation bolt M36 x 800 3.6 II 650 - 850 Nm
012** Cover plate pump side M30 x 80 8.8 II 800 - 900 Nm
013** Cover plate flywheel side M30 x 80 8.8 II 800 - 900 Nm
014** Coupling bolts M24 x 153 C45E II 300 - 400 Nm
015** Crankshaft nut M98 x 2 C60E II 1100 - 1200 Nm
016** Counterweight
fixation with Locking wire M30 x 136 34CrNiMo6 II 350 - 550 Nm

fixation with NORD-LOCK M30 x 123 A193 B16 II 750 800 Nm
017** Frame cover plate
-1 guide bearing M20 x 45 8.8 II 240 - 270 Nm
-2 crankshaft M24 x 55 8.8 II 400 - 450 Nm
018** Guide bearing M16 x 35 8.8 II 120 - 150 Nm
= The proper tightness of the bolt connections marked with must be checked periodically.
Lubricate all bolt connections.

*Lubricate the bolts at the cylinder with Lubrication Grease BLG05.
**Lubricate the bolts at the frame and at the base plate with Molykote G-N PLUS.
Lubricate all the other bolt connections according to the instructions, stated in data sheet MBN 0707.
DOK.-NR.:
REV. INDEX
(TDO)
2013023
ERSTELLT / PREPARED 10.01.2007 HAUETER_D
UEBERPRUEFT / REVIEWED SEITE / PAGE
GENEHMIGT / APPROVED 18.01.2007 SCHWARZ_D SW / 11-04-00 / rev. 0 VON / OF

Index
Numerics overview 4-3

1,3-Butadiene 2-30 Compressor design and function 4-1
1-Butene 2-32 Compressor designation 1-5
Compressor maintenance 2-12
A Compressor operation 2-11
Absorbent agent 5-57, 11-4 Connecting rod 4-19, 9-50
Acids 2-9 Connecting rod bearing 8-30, 9-48
Actuator 4-33 Conservation of cleanliness 10-11
Address 1-5 Control elements 3-16
Customer Support Service 1-5 Controlled suction valve 4-33, 9-7
order address 12-3 Controlled suction valves 8-49
Algae 8-19 Coolant treatment 3-12
Align electric motor 5-27 Cooling system 3-11, 3-12, 8-17
Ammonia 2-37 Coupling 5-28, 9-54
Assemble compressor 5-17 Crankgear 4-7, 8-27
Assemble compressor components 9-1 maximum operating pressure 4-7
Assess vibrations 5-55 Crankshaft 4-8
Crankshaft bearing 4-8
B Crankshaft deflection 5-20
Bearing bracket 9-58 Crankshaft seal 4-11, 9-57
BLG05 4-27 gastight design 4-11
Brands 1-9 Crosshead 4-20, 8-31, 9-50
Burckhardt Lubrication Grease BLG05 4-27 lubrication 4-20
Burckhardt Plate Valve 4-28 Crosshead pin bearing 8-32, 9-51
Bypass 3-4 Cylinder 4-23, 8-34, 9-41
Cylinder configuration 4-23
C Cylinder cover 9-22
Calcium deposits 8-19
Capacity control 4-31 D
Check crankshaft deflection 5-29, 8-27 Definitions for this document 1-1
Check fabrication 5-37 Deposits 3-12
Checks after liquid knock 8-33 Deposits of sand 8-19
Chemical handling 2-7 Depressurize plant 8-5
Clean compressor plant 8-6 Dimensions 5-9, 8-21
Cleaning Discharge pressure 4-6
tools and facility 10-6 Discharge valve 4-28
working environment 10-5 Discharge valves 8-46, 9-10
workplace 10-5 Dismantle compressor components 9-1
Cleaning method Dismantle crankshaft sidewards 9-59
chemical cleaning 10-9 Disposal 11-5
degreasing with solvent vapor 10-10 Dispose components 11-5
flushing 10-10 Distance piece 4-22
immersion 10-10 Drain lubricating oil 9-24
mechanical cleaning 10-9 Drive system 3-3
spraying 10-10
ultrasonic cleaning 10-11 E
wiping 10-10 Electric motor 5-25, 9-54
Cleaning methods 10-8 Electric motor rating 4-6
Cleaning of compressor plant 2-12 Electrical hazard 2-6
Cleaning specification 10-3 Electrical motor and coupling 8-14
Cleansing agent 10-6 Emergency stop 3-17
Clearance measurement 8-23 Ethane 2-24
Commissioning 6-3 Ethylene 2-22
Commissioning after maintenance 2-13
Compressor
F
design data 4-6 Fabricate piping 5-35

Index
Failed piston 8-39 Leveling screws 5-14

Final assembly 5-45 Lift cylinder 5-12
Flammable process gas 2-11 Lifting procedure 5-10
Flange connections 8-14 Liquid knock 3-10
Flow monitoring 3-18 Log sheet 6-8
Flywheel 5-17, 9-55 Lubricant handling 2-6
Frame covers 9-23 Lubricating system 3-15
instrumentation 8-20
G Lubrication
Gas specification 2-13 Burckhardt Lubrication Grease BLG05 4-27
Gas system 3-4 crosshead 4-20
check cleanliness 5-49 guide bearing 4-22
Gear oil pump 4-16, 9-52 piston 4-25
Grouting Material 5-13 Lyes 2-9
Guide bearing 4-21, 8-33, 9-46
lubrication 4-22 M
Guide bearing bush 9-46 Main bearing 9-58
Guide bearing clearance check 8-33 Main bearing drive end 4-10
Main bearing non-drive end 4-9
H Maintain plant during decommissioning 5-57,
Hand-operated control unit 4-31 11-4
Hazard identification diamond 2-14 Maintenance
Hazard seriousness 1-6 prerequisites 8-3
caution 1-7 Maintenance practices 2-12
danger 1-7 Maintenance Schedule
warning 1-7 plant 8-12
Heating system 3-12 Maintenance schedule 8-11
Hydraulic pressure test 5-46, 8-20 compressor 8-12
Mandatory tightening torques 5-4
I Marking of compressor components 8-21
Importance of Cleanliness 5-3 Marking of Packages 5-6
Important notes 5-3 Mass flow 4-6
Inspect compressor plant 5-55 Maximum power requirement 4-6
Install compressor 5-13 Mechanical hazard 2-5
Install coupling 5-25 Methane 2-18
Install electric motor 5-25 Methyl chloride 2-16
Install Pipe Work 5-34
Install plant components 5-33 N
Install skid on Hulls steel structure 5-31 Name plate 1-5
Installation 5-1 n-Butane 2-34
Instruction Manual NFPA-Rating 2-14
applicability 1-4 Nitrogen 2-36
document structure 1-6 Non-return valve 3-18, 5-47, 9-4
revision sheets 1-3 NORD-LOCK securing system 4-30
symbols 1-6
target group 1-4 O
warnings 1-6 Obligations 2-3
Intended use 2-11 Oil change 8-25
Intermediate piece 5-23 Oil drain 4-14
Internal gas leakage pipes 9-39 Oil feeding valve 4-15
Oil leakage 4-11
L Oil pressure 4-17
Labyrinth piston 4-26 Oil scrapers 9-43
Level compressor 5-14, 5-15 Oil shield 4-22
Level indicator 3-18 Oil sight glass 4-14
Level monitoring 3-18 Oil strainer 4-14, 9-26

Index
Oil trap 9-57 Relief valve 4-17

Operating elements 3-16 Revisions 1-3
Operation 6-1 Rotation speed 4-6
prepare 6-3 Run-in pistons 5-52
safety precaution 6-5, 8-3
Operation with process gas 6-5 S
Organic solvents 2-10 Safety
Orifice plates 3-9 preventive measures 2-5
Safety advice 2-1
P Safety devices 2-5, 3-16, 8-20
Pipe fastenings 8-14 Safety measures 2-4
Pipe support 5-39 Safety of transport 5-5
Pipe work Safety valve 3-17
blow-out 5-50 Safety valves 8-20
fabrication 5-34 Scope of supply 5-7
Piston 4-25, 8-35, 9-27 Separator 3-10
labyrinth principle 4-26 Serial number 1-5
lubrication 4-25 Shaft system 5-24
Piston nut seizure 4-28 Shipping condition 5-7
Piston nut SUPERBOLT 4-27 Shipping Package 5-5
Piston rod 4-25, 8-34, 9-27 Space requirement 5-9, 8-21
Piston rod gland 4-24, 8-34, 9-39 Spare Parts
Place compressor 5-14, 5-15 order address 12-3
Plant configuration and function 3-1 Spare parts 12-1
Pre-comissioning of compressor plant 5-47 Spare parts drawings 12-17
Pre-Commissionin 5-1 Spare parts list 12-8
Pre-commissioning Spare parts recommendation 12-5
coolant system 5-48 Spares inventory 12-4
oil System 5-49 Standard volume 4-6
Prepare assembly 5-17 Standstill 5-55, 6-9, 11-3
Prepare installation 5-14, 5-33 Start compressor 6-6
Preserve compressor plant 11-3 Stop compressor 6-7
Preserve compressor plant after installation 5- Store components 5-8
55 Suction pressure 4-6
Pressure monitoring 3-17 Suction strainer 3-4
Preventive maintenance 8-1 Suction temperature 4-6
Process gas 2-13 Suction valve 4-28
Propane 2-28 Suction valves 8-46, 9-10
Propylene 2-26 Suction volume 4-6
Protection against loud noise 2-6 SUPERBOLT 4-27, 8-40
Pulsation damper 3-9 Switch off compressor 9-3
Purge gas 2-13 Switch off cooling system 9-3
Purge plant 6-4, 8-5
Purge system 3-4 T
Purging prior to maintenance 3-4 Tank evacuation 6-6
Purging prior to normal operation 3-4 Technical Documentation 1-4
Technical support 5-3
R Temperature monitoring 3-17
Raschig filter 4-18 Thermal barrier 3-11
Recommission plant 5-58, 11-5 Thermal hazard 2-5
Reference documents 1-4 Tighten fastening bolts 5-16
Refill lubricating oil 9-24 Tightening Methods 8-25
Refrigeration Tightening torques for attachment gear 5-11
capacity 3-5 Tools 8-7
cycles 3-5 special 8-10
Registered trademarks 1-9 standard 8-7

Index
Transport 5-1, 5-5 Valve components 4-30

Trouble Shooting Valve failures 8-47
compressor noise 7-18 Valve service 8-46
compressor shutdown 7-25 Valves 8-46
compressor vibrations 7-24 VCI mat 5-57, 11-4
coolant system 7-10 VCM 2-20
lubricating system 7-12 Vinyl chloride 2-20
prerequisites 7-3
process gas system 7-4 W
Trouble shooting 7-1 Warning signs at compressor site 2-4
Turn flywheel 5-23, 5-50 Warning symbols 1-7
Weights 5-9, 8-21
U
Unload compressor 5-7 Y
Year of manufacture 4-6
V
Valve 4-28

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Compressor Type

IM 100822en Key Word

Laby Compressor Order No.

1 Definitions for This Document

2 Elementary Safety Advice

3 Plant Configuration and Function

4 Compressor Design and Function

5 Transport, Installation and Pre-Commissioning

9 Dismantle and Assemble Compressor Components

10 Clean and Degrease Plant and Compressor

11 Decommissioning or Dispose Plant

20.06.2007 Rev. 001/kaufmann_w 2K158-2D_1 IM 100822en

IM 100822en 2K158-2D_1 Rev. 001/kaufmann_w 20.06.2007

1 Definitions for This Document

1.1 Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

27.06.2007 Rev. 001/kaufmann_w 2K158-2D_1 IM 100822en 11

12 IM 100822en 2K158-2D_1 Rev. 001/kaufmann_w 27.06.2007

Book Chapter Technical Page Description

If there have been necessary technical modifications, the present Instruc-

27.06.2007 Rev. 001/kaufmann_w 2K158-2D_1 IM 100822en 13

1.2 Purpose of This Manual

The Instruction Manual must be read carefully before commissioning, as

1.2.2 Target Groups and Assumed Knowledge

Target group Description Tasks and responsibilities Chapter

14 IM 100822en 2K158-2D_1 Rev. 001/kaufmann_w 27.06.2007

1.2.3 Compressor Designation

The serial number is located on the name plate (1).

1 Number of crankthrows 4 Design of crankgear

1.3 Contact Address

27.06.2007 Rev. 001/kaufmann_w 2K158-2D_1 IM 100822en 15

1.4 Structure and Layout

1.4.1 Document Structure

1.4.2 Visual Elements

1.5 Term Used for Compression Media

1.6 Warnings and Symbols

1.6.1 Level of Hazard Seriousness

16 IM 100822en 2K158-2D_1 Rev. 001/kaufmann_w 27.06.2007

1.6.2 Useful Information

1.6.3 Warning Symbols Used in This Instruction Manual

Common safety sign. Generally, the triangular warning

Whenever possible, the symbol indicates the hazard a person is exposed

Automatic start-up possible

Electrical danger or hazard

Machine under maintenance or overhaul

27.06.2007 Rev. 001/kaufmann_w 2K158-2D_1 IM 100822en 17

Flammable material or risk of fire

Potentially explosive atmosphere

Hot surface, dont touch!

Pressurized vessel or pipe depressurize plant before

Slip hazard watch your step!

Corrosion hazard, avoid contact with caustic substances!

Risk of frost or low temperature

Read instruction for operation and maintenance

Wear hearing protection

Do not remove Instruction Manual from compressor site

18 IM 100822en 2K158-2D_1 Rev. 001/kaufmann_w 27.06.2007

without our authorization.

1.8 Registered Trademarks and Brands

27.06.2007 Rev. 001/kaufmann_w 2K158-2D_1 IM 100822en 19

1 10 IM 100822en 2K158-2D_1 Rev. 001/kaufmann_w 27.06.2007

2 Elementary Safety Advice

2.1 Avoiding Dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3

27.06.2007 Rev. 001/kaufmann_w 2K158-2D_1 IM 100822en 21

22 IM 100822en 2K158-2D_1 Rev. 001/kaufmann_w 27.06.2007