B08 - Attachment 1 - Maintenance and Troubleshooting.pdf

MAINTENANCE INTERVALS & TROUBLESHOOTING

(FOR MODELS: JGC AND JGD)

Recommended Maintenance Intervals Continuous Duty - Reciprocating Compressors

Ariel compressors, like all industrial equipment, require maintenance. The severity of compressor service directly influences the frequency and amount of maintenance needed. Below are recommended intervals for inspections and replacements to help determine appropriate intervals for a given compressor application. Careful documentation of inspection results is critical to establish whether recommended intervals are adequate or require more or less frequency.

For intermittent duty service, see ER-S.2.2.

As part of your maintenance program, Ariel recommends:

• Consistent adherence to safety policies, procedures, and equipment warning labels.

• Daily operational checks.

• Routine trending and review of operational parameters.

• Routine oil analysis and trending.

• Detailed records of all maintenance.

To avoid contamination, keep all covers in place where access is not required. Use lint free cloths or paper towels during internal maintenance.

CAUTION: Gas compressors are complicated and dangerous pieces of equipment. Only fully trained operators and mechanics familiar with unit operation should attempt any maintenance. Read and thoroughly understand your manual and always wear appropriate personal protection equipment during maintenance.

Never adjust any fastener torques while the unit is operating or pressurized.

To prevent serious personal injury or death, verify driver or compressor cylinder gas pressure cannot turn compressor crankshaft during maintenance. For engine-driven compressors, either remove the center coupling or lock the flywheel; for electric motor-driven compressors, either detach the driver from the compressor or lock out the driver switch gear. Before any maintenance or component removal, relieve all pressure from compressor cylinders. See packager information to completely vent the system or call the packager for assistance. After maintenance, purge the entire system with gas prior to operation to avoid a potentially explosive air/gas mixture.

CAUTION: Gas compressors are complicated and dangerous pieces of equipment. Only

Initial Maintenance

Comply with Ariel Packager Standards and the compressor Start Up Check List. Adhere to all items before and after start-up. After running a new, relocated, reconfigured, or overhauled compressor for 24 hours, shut down, vent the gas system, and perform the following maintenance:

1. Perform a hot coupling alignment check within 30 minutes of shutdown; bar driver shaft to packager recommendations.

To ensure parallel and concentric drive train alignment, position connected equipment so the total indicator reading (TIR) is as close to zero as possible on the coupling hub faces and outside diameters at normal operating temperature. Do not exceed 0.005 inches (0.13

mm) on the face and outside diameter, except for outside diameters above 17 in. (43 cm) where the angular face TIR limit is 0° l' (0.0167°) .

Hub 0.0. > 17 in. x 0.00029 = angular coupling-hub face TIR, in. max .

Hub 0.0. > 43 cm x 0.0029 = angular coupling-hub face TIR, mm max.)

Center the coupling between the driver and compressor. It must not thrust or force the crankshaft against either thrust face.

For cold alignment, account for the difference in thermal height between the compressor and driver. Table 1 lists compressor centerline height change based on 6.5 x 10^-6/℉ (11.7 x 10^-6°C) and a differential temperature of 100°F (55.6°C). Obtain driver thermal growth predictions from the driver manufacturer.

2. At hot alignment check, adjust discharge bottle supports and head end supports, if applicable. NOTE: To avoid cylinder distortion, lift discharge bottles only 0.003 to

0.005 inch using the supports.

3. Check fastener torque on gas nozzle flanges, valve caps, cylinder heads, piston rod packing flanges, and crosshead guide to frame bolting, if applicable. See Maintenance and Repair Manual or Ariel document ER-63 for correct torques. After the first week or 150 hours, recheck fastener torques.

4. Repeat torque check after the first month or 650 hours; re-check fasteners that turn after the second month or 1300 hours. If loosening persists, consult your packager or Ariel for probable cause and recommended correction.

Daily Maintenance (BLM RESPONSIBILITY)

1. Log and trend the following:

a. Operating RPM, gas pressure and temperatures - determine if the unit is operating within design parameters and expectations. NOTE: Verify high and low pressure shutdowns are set as close as practical to normal operating conditions. Set points must protect the machine from exceeding compressor limits.

b. Bearing temperatures - if the unit is equipped with main bearing temperature sensors.

c. Frame oil pressure - at operating temperature (190°F (88°C) max. inlet oil temperature), it should be 50 to 60 psig (3.5 to 4.2 barg) at the filter gauges. If pressure falls below 50 psig, shut down the compressor then determine and correct the cause.

d. Frame inlet oil temperature.

e. Oil filter differential pressure - differential pressure exceeding the filter change value indicates a need for a filter change. See filter information plate on top cover or Maintenance and Repair Manual for procedure.

2. Check frame oil level. It should be about mid-level in the sight glass and free of foam when running. If not, determine and correct the cause. Do not overfill. Check oil makeup tank for sufficient oil supply. For dry sump frames, check the package sump oil level.

3. Check force feed lubricator box oil level. It should be full to the overflow line.

4. Log and trend packing vent temperature and check cross head guide vents for leakage.

5. If applicable, check suction valve unloader actuator vents for leakage.

6. If applicable, check clearance pocket vents for leakage.

7. Verify the high discharge gas temperature shutdown is set to within 10%, or as close as practical, above the normal operating discharge temperature. Do not exceed the maximum discharge temperature shutdown setting for the application.

8. Log and trend valve cap temperatures.

9. Check lubricator block cycle time. See lubricator box data plate for correct cycle time.

Contaminated gas may require a shorter cycle time. Check lube sheet for units not running at rated speed.

10. Check for gas, oil, and coolant leaks. CAUTION: Do not attempt to repair leaks while the unit is operating or pressurized.

11. Check for unusual noises or vibrations.

12. See packager documentation for additional recommended checks, i.e. scrubber liquid levels, dump valve operation, cooler louver positions, etc.

Monthly Maintenance (BLM RESPONSIBILITY)

1. Perform all Daily maintenance.

2. Sample frame oil and send it to a reputable lubricant lab for analysis. See Ariel Packager

Standards (ER-56.06) for a list of what an oil analysis should provide. If analysis results indicate increasing levels of lead, tin, or copper particles in the oil, shut down unit.

Remove frame top cover and cross head guide side covers. Visually inspect for debris.

Do not disassemble further without good reason. If debris indicates, replace affected parts, then change the oil, oil filter, and clean the oil strainer with a suitable solvent.

Six-Month (4,000 Hour) Maintenance (CONTRACTOR RESPONSIBILITY)

1. Shut down unit and allow sufficient time for components to cool.

2. Drain and replace force feed lubricator box oil.

3. Clean sintered element in the small oil filter on the force feed lubrication system now or at every main oil filter change. Use a suitable solvent.

4. Change oil filter. See top cover filter information plate or Maintenance and Repair

Manual for procedure). NOTE: On replaceable element style filters, drain the canister completely before removing the element. NOTE: Replaceable filter elements have a finite shelf life. Check the "Install by" date on the filter element before installation.

Inspect elements for cleanliness and damage. Do not install dirty or damaged elements.

5. Change oil. Extremely dirty environments, oil supplier recommendations, or oil analysis may dictate a different oil change interval. Follow these steps:

a. Drain oil from frame, associated piping, and oil cooler.

b. Clean oil strainer with suitable solvent.

c. Open frame top cover and crosshead guide side covers. Visually inspect for debris. Do not disassemble further without good reason. If debris indicates, replace affected parts, then change the oil and filter and clean the strainer with a suitable solvent.

d. Refill frame with fresh, clean oil.

6. Check cylinder lubrication. See Maintenance and Repair Manual for procedure.

7. Re-tighten hold down nuts to proper torque. Inspect for frame twist or bending to verify main bearing bore alignment. See Ariel document ER-82 for flatness and soft foot requirements.

8. Perform a coupling alignment (see "Initial Maintenance" above).

One-Year (8,000 Hour) Maintenance (CONTRACTOR RESPONSIBILITY)

1. Perform all Six-Month maintenance.

2. Grease WCP stem threads at grease fitting, with 2 to 3 pumps of multi-purpose grease using a standard hand pump grease gun. Turn WCP adjustment handle all the way in and all the way out to lubricate the threads. Measure or count turns to return the handle to its original position.

3. Open force feed lubricator box and visually inspect pump followers, cams, and gears for wear.

4. Pressure test distribution blocks. See Maintenance and Repair Manual for procedure.

5. Measure, log, and trend the following:

a. Main bearing, connecting rod bearing, and crankshaft jack and thrust clearances.

NOTE: Clearance trends along with oil analysis and crankcase visual inspection can indicate the need for bearing replacement. Contact Ariel for original assembly clearances.

b. Crosshead to guide clearances.

c. Piston rod run out.

See Maintenance and Repair Manual for procedures. If any of the above items are outside limits listed in the Maintenance and Repair Manual, replace the affected parts.

6. Remove valves and valve gaskets:

a. Visually inspect valve pockets for damage. Verify all old valve seat gaskets are removed.

b. Have a qualified valve repair shop disassemble, visually inspect, and refurbish the valves where needed. Provide the valve repair shop an Ariel torque chart and valve service guide.

c. Visually inspect cylinder gas passages and clean them of all debris.

7. If applicable, visually inspect suction valve unloader actuator stems for damage or wear.

Visually inspect stem seals for damage or wear and confirm that the actuator moves freely.

8. If applicable, visually inspect valve pneumatic clearance pockets for damage or wear (seating surface and stems/stem seals). Confirm that actuator moves freely.

9. Inspect cylinder bores for damage or wear. Replace the cylinder body or restore the bore if any of the following conditions exist:

a. Bore surface blemishes or gouges.

b. Bore out of round more than 0.001 inch per inch of bore diameter (0.001 mm/mm) or tapered.

10. Inspect piston rings and wearband:

a. Measure and log piston ring condition, end gap, and side clearance.

b. Replace rings that are damaged or outside limits listed in Maintenance and Repair Manual.

c. When replacing rings, re-measure and log ring side clearance to check for groove wear.

d. Measure and log radial projection of wear band.

11. Inspect piston rods for damage and excessive wear. Replace rod if any of these conditions exist:

a. Gouges or scratches on the rod.

b. Under size more than 0.005 inch (0.13 mm).

c. Out of round more than 0.001 inch (0.03 mm) per inch of rod diameter.

d. Tapered more than 0.002 inch (0.05 mm) per inch of rod diameter.

12. Rebuild piston rod pressure packing cases. See Maintenance and Repair Manual for procedure.

13. Re-install valves, retainers, and valve caps using new valve gaskets and valve cap o-rings/seals. Use proper installation techniques and torque procedures for valve caps.

14. Check and re-calibrate all required instrumentation.

15. Clean crankcase breather filter with suitable solvent.

16. Check and, if needed, adjust drive chains. See ER-74 for procedure.

17. If the compressor is equipped with crankcase over-pressure relief valves, visually inspect and exercise valves to manufacturer recommendations.

18. Check fastener torques of gas nozzle flange, valve cap, piston rod packing, cross head pin through bolt, crosshead guide to frame, crosshead guide to cylinder, cylinder mounting flange to forged steel cylinder, distance piece to cylinder, distance piece to crosshead guide, and tandem cylinder to cylinder.

Two-Year (16,000 Hour) Maintenance (CONTRACTOR RESPONSIBILITY)

1. Perform all Daily, Monthly, Six-Month, and One-Year maintenance.

2. Rebuild oil wiper cases.

3. If applicable, use new piston and stem seals to rebuild actuators on suction valve unloaders and fix volume pneumatic pockets. Replace piston stem assemblies where stem is damaged or worn.

4. Check auxiliary end chain drive for undercut sprocket teeth and chain for excessive stretching. Replace as required.

Three-Year (24,000 Hour) Maintenance (CONTRACTOR RESPONSIBILITY)

1. Perform all Daily, Monthly, Six-Month, and One-Year maintenance.

2. Replace non-ELP connecting rod bearings for JGJ:E:T:C:D:U:Z:B:V and KBB:V. See

Maintenance and Repair manual for procedure. NOTE: Main and connecting rod bearing wear and replacement intervals are heavily dependent on many factors including speed, load, oil temperature, oil cleanliness, and oil quality. Depending on the severity of service, the bearing maintenance interval may be longer or shorter.

Four-Year (32,000 Hour) Maintenance (CONTRACTOR RESPONSIBILITY)

1. Perform all Daily, Monthly, Six-Month, One-Year, and Two-Year maintenance.

2. Remove crosshead pins. Measure and log crosshead pin to crosshead pin bore and connecting rod bushing bore clearances. Check the crosshead pin end caps and through bolt for wear. Replace if needed.

3. Check for bushing wear in the auxiliary end drive chain tightener.

4. Check for ring groove wear in pistons.

Trouble Shooting

Minor problems can be expected during the routine operation of an Ariel compressor. These troubles are most often traced to liquid, dirt, improper adjustment or to operating personnel being unfamiliar with Ariel compressors. Difficulties of this type can usually be corrected by cleaning, proper adjustment, elimination of an adverse condition, replacement of a relatively minor part or proper training of the operating personnel.

Major problems can usually be traced to long periods of operation with unsuitable lubrication, careless operation, lack of routine maintenance or the use of the compressor for purposes for which it was not intended.

Recording of the interstage pressures and temperatures on multi-stage units is valuable because any variation, when operating at a given load point, indicates trouble in one of the stages.

Normally, if the interstage pressure drops the trouble is in the lower-pressure cylinder. If it rises, the problem is normally in the higher-pressure cylinder.

While it would be impossible to compile a complete list of every possible problem, listed below are some of the more common ones with their possible causes.

Problem Possible Causes (Reference)

Maintenance and Repair Manual

11.0 Normal operation - Maintenance

11.1. After 24 hours of operation at normal design conditions, adjust the wedge blocks under the discharge bottles, if provided, per the guidelines given in the Wedge Block Adjustment Procedure - SDF038.2

11.2. After 24 hours of operation at normal design conditions, perform a hot alignment on the equipment to account for the thermal growth the equipment has.

11.3. Monitor compressor valve temperatures.

11.3.1. Even though all the pipe runs in the new plant have been cleaned, it is still common that during initial system start-up some of the remaining debris in the piping systems will be caught in the compressor valves. The initial set of compressor valves will usually have a relatively short life.

11.3.2. Subsequent valve sets will exhibit the normal valve life. Many factors will affect valve life, including the gas type, gas cleanliness, pulsations, temperatures, pressures, unloaders, valve material, etc. Normal valve life maybe as short as a number of months to as long as a couple of years.

11.3.3. Keep a spare set of valves or at least valve repair parts in inventory. When you notice a valve temperature start to rise, change it out. If you wait on the repair of a damaged valve, the damage will spread to the other valves in the cylinder.

11.3.4. If you do experience a shorter normal valve life, the valve manufacturers can run a special study to evaluate the valve performance in your specific operating conditions.

11.4. Monitor the operation of the system control valves.

11.4.1. Many process control valves are controlled by digital controllers utilizing PID loops.

These loops will need to be tuned for the optimum performance of the compressor system.

11.4.2. Our start-up technicians are capable of making the initial system settings. However, the final tuning of the system is best accomplished by the client's instrument technicians. The instrument technicians are much better versed in tuning instruments.

11.5. Drain condensate from manual drains daily.

11.6. Check oil level daily.

11.7. Confirm automatic drains function correctly weekly.

11.8. Check air filters weekly. In clean environments check air filters monthly.

11.9. Change oil semi-annually or every 2000 hours service, which ever comes sooner.

11.9.1. The approximate service life of most compressor and engine lubricants is approximately 2000 hours. The best way to determine the actual service life is to have an oil sample analyzed to determine its current condition. Samples of the lubricant should be sent to the oil manufacturer for analysis on the following interval schedule until you are able to determine the actual service life for your specific conditions. One week run time; Two weeks run time; One month run time; Two months run time; Four months run time; Every four months thereafter

11.10. Check for belt tension after 40 hours service.

11.10.1. New belts will stretch during the initial running. Check the belt tension after one day, then one week, then two weeks. After this initial break in period use the schedule above.

11.10.2. Check for belt wear and belt tension with each oil change.

11.11. Check for loose bolts and equipment monthly.

11.12. Maintain a daily log of the compressor operating conditions.

11.12.1. The operator will record all temperatures, pressures, levels, and any comments on the daily operation of this compressor. This practice will prove invaluable in determining the compressors performance over a period of time and can be very beneficial in troubleshooting any problems that might develop with the equipment.

11.13. Re-Check for correct operation of shutdowns

11.13.1. Each individual safety shutdown shall be re-calibrated on an annual basis regardless of compressor run time.

11.13.2. Each shutdown shall be individually tripped or tested to verify that the control signal is received in the control panel.

11.13.3. The control panel shutdown system shall be tested to verify that the panel is actually capable of shutting down the unit.

WEDGE BLOCK ADJUSTMENT PROCEDURE

1. General- The primary purpose of this procedure is to convey UE Compression, LLC requirements for wedge block adjustment. It is very important that the wedge blocks under the compressor bottles be adjusted properly and maintained properly to assure proper operation of the compressor package.

1.1. It is important to note that the wedge supports are not to contain a load per-se but rather to ensure the system natural frequencies do not coincide with an order of run speed. The wedge supports are for extra stiffness, not a restraint to carry load. The bottle and orifice plates are designed to control forces to reasonable levels. The compressor frame/ cylinder assembly / crosshead guide support is designed to control motion due to gas rod loads. The wedge supports are necessary to add stiffness to avoid high vibrations due to resonance.

1.2. The general concept is that when the compressor is running and up to normal operating temperatures, the discharge bottle and compressor cylinder has grown in size due to thermal expansion. This is the point at which the wedge block should cradle the bottle and minimize the vibrations that might exist. When the compressor is turned off and allowed to cool down to ambient temperatures, the discharge bottle will thermally shrink away from the wedge block.

2. Initial installation and adjustment-

2.1. The wedge blocks shall be installed per the installation drawings.

2.2. Inspect the components to verify that all components fit together properly and that the wedge blocks will be able to slide into place under the bottle.

2.3. Verify the surface of the wedge block that contacts the bottle is smooth and free of any deformity that might damage the bottle.

2.4. Verify the contact face of the wedge block makes contact with the bottle across its entire face. The block shall not be cocked or turned such that contact is made only on one edge.

2.5. Slide the wedge blocks up to just contact the bottle and tighten the draw bolt to hold the blocks in place.

2.6. The draw bolt is secured with a double nut or with a nylok type nut. This is important as the bolting is generally loose when the equipment is cold. When the equipment starts the loose bolting will rattle until it warms up. If the bolting is not secured with a type of nut that resists movement, the adjustment will be lost.

2.7. Initial adjustment of Wedge blocks with band clamps (typically an end of the bottle extending away from the cylinder)

2.7.1. The wedge blocks and band clamp shall be adjusted to hold the bottle in place. It is important that the adjustment does not pull the bottle down nor push the bottle up.

2.7.2. Tighten the wedge block draw bolt until the wedge blocks are snug up against the bottle.

The wedge blocks should not lift the bottle above its normal position. In cases utilizing very long, overhung bottles, the wedge blocks can be used to lift the bottle end up to a neutral position.

2.7.3. Position the clamp over the bottle and verify its bolting will pull the clamp straight down.

The clamp must not be twisted or distorted.

2.7.4. Leave the clamp bolts loose.

3. Hot adjustment -

3.1. Allow the compressor to operate at normal operating conditions long enough for the discharge bottle to come up to normal discharge temperature.

3.2. Adjustment of Wedge blocks without band clamps (typically under the cylinder nozzle)

3.2.1. Loosen the wedge block draw bolt and knock the wedge block back so it is loose.

3.2.2. Observe the amount of vibration in the discharge bottle, cylinder and suction bottle. If you have access to a vibration monitor, it would be beneficial to measure the vibration levds.

3.2.3. Tighten the wedge block draw bolt until the blocks come into contact with the bottle.

3.2.4. Check the vibration levds again.

3.2.5. Tighten the wedge block draw bolt a little more and observe the vibration levd again.

3.2.6. Altematdy observe the amount of vibration and tighten the wedge block draw bolts. There will be a point at which the vibration is minimal. That point might occur when the block is just in contact, it might occur when the draw bolt is quite tight, or somewhere in between.

3.2.7. Do not tighten the draw bolts any more than necessary to reach the minimal vibration levds achievable. Over tightening the draw bolts puts unnecessary strain on all components which may result in bolt failures or premature wear and failures of the compressor cylinder components.

3.3. Adjustment of Wedge blocks with band clamps (typically an end of the bottle extending away from the cylinder)

3.3.1. Observe the amount of vibration in the discharge bottle, cylinder and suction bottle. If you have access to a vibration monitor, it would be beneficial to measure the vibration levds.

3.3.2. Tighten the wedge block bolts to bring the block into firm contact with the bottle.

3.3.3. Tighten the band clamp bolts to bring the clamp firmly into contact with the bottle.

3.3.4. Check the vibration levels again.

3.3.5. Tighten the band clamp bolt a little more and observe the vibration level again.

3.3.6. Alternately observe the amount of vibration and tighten the band clamp bolts. There will be a point at which the vibration is minimal. That point might occur when the band is just in contact, it might occur when the clamp is quite tight, or somewhere in between.

3.3.7. Do not tighten the clamp bolts any more than necessary to reach the minimal vibration levels achievable. Over tightening the clamp bolts puts unnecessary strain on the bolts and may cause the bolting or clamp to fail.

3.4. When adjusting the wedge block draw bolts, typical adjustment will be less that 1 full turn from the point that the block is in contact with the bottle. The initial contact can be made by turning the draw bolt nuts by hand.

3.5. When the equipment is shutdown and allowed to cool, the wedge block draw bolt and the band clamp may appear loose. This is normal. Do not re-adjust the draw bolt when the compressor is cooled down. Perform hot adjustments only.

4. Maintenance-

4.1. Maintenance is very important on wedge blocks. Initial operation will see the various parts go through a break-in period. During this break-in period the wedge blocks will wear into a normal position, the draw bolts will stretch, the support structure will settle in and all the parts will generally work into a normal operating position. During this break-in period the wedge blocks will need to be adjusted to take up the slack that is created when these parts work into their natural position.

4.2. Adjust the blocks for the initial hot adjustment.

4.3. Run the equipment for a few weeks and re-check the wedge block adjustment.

4.4. Run the equipment for 1 month and check the wedge block adjustment.

4.5. After this point you will need to adjust the wedge blocks as needed. Monitor the condition of the wedge blocks and you will be able to determine the frequency at which you will need to make adjustments.

LONG TERM STORAGE OF COMPRESSOR PACKAGE

1. General-

1.1. The purpose of this procedure is to convey the UE Compression (UEC) requirements for unit preservation. It is of the utmost importance that all equipment shipped be protected from the environment for the period of time that it is expected to be idle prior to commissioning. There are three main areas of concern. The compressor and piping system, the driver and the control system. The goal of the unit preservation is to reduce the possibility of corrosion on any unpainted or machined surfaces.

1.2. This procedure offers three different preservation schemes based on the expected length of time the unit will sit idle prior to commissioning. Normal preservation - units shipping to site with immediate commencement of installation and start-up within the next 6 months. Extended preservation - units shipping to the site with intention of a long cycle time between installation and eventual start-up - up to a year. Long term storage/preservation - units shipping to the site with intention of the equipment sitting dormant, then eventual installation and start-up - over a year anticipated storage.

1.3. The Compressor package should ideally be stored indoors in a dry warehouse prior to installation. However, the package can be stored outside, if indoor storage is not possible.

1.4. The package needs to be visually inspected at least once a week. The condition of the purge system, space heater operation, tarp condition and general condition shall be checked.

1.5. The package also needs to be inspected prior to any extreme weather forecasts, to check the tarp is in place. The package should also be inspected after any extreme weather such as windstorms, snowstorms or heavy rain. Any discrepancy needs to be corrected immediately.

1.6. Engines, compressors and electric motors shall be fully inspected at 1 year from the time of preservation. The equipment shall be evaluated for its condition and the performance of the preservation system. If continued storage of the equipment is required the protection system shall be re-applied. If there is any concern of the condition of the equipment at any time the component manufacturer shall be contacted for their recommendations of repairs and further preservation measurers.

2. Definitions

2.1. Vapor corrosion inhibiting oil (VCI) - this is a special preservative oil that gives off corrosion inhibiting oil vapors. When the oil is poured into the crankcase and distance pieces, the vapors will protect all bare metal surfaces in these areas. When the oil is sprayed into the piping runs, the oil vapors protect the interior surfaces of the pipe and valve runs. A suitable VCI oil is NOX-RUST VCI-lO OIL from Daubert Chemical.

2.2. Corrosion protective coatings(CPC) - these coatings are a surface applied coating that will adhere to the surface to which it is applied and protect that surface. There is a wide variety of this type of coatings including spray on and brush on products. The products include greases, oils, plastics, etc. These products are readily available. A suitable CPC for the internal surfaces of the compressor is Mobilarma 247 from Mobil oil or Tectyl 502-C from Tectyl.

2.3. Waterproof tape - Duct tape does not provide a suitable long term seal. The tape will breakdown relatively quickly. Use a good quality waterproof sealing tape such as Grainger Preservation sealing tape #1YAX9, Black 2".

2.4. Plastic bags and sheeting. Use black or dark plastic for sealing as clear plastic will break down sooner when exposed to sunlight.

3. Normal preservation - units shipping to site with immediate commencement of installation and start-up within the next 6 months.

3.1. Reciprocating Compressor protection

3.1.1. During the final minutes of test run, spray VCI oil into the compressor inlet flange. All scrubbers, bottles, cylinders and stages must receive VCI oil in moderate quantities.

3.1.2. After test run drain oil from crankcase and then remove a plug in the top of the frame cover and each distance piece. Pour VCI oil of the specified quantity (see Appendix A) into each of the cavities of the compressor.

3.1.3. Insure that all compressor openings to atmosphere are sealed and that the crankcase breather ports are sealed with plastic threaded plugs not push in plugs.

3.2. Rotary Compressor protection

3.2.1. VCI oil must be checked for compatibility with compressor oil selection.

3.2.2. During the final minutes of test run, spray VCI oil into the compressor inlet flange. All scrubbers and compressors must receive VCI oil in moderate quantities.

3.2.3. After test run drain oil from gas oil separator and oil cooler.

3.2.4. VCI oil can only be added to oil systems where the compatibility of the lubricant and the VCI oil has been verified. VCI oil cannot be used in oil systems that are intended to use PAG lubricants.

3.2.5. Remove a plug in the top of the compressor frame. Pour 1/2 gallon of a SO/SO mixture ofVCI oil and compressor lubricant into the compressor.

3.2.6. Add VCI oil to the gas oil separator at a rate of 1 % of separator oil capacity. For example a 100 gallon sump capacity shall have 1 gallon ofVCI oil added to the separator.

3.2.7. Insure that all compressor openings to atmosphere are sealed.

3.2.8. Compressor drive shaft must be rotated 2700 by hand on a monthly basis when unit is not in service.

3.3. Engine -

3.3.1. The engine is protected with the VCI rust preventative oil. The VCI that is applied to the engine shall always be applied in a 50/50 mixture ofVCI and engine oil.

3.3.2. Drain oil from crankcase.

3.3.3. Remove the cover on the crankcase ventilation oil separator. Spray preservative oil into lower section of separator for a count of 10 seconds. Reinstall cover insuring the cover gasket is in the correct position.

3.3.4. Add 50/50 VCI mixture to the engine crankcase at a rate of 8% of engine oil capacity. For example a 100 gallon sump capacity shall have 8 gallons of 50/50 VCI mixture added to the crankcase.

3.3.5. Insure that all openings to atmosphere are sealed with covers or cosmoline wrap and waterproof tape. Any openings to atmosphere will allow preservative oil to evaporate from within the crankcase and thus lose rust protection.

3.3.6. Remove air filter elements. Spray VCI into the inlet. Wrap the fliter element in a black plastic bag, seal it with tape and re-install in the filter housing. Place tape over all openings to seal the VCI vapors in the engine.

3.3.7. Reseal crankcase breathers. Plug with screw-in type plastic plugs or cosmoline wrap and waterproof tape.

3.3.8. Spray VCI into the turbocharger or exhaust opening. Reseal turbocharger or exhaust connections.

3.4. Motors -

3.4.1. Given the short duration of the storage period there are no special procedures for storage of electric motors.

3.5. Panels -

3.5.1. The panel shall be wrapped with protective packing to prevent accidental damage to the operator interface.

4. Extended preservation - units shipping to the site with intention of a long cycle time between installation and eventual start-up - up to a year.

4.1. Compressor protection

4.1.1. During the final minutes of test run, spray VCI oil into the compressor inlet flange. All cylinders and stages must receive VCI oil in moderate quantities.

4.1.2. After test run drain oil from crankcase and then remove a plug in the top of the frame cover and each distance piece. Pour VCI oil of the specified quantity (see Appendix A) into each of the cavities of the compressor.

4.1.3. Remove a side plug or cover from the lubricator gearbox and spray VCI oil into gearbox for a count of 2 seconds.

4.1.4. Insure that all compressor openings to atmosphere are sealed and that the crankcase breather ports are sealed with plastic threaded plugs not push in plugs.

4.1.5. Spray the coupling and exposed shafting with gray primer. Wrap where possible, with cosmoline wrap and waterproof tape.

4.2. Rotary Compressor protection

4.2.1. VCI oil must be checked for compatibility with compressor oil selection.

4.2.2. During the final minutes of test run, spray VCI oil into the compressor inlet flange. All scrubbers and compressors must receive VCI oil in moderate quantities.

4.2.3. After test run drain oil from gas oil separator and oil cooler.

4.2.4. VCI oil can only be added to oil systems where the compatibility of the lubricant and the VCI oil has been verified. VCI oil cannot be used in oil systems that are intended to use PAG lubricants.

4.2.5. Remove a plug in the top of the compressor frame. Pour 1/2 gallon of a 50/50 mixture ofVCI oil and compressor lubricant into the compressor.

4.2.6. Add VCI oil to the gas oil separator at a rate of 1 % of separator oil capacity. For example a 100 gallon sump capacity shall have 1 gallon ofVCI oil added to the separator.

4.2.7. Insure that all compressor openings to atmosphere are sealed.

4.2.8. Spray the coupling and exposed shafting with gray primer. Wrap where possible, with cosmoline wrap and waterproof tape.

4.2.9. Compressor drive shaft must be rotated 2700 by hand on a monthly basis when unit is not in service.

4.3. Engine -

4.3.1. The engine is protected with the VCI rust preventative oil. The VCI that is applied to the engine shall always be applied in a 50/50 mixture ofVCI and engine oil.

4.3.2. Pre-lube the engine with the engine oil prior to rotating the crankshaft.

4.3.3. If equipped with an air starter, fill the reservoir with the 50/50 VCI mixture. Tape over any vent connection on the reservoir.

4.3.4. Remove the air filter elements. Use a sprayer to add the 50/50 VCI mixture into the air inlet or turbocharger inlet. The application rate is 3 ounces per 1000 cu in displacement.

4.3.5. The 50/50 VCI mixture can be added to the inlet by removing the plug that is used for checking turbocharger boost pressure.

4.3.6. Seal the air filter opening by wrapping the air filter element in black plastic and reinstalling the element. Tape over all opening to seal in the VCI vapors.

4.3.7. Spray the 50/50 VCI mixture into the exhaust openings at an application rate of 3 ounces per 1000 cu in displacement.

4.3.8. Seal the exhaust openings to seal in the vapors. Use blind flanges or plywood covers in conjunction with cosmoline wrap and tape for durable sealing.

4.3.9. Remove sparkplug extensions and blow debris from sparkplug cavities. Remove sparkplugs and spray the 50/50 VCI mixture into each cylinder at an application rate of 1 ounce per cylinder.

4.3.10. Use a barring device to rotate the crankshaft and put oil on the cylinder walls. Reinstall the sparkplugs to the correct torque specification.

4.3.11. Remove the rocker cover bolt closest to the exhaust manifold and spray preservative oil into the rocker arm area for a count of 5 seconds. Oscillate the sprayer to help distribute the oil beneath the cover and reinstall rocker cover bolt.

4.3.12. Drain oil from crankcase.

4.3.13. Add 50/50 VCI mixture to the engine crankcase at a rate of 8% of engine oil capacity.

For example a 100 gallon sump capacity shall have 8 gallons of 50/50 VCI mixture added to the crankcase.

4.3.14. If the engine is equipped with a hydraulic governor, spray preservative oil into the governor top fill point for a count of 2 seconds.

4.3.15. Remove the cover on the crankcase ventilation oil separator. Spray preservative oil into lower section of separator for a count of 10 seconds. Reinstall cover insuring the cover gasket is in the correct position.

4.3.16. If provided with an external oil fllter canister, partially lift the oil fllter canister lid and spray preservative oil into the canister for a count of 10 seconds.

4.3.17. Insure that all openings to atmosphere are sealed with covers or cosmoline wrap and waterproof tape. Any openings to atmosphere will allow preservative oil to evaporate from within the crankcase and thus lose rust protection.

4.3.18. Reseal crankcase breathers. Plug with screw-in type plastic plugs or tape with waterproof tape.

4.3.19. Spray the flywheel and exposed shafting with gray primer. Wrap where possible, with cosmoline wrap and waterproof tape.

4.3.20. Loosen the v-belts.

4.4. Motors -

4.4.1. The primary protection for the main drive motor is to connect the power to the motor space heaters. With the space heaters on, the interior of the motor will be warm, preventing condensation.

4.4.2. Spray the exposed motor shaft with CPC.

4.4.3. The motor manufacturer may have other special precautions and preparations for long term motor storage. As these requirements vary significantly between motormanufacturers, this document does not specifically address motor preservation requirements.

4.5. Panels -

4.5.1. Place desiccant bags inside the panel to adsorb any condensation that might occur.

4.5.2. The panel shall be wrapped with protective packing to prevent accidental damage to the operator interface.

5. Long term storage/preservation - units shipping to the site with intention of the equipment sitting dormant, then eventual installation and start-up - over a year anticipated storage. Annual re-preservation required as a minimum. See the O&M manuals for each piece of equipment for specific details.

5.1. Compressor protection

5.1.1. During the final minutes of test run, spray VCI oil into the compressor inlet flange. All cylinders and stages must receive VCI oil in moderate quantities.

5.1.2. After test run drain oil from crankcase.

5.1.3. Prime the lube oil system with a 50/50 mixture of compressor fame oil and cpc. Prelube the compressor for a minimum of 2 minutes at 10 psi.

5.1.4. Remove all distance piece doors and top cover of compressor frame. Remove 1 crank end suction valve, 1 head end suction valve from each cylinder and 1 head end discharge valve cover.

5.1.5. Drain any excess oil/CPC mixture from the frame and distance pieces. The lube oil piping should remain filled.

5.1.6. Spray CPC inside the frame, crosshead guides and distance pieces, ensuring that all internal surfaces are coated.

5.1.7. Spray CPC rust preventative inside each compressor cylinder, covering all internal surfaces in the cylinder including the unloaders, piston rod, valve pocket surfaces, retainers, valve caps, suction and discharge gas passages, and valves.

5.1.8. Rotate the crankshaft 360 degrees plus 180 degrees and re-spray all surfaces inside of the frame, crosshead guides, distance pieces, and cylinder bores.

5.1.9. There should be no noticeable accumulation of excess rust preventative in the bottom of treated cavities.

5.1.10. Add minimum quantity of VCI corrosion inhibitor to the frame per Appendix A. Apply by pouring or fogging the VCI into the frame. When pouring the VCI liquid into the frame, distribute evenly throughout the cavity. Do not pour VCI direcdy on any bearing surfaces.

5.1.11. Add minimum quantity of VCI corrosion inhibitor to guide and distance piece cavities per Appendix A. Apply by pouring or fogging the VCI into the cavity being preserved. When pouring the vcr liquid into a cavity, distribute evenly throughout the cavity. Do not pour VCI direcdy on any bearing surfaces.

5.1.12. Add minimum quantity of VCI corrosion inhibitor to the cylinder per Appendix A.

Apply by pouring or fogging the VCI into the cylinder. When pouring the VCI liquid into a cavity, distribute evenly throughout the cavity. Distribute 75% of the minimum quantity evenly between the cylinder suction and discharge gas passages. Distribute 25% of the minimum quantity evenly between the crank end and head end of the cylinder bore.

5.1.13. Add V2 ounce of VCI to the lubricator gearbox through the fill plug.

5.1.14. Add 1 ounce of VCI to oil filter housings if they are drained for shipment. This does not apply to spin on elements or filled oil piping systems.

5.1.15. add % ounce ofVCI to the discharge port of the oil pump if there is not a complete oil piping system.

5.1.16. VCI corrosion inhibitors require protected cavities to remain sealed during the storage period. Open cavities will deplete the VCI concentration, rendering the VCI ineffective.

5.1.17. Reassemble all covers and inspection openings. Insure that all compressor openings to atmosphere are sealed and that the crankcase breather ports are sealed with plastic threaded plugs not push in plugs.

5.1.18. Spray the coupling and exposed shafting with gray primer. Wrap where possible, with cosmoline wrap and waterproof tape.

5.2. Rotary Compressor protection

5.2.1. VCI oil must be checked for compatibility with compressor oil selection.

5.2.2. During the final minutes of test run, spray VCI oil into the compressor inlet flange. All scrubbers and compressors must receive VCI oil in moderate quantities.

5.2.3. After test run drain oil from gas oil separator and oil cooler.

5.2.4. VCI oil can only be added to oil systems where the compatibility of the lubricant and the VCI oil has been verified. VCI oil cannot be used in oil systems that are intended to use PAG lubricants.

5.2.5. Remove a plug in the top of the compressor frame. Pour V2 gallon of a 50/50 mixture ofVCI oil and compressor lubricant into the compressor.

5.2.6. Add VCI oil to the gas oil separator at a rate of 1 % of separator oil capacity. For example a 100 gallon sump capacity shall have 1 gallon ofVCI oil added to the separator.

5.2.7. Insure that all compressor openings to atmosphere are sealed.

5.2.8. Spray the coupling and exposed shafting with gray primer. Wrap where possible, with cosmoline wrap and waterproof tape.

5.2.9. Compressor drive shaft must be rotated 2700 by hand on a monthly basis when unit is not in service.

5.3. Engine-

5.3.1. The engine is protected with the VCI rust preventative oil. The VCI that is applied to the engine shall always be applied in a 50/50 mixture of VCI and engine oil.

5.3.2. Pre-lube the engine with the engine oil prior to rotating the crankshaft.

5.3.3. If equipped with an air starter, fill the reservoir with the 50/50 VCI mixture. cosmoline wrap and tape over any vent connection on the reservoir.

5.3.4. Remove the air filter elements. Use a sprayer to add the 50/50 VCI mixture into the air inlet or turbocharger inlet. The application rate is 3 ounces per 1000 cu in displacement.

5.3.5. The 50/50 VCI mixture can be added to the inlet by removing the plug that is used for checking turbocharger boost pressure.

5.3.6. Seal the air filter opening by wrapping the air filter element in black plastic and reinstalling the element. Tape over all opening to seal in the VCI vapors.

5.3.7. Spray the 50/50 VCI mixture into the exhaust openings at an application rate of 3 ounces per 1000 cu in displacement.

5.3.8. Seal the exhaust openings to seal in the vapors. Use blind flanges or plywood covers in conjunction with cosmoline wrap and tape for durable sealing.

5.3.9. Remove sparkplug extensions and blow debris from sparkplug cavities. Remove sparkplugs and spray the 50/50 VCI mixture into each cylinder at an application rate of 1 ounce per cylinder.

5.3.10. Use a barring device to rotate the crankshaft and put oil on the cylinder walls. Reinstall the sparkplugs to the correct torque specification.

5.3.11. Remove the rocker cover bolt closest to the exhaust manifold and spray preservative oil into the rocker arm area for a count of 5 seconds. Oscillate the sprayer to help distribute the oil beneath the cover and reinstall rocker cover bolt.

5.3.12. Drain oil from crankcase.

5.3.13. Add SO/50 VCI mixture to the engine crankcase at a rate of8% of engine oil capacity.

For example a 100 gallon sump capacity shall have 8 gallons of SO/50 VCI mixture added to the crankcase.

5.3.14. If the engine is equipped with a hydraulic governor, spray preservative oil into the governor top fill point for a count of 2 seconds.

5.3.15. Remove the cover on the crankcase ventilation oil separator. Spray VCI oil into lower section of separator for a count of 10 seconds. Reinstall cover insuring the cover gasket is in the correct position.

5.3.16. If provided with an external oil ftlter canister, partially lift the oil ftlter canister lid and spray preservative oil into the canister for a count of 10 seconds.

5.3.17. Insure that all openings to atmosphere are sealed with covers or waterproof tape. Any openings to atmosphere will allow preservative oil to evaporate from within the crankcase and thus lose rust protection.

5.3.18. Reseal crankcase breathers. Plug with screw-in type plastic plugs or cosmoline wrap and waterproof tape.

5.3.19. Spray the flywheel and exposed shafting with gray primer. Wrap where possible, with cosmoline wrap and waterproof tape.

5.3.20. Loosen the v-belts.

5.4. Motors -

5.4.1. The primary protection for the main drive motor is to connect the power to the motor space heaters. With the space heaters on, the interior of the motor will be warm, preventing condensation.

5.4.2. Spray the exposed motor shaft with Cpc.

5.4.3. The motor manufacturer may have other special precautions and preparations for long term motor storage. As these requirements vary significantly between motor manufacturers, this document does not specifically address motor preservation requirements.

5.5. Panels -

5.5.1. Place desiccant bags inside the panel to adsorb any condensation that might occur.

5.5.2. The panel shall be wrapped with protective packing to prevent accidental damage to the operator interface.

6. Alternative Compressor/Engine protection - Nitrogen purge protection

6.1.1. All vents and drains in the engine or compressor frame and distance pieces shall be plugged.

6.1.2. The engine or compressor frame will be purged with Nitrogen (N2) and then a controlled flow of Nitrogen will be metered into the frame. The flow rate shall be controlled to provide approximately 10 standard cubic feet per day. The maximum pressure in the compressor frame shall be controlled to not exceed 2 psig. This can be done either with a pressure regulator set to 2 psig or by adjusting the flow rate to not exceed 2 psig. It is not practical to expect a positive pressure to be maintained as the Nitrogen will escape around the shaft seal. This positive flow will assure there is no air and therefore no condensation or corrosion occurring in the frame areas.

6.1.3. The frame shall be tagged with a tag that reads as follows:

CAUTION: This unit is purged and pressurized up to 1-2 PSIG with Nitrogen (N2) When unit is ready for installation, carefully relieve the Nitrogen Pressure and remove this sign.

6.2. Compressor cylinders and gas piping system

6.2.1. All process piping connections shall be blind flanged closed with flanges or plates capable of containing 50 psi. All other vents and drains shall be plugged.

6.2.2. The compressor cylinders and gas piping will be purged with Nitrogen (N2) and then a controlled flow of Nitrogen will be metered into the compressor frame.

6.2.3. The compressor cylinders and gas piping will be purged by pressurizing the system up to 50 psig with nitrogen from one end and blowing it down from the opposite end. This purging cycle shall be repeated twice which will reduce the oxygen content to less than 1 % in the piping system.

6.2.4. The flow rate shall be controlled to provide approximately 10 standard cubic feet per day.

It is not practical to expect a positive pressure to be maintained as the Nitrogen will escape around the piston rod packing. This positive flow will assure there is no air and therefore no condensation or corrosion occurring in the piping and cylinder areas.

6.2.5. If the piping system is purged separately from the compressor system, it shall also have a caution tag similarly applied as the compressor.

7. Miscellaneous considerations

7.1. The complete package shall be tarped for weather protection with vent in the top of the tarp.

This vent is required due to the humidity that can build up inside of the tarp and will therefore vent any humidity when the ambient temperature rises.

8. Re-commissioning

8.1. When a unit is re-commissioned for usage after preservation, the manufacturers recommendations shall…