RAM Data Book
RAM Data Book
RAM Data Book
COMPRESSOR CYLINDER
Table of Contents:
Compressor Cylinder
Compressor Cylinder Technical Data Book: RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
Table of Contents
Chapter 1 General
TOC-vi RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
RAM 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Frame Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
RAM 54 Standard Auxiliary Equipment Specifications . . . . . . 2-32
RAM 54 Frame Construction Specifications . . . . . . . . . . . . . . 2-33
RAM 54 Frame Material Specifications . . . . . . . . . . . . . . . . . . 2-36
RAM 54 Starting Torque Data . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
TOC-viii RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
RAM COMPRESSORS
Chapter 1 General:
Application and Performance Data
RAM Compressors Technical Data Book: RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
Number of
Weights Socket Head Capscrew
Qty. Size Part No.
1 2 5/8-11 x 1-1/4" O4CS1O1OPC
2 2 5/8-11 x 2" O4CS1O16PC
3 2 5/8-11 x 2-3/4" O4CS1O22PC
4 2 5/8-11 x 3-1/4" O4CS1O26PC
5 2 5/8-11 x 4" O4CS1O32PC
5 2 5/8-11 x 4-3/4" O4CS1O38PC
*7 2 5/8-11 x 5-1/2" O4CS1O44PC
1-4 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
CI 4.50 0-A 1-A 5-A 7-A 4-B 4-B 3-A 5-A 7-A 8-A 3-B 3-B 2-B 3-B 2-B 2-B 12-B 12-B 12-B 12-B * *
CI 5.00 0-A 4-A 6-A 2-B 3-B 2-A 3-A 6-A 7-A 2-B 2-B 0-B 1-B 1-B 1-B 11-B 11-B 11-B 11-B * *
CI 5.50 0-A 2-A 6-A 7-A 0-A 0-A 2-A 3-A 6-A 7-A 4-A 5-A 4-A 5-A 7-B 7-B 7-B 7-B 9-B 10-B
CI 6.00 0-A 4-A 5-A 0-A 0-A 0-A A 4-A 4-A 2-A 3-A 2-A 2-A 4-B 4-B 4-B 4-B 6-B 6-B
CI 6.50 0-A 1-A 0-A 0-A 0-A 0-A 0-A 0-A 0-A 0-A 0-A 0-A 1-B 1-B 0-B 1-B 2-B 4-B
AL 7.75 2-A 4-A 0-B 1-B 0-A 1-A 4-A 5-A 8-A 1-B 6-A 7-A 6-A 7-A 9-B 9-B 9-B 9-B 11-B 12-B
AL 8.25 1-A 3-A 5-A 0-B 0-A 2-A 4-A 7-A 7-A 5-A 6-A 5-A 5-A 8-B 8-B 7-B 8-B 9-B 11-B
AL 9.00 5-A 5-A 0-A 1-A 4-A 5-A 3-A 4-A 3-A 3-A 5-B 6-B 5-B 5-B 7-B 8-B
AL 9.50 3-A 4-A 0-A 3-A 4-A 1-A 2-A 1-A 2-A 4-B 4-B 4-B 4-B 6-B 7-B
AL 10.50 1-A 0-A 1-A 0-A 0-A 0-A 0-A 1-B 1-B 1-B 1-B 3-B 4-B
AL 11.00 0-A 0-A 0-A 0-A 0-A 0-A 0-B 1-B 0-B 0-B 2-B 3-B
AL 12.00 2-A 3-A 2-A 2-A 0-A 1-A 0-A 0-A 3-B 3-B 2-B 3-B 4-B 6-B
AL 12.50 1-A 2-A 1-A 1-A 0-A 0-A 0-A 2-B 2-B 1-B 2-B 3-B 5-B
AL 13.50 2-A 3-A 2-A 2-A 1-A 0-A 0-A 2-B 3-B 2-B 2-B 4-B 5-B
AL 14.00 2-A 2-A 1-A 2-A 1-A 0-A 2-B 3-B 2-B 2-B 4-B 5-B
AL 20.00 0-A
Example 1
Mount a 5.5" cylinder across from a 13.5" cylinder.
Step 1: Start with the small bore 5.5" diam. first.
a. Read down the left hand diameter column to the 5.50 line.
b. Follow across that line to the 13.50 column.
c. At that intersection, you will read the code ‘4-A.’ ‘4’ is the
number 01 weights required and ‘A’ is the light 56 lb
crosshead.
Step 2: Now the large bore 13.5" diameter.
a. Read down the left hand diameter column to the 13.50 line
b. Follow across that line to the 5.50 column.
c. At that intersection you will find a blank space. Any blank
space indicates a ‘0-A’ code. That would mean no weights
and a 56 lb crosshead.
To summarize, the 5.5" diameter cylinder requires four weights and the
light 56 lb crosshead and the 13.5" diameter needs no weights and a light
crosshead.
1-6 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
As a further check, the weights can be added and the difference checked.
Piston and rod assembly weights are at the top line of the Balance i The lightest crosshead
should generally be
Data table. used on the heavier
throw having the biggest
cylinder: however, there may
be exceptions. The table
Cylinder Diameter 5.5" 13.5" indicates which combinations
to consider for any given
Piston and Rod Weight 77 lb 99 lb cylinder..
Crosshead Weight 56 lb 55 lb
Balance Weights 4x5= 20 lb 0 lb
Total Difference =1 lb 153 lb 154lb i When trying to
achieve maximum
balance weight, do
not exceed 222 lbs for
Example 2 the piston and rod
assembly, crosshead, and
Mount a 7.0" cylinder across from a 9.0" cylinder. balance weight total.
This example points out that it is possible for a larger diameter cylinder to
have a lower piston and rod assembly weight than a smaller bore cylinder.
The larger bore then requires more balance weight. In this case the 7.0"
cylinder will use a light, 55-57 lb crosshead and no balance weights while the
9.0" cylinder will use the light crosshead and five balance weights.
Definition of Codes in Balance Data Table
Represents the total number of weights to be used
with the cylinder indicated in the left hand column
# of the table.
12 - total number of weights available for
use per active throw.
A or B 14 - total number of weights available for use per
blank throw.
Represents the crosshead size or balancing stub rod
(blank throw only) to be used with the cylinder
indicated in the left hand column.
A - 55-57 lbs (light crosshead)
B - 95-97 lbs (heavy crosshead)
1-8 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
Operating Limits
The following speed limitations have been set forth on all RAM Series
compressors and should be reviewed for each application. The limitations
are as follows:
1. The maximum allowable piston assembly weight is 200 (90.5kg) pounds.
2. A maximum total reciprocating weight limit applies to all 1200 RPM
Superior machines. This total weight value is for the sum of:
Reciprocating Weights OR Balance Sheet Weights
The piston and piston rod, Piston and piston rod assembly,
The crosshead assembly, Crosshead assembly,
The crosshead pin, * and Connecting rod, and *
The balance nuts or balance Balance nuts or balance
weights. weights.
* For reciprocating weight measurements, the connecting rod
is not included and for balance sheet weight measurements, the
crosshead pin is not included.
The weight limit value for the RAM is:
• Max limit for recip. weight 270 lb (122 kg)
• Balance sheet weight 331 lb (150 kg)
3. All of the RAM cylinders were designed for Hoerbiger valves which
will always be assembled with MT or PEEK plates. Accordingly, the
discharge temperature limit is 340° F (171 °C) MT, 350° F (177 °C)
PEEK for the air-cooled RAM cylinders.
4. The maximum piston assembly weight for 1500 rpm is 144 lb (65 kg).
5. The maximum piston assembly weight for 1400 rpm is 182 lb (82 kg).
6. The cylinders require cylinder head supports for 1500 rpm.
7. The maximum cylinder size for 1500 rpm is 14" dia.
8. The maximum cylinder size for 1400 rpm is 16" dia.
9. The maximum unbalanced couple of the RAM52 is 20000 ft-lbs.
10. The maximum unbalanced couple of the RAM54 is 29000 ft-lbs.
11. The allowable gas specific gravity is less than 1.0
Units of Length
* Inches (in) . . . . . . . . . . . . . . . . . . . . . . . . 25.40 . . . . . . . . . . . . . . . . . . Millimeters (mm)
Inches (in) . . . . . . . . . . . . . . . . . . . . . . . . 2.54 . . . . . . . . . . . . . . . . . . . Centimeters (cm)
Inches (in) . . . . . . . . . . . . . . . . . . . . . . . . 0.0254 . . . . . . . . . . . . . . . . . Meters (m)
* Feet (ft) . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3048 . . . . . . . . . . . . . . . . . Meters (m)
* Yards (yd) . . . . . . . . . . . . . . . . . . . . . . . . 0.9144 . . . . . . . . . . . . . . . . . Meters (m)
Miles (mi) . . . . . . . . . . . . . . . . . . . . . . . . 1.6093 . . . . . . . . . . . . . . . . . Kilometers (km)
Units of Area
* Square Inches (in2) . . . . . . . . . . . . . . . . . 645.20 . . . . . . . . . . . . . . . . . Sq. Millimeters (mm2)
Square Inches (in2) . . . . . . . . . . . . . . . . . 6.452 . . . . . . . . . . . . . . . . . . Sq. Centimeters (cm2)
Square Feet (ft2) . . . . . . . . . . . . . . . . . . . 929.0 . . . . . . . . . . . . . . . . . . Sq. Centimeters (cm2)
* Square Feet (ft2) . . . . . . . . . . . . . . . . . . . 0.0929 . . . . . . . . . . . . . . . . . Sq. Meters (m2)
Square Yards (yd2). . . . . . . . . . . . . . . . . . 0.8361 . . . . . . . . . . . . . . . . . Sq. Meters (m2)
Square Miles (mi2) . . . . . . . . . . . . . . . . . 2.590 . . . . . . . . . . . . . . . . . . Sq. Kilometers (km2)
Units of Volume
Cubic Inches (in3) . . . . . . . . . . . . . . . . . . 16.388 . . . . . . . . . . . . . . . . . Cu. Centimeters (cm3)
Fluid Ounces (fl oz) . . . . . . . . . . . . . . . . 29.577 . . . . . . . . . . . . . . . . . Cu. Centimeters (cm3)
* Cubic Feet (ft3) . . . . . . . . . . . . . . . . . . . . 0.02832 . . . . . . . . . . . . . . . . Cu. Meters (m3)
Cubic Yards (yd3) . . . . . . . . . . . . . . . . . . 0.7645 . . . . . . . . . . . . . . . . . Cu. Meters (m3)
Cubic Inches (in3) . . . . . . . . . . . . . . . . . . 0.01639 . . . . . . . . . . . . . . . . Liters (l)
Fluid Ounces (fl oz) . . . . . . . . . . . . . . . . 0.02957 . . . . . . . . . . . . . . . . Liters (l)
Cubic Feet (ft3) . . . . . . . . . . . . . . . . . . . . 28.32 . . . . . . . . . . . . . . . . . . Liters (l)
Cubic Yards (yd3) . . . . . . . . . . . . . . . . . . 764.6 . . . . . . . . . . . . . . . . . . Liters (l)
* U.S. Gallons . . . . . . . . . . . . . . . . . . . . . . 3.785 . . . . . . . . . . . . . . . . . . Liters(l)
Imperial Gallons . . . . . . . . . . . . . . . . . . . 4.546 . . . . . . . . . . . . . . . . . . Liters (l)
Units of Weight
Grains . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0648 . . . . . . . . . . . . . . . . . Grams (g)
Ounces (oz) . . . . . . . . . . . . . . . . . . . . . . . 28.35 . . . . . . . . . . . . . . . . . . Grams (g)
Ounces (oz) . . . . . . . . . . . . . . . . . . . . . . . 0.02835 . . . . . . . . . . . . . . . . Kilograms (kg)
Pounds (lb) . . . . . . . . . . . . . . . . . . . . . . . 453.6 . . . . . . . . . . . . . . . . . . Grams (g)
* Pounds (lb) . . . . . . . . . . . . . . . . . . . . . . . 0.4536 . . . . . . . . . . . . . . . . . Kilograms (kg)
U.S. Tons. . . . . . . . . . . . . . . . . . . . . . . . . 907.2 . . . . . . . . . . . . . . . . . . Kilograms (kg)
U.S. Tons. . . . . . . . . . . . . . . . . . . . . . . . . 0.9072 . . . . . . . . . . . . . . . . . Tonnes
Tons, long . . . . . . . . . . . . . . . . . . . . . . . . 1016 . . . . . . . . . . . . . . . . . . Kilograms (kg)
1-10 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
Units of Pressure
Pounds/Sq Inch (psi). . . . . . . . . . . . . . . . 70.32 . . . . . . . . . . . . . . . . . . Grams/Sq cm (g/cm2)
Pounds/Cu Inch (lb/in3). . . . . . . . . . . . . . 27.70 . . . . . . . . . . . . . . . . . . Grams/Cu cm (g/cm3)
Pounds/Sq Inch (psi). . . . . . . . . . . . . . . . 0.07032 . . . . . . . . . . . . . . . . Kilograms/Sq cm (kg/cm2)
Inches of Hg (in Hg) . . . . . . . . . . . . . . . . 0.03453 . . . . . . . . . . . . . . . . Kilograms/Sq cm (kg/cm2)
Inches of Water (in H2O). . . . . . . . . . . . . 0.00254 . . . . . . . . . . . . . . . . Kilograms/Sq cm (kg/cm2)
Feet of Water (ft H2O). . . . . . . . . . . . . . . 0.03048 . . . . . . . . . . . . . . . . Kilograms/Sq cm (kg/cm2)
Atmospheres (atm) . . . . . . . . . . . . . . . . . 1.03327 . . . . . . . . . . . . . . . . Kilograms/Sq cm (kg/cm2)
Pounds/Sq Inch (psi). . . . . . . . . . . . . . . . 703.10 . . . . . . . . . . . . . . . . . Kilograms/Sq m (kg/m2)
Pounds/Cu Foot (lb/ft3) . . . . . . . . . . . . . . 16.0256 . . . . . . . . . . . . . . . . Kilograms/Cu m (kg/m3)
Pound/Feet (lb/ft) . . . . . . . . . . . . . . . . . . 1.4881 . . . . . . . . . . . . . . . . . Kilograms/meter (kg/m)
Pounds/Sq Inch (psi). . . . . . . . . . . . . . . . 51.7063 . . . . . . . . . . . . . . . . Millimeters Hg (mm Hg)
Inches of Hg (in Hg) . . . . . . . . . . . . . . . . 25.40 . . . . . . . . . . . . . . . . . . Millimeters Hg (mm Hg)
Feet of Water (ft H2O). . . . . . . . . . . . . . . 2.24215 . . . . . . . . . . . . . . . . Centimeters Hg (cm Hg)
Pounds/Sq Inch (psi). . . . . . . . . . . . . . . . 5.17063 . . . . . . . . . . . . . . . . Centimeters Hg (cm Hg)
Inches of Hg (in Hg) . . . . . . . . . . . . . . . . 0.3453 . . . . . . . . . . . . . . . . . Meters Water (m H2O)
Feet of Water (ft H2O). . . . . . . . . . . . . . . 0.3048 . . . . . . . . . . . . . . . . . Meters Water (m H2O)
Pounds/Sq Inch (psi). . . . . . . . . . . . . . . . 0.7032 . . . . . . . . . . . . . . . . . Meters Water (m H2O)
Pounds/Sq Inch (psi). . . . . . . . . . . . . . . . 0.7032/sp gr . . . . . . . . . . . . Meters - any liquid
* Pounds/Sq Inch (psi). . . . . . . . . . . . . . . . 6.89655 . . . . . . . . . . . . . . . . Kilos Pascal (kPa)
Pounds/Sq Inch (psi). . . . . . . . . . . . . . . . 6.89655 . . . . . . . . . . . . . . . . Kilos Newton/Sq.m (kN/m2)
Inches of Hg (in Hg) . . . . . . . . . . . . . . . . 0.03342 . . . . . . . . . . . . . . . . Atmospheres (atm)
Pounds/Sq Inch (psi). . . . . . . . . . . . . . . . 0.06804 . . . . . . . . . . . . . . . . Atmospheres (atm)
Inches of Hg (in Hg) . . . . . . . . . . . . . . . . 0.03386 . . . . . . . . . . . . . . . . Bar
Pounds/Sq In (psi). . . . . . . . . . . . . . . . . . 0.06896 . . . . . . . . . . . . . . . . Bar
* Inches of Water (in H2O). . . . . . . . . . . . . 0.2488 . . . . . . . . . . . . . . . . . Kilos Pascal (kPa)
* Inches of Hg (in Hg) . . . . . . . . . . . . . . . . 3.3769 . . . . . . . . . . . . . . . . . Kilos Pascal (kPa)
Units of Power
Foot-Pounds/Sec(ft-lb/sec) . . . . . . . . . . . 1.356 . . . . . . . . . . . . . . . . . . Watts (W)
Horsepower (hp) . . . . . . . . . . . . . . . . . . . 745.7 . . . . . . . . . . . . . . . . . . Watts (W)
Btu/Min. . . . . . . . . . . . . . . . . . . . . . . . . . 17.57 . . . . . . . . . . . . . . . . . . Watts (W)
Foot-Pounds/Sec (ft-lb/sec) . . . . . . . . . . 0.001356 . . . . . . . . . . . . . . . Kilowatts (kW)
* Horsepower (hp) . . . . . . . . . . . . . . . . . . . 0.7457 . . . . . . . . . . . . . . . . . Kilowatts (kW)
Btu/Min. . . . . . . . . . . . . . . . . . . . . . . . . . 0.01757 . . . . . . . . . . . . . . . . Kilowatts (kW)
Horsepower (hp) . . . . . . . . . . . . . . . . . . . 1.014 . . . . . . . . . . . . . . . . . . Metric Horsepower (mhp)
Horsepower (hp) . . . . . . . . . . . . . . . . . . . 10.70 . . . . . . . . . . . . . . . . . . Kg-Calories/Min
Btu/Min. . . . . . . . . . . . . . . . . . . . . . . . . . 0.2530 . . . . . . . . . . . . . . . . . Kg-Calories/Min
* Btu/Hour . . . . . . . . . . . . . . . . . . . . . . . . . 0.2931 . . . . . . . . . . . . . . . . . Watts (W)
Units of Velocity
* Feet/Sec (ft/sec) . . . . . . . . . . . . . . . . . . . 0.3048 . . . . . . . . . . . . . . . . . Meters/Sec (m/sec)
* Feet/Min (ft/min) . . . . . . . . . . . . . . . . . . 0.00508 . . . . . . . . . . . . . . . . Meters/Sec (m/sec)
Feet/Min (ft/min) . . . . . . . . . . . . . . . . . . 0.0183 . . . . . . . . . . . . . . . . . Kilometers/Hour (km/hr)
Miles/Hour (mph) . . . . . . . . . . . . . . . . . . 1.6093 . . . . . . . . . . . . . . . . . Kilometers/Hour (km/hr)
1-12 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
Units of Density
Pounds/Cubic Inch (lb/in3) . . . . . . . . . . . 27.68 . . . . . . . . . . . . . . . . . . Grams/Cubic cm (g/cm3)
Pounds/Cubic Foot (lb/ft3) . . . . . . . . . . . 16.0184 . . . . . . . . . . . . . . . . Kilograms/Cubic Meter
(kg/m3)
Units of Force
Pounds Force (lb f) . . . . . . . . . . . . . . . . . 0.4535 . . . . . . . . . . . . . . . . . Kilograms Force (kg f)
Pounds Force (lb f) . . . . . . . . . . . . . . . . . 0.00445 . . . . . . . . . . . . . . . . KiloNewtons (kN)
* Pounds Force (lb f) . . . . . . . . . . . . . . . . . 4.4482 . . . . . . . . . . . . . . . . . Newtons (N)
Units of Torque
Pound-Feet (lb-ft) . . . . . . . . . . . . . . . . . . 0.1383 . . . . . . . . . . . . . . . . . Meter-Kilograms (m-kg)
* Pound-Feet (lb-ft) . . . . . . . . . . . . . . . . . . 1.35575 . . . . . . . . . . . . . . . . Newton Meters (Nm)
Capacity, Displacement
Cubic Inches/Revolution (in3). . . . . . . . . 0.01639 . . . . . . . . . . . . . . . . Liters/Revolution
Cubic Inches/Revolution (in3). . . . . . . . . 16.39 . . . . . . . . . . . . . . . . . . Millimeters/Revolution
Specific Heat
* Btu/lb . . . . . . . . . . . . . . . . . . . . . . . . . . . 4184 . . . . . . . . . . . . . . . . . . Joules/Kiolgram-Kelvin
Useful Equivalents
1 U.S. Gallon . . . . . . . . . . . . . . . . . = 0.833 . . . . . . . . Imperial Gallon
Revolutions/Minute . . . . . . . . . . . . = 6 ............ Degrees/Second
Revolutions/Minute . . . . . . . . . . . . = 0.01472 . . . . . . . Radians/Second (rad/s)
1 Cubic Foot of Water . . . . . . . . . . = 7.48 . . . . . . . . . . U.S. Gallons
1 Cubic Meter per Hour . . . . . . . . = 4.40 . . . . . . . . . . GPM
1 Cubic Foot of Air . . . . . . . . . . . . = 0.076 . . . . . . . . . Pound (STP)
1 Pound of Air . . . . . . . . . . . . . . . . = 13.15 . . . . . . . . . Cubic Feet (STP)
1 British Thermal Unit . . . . . . . . . = 778 . . . . . . . . . . Foot-Pounds (ft-lb)
1 Horsepower . . . . . . . . . . . . . . . . = 550 . . . . . . . . . . Foot-Pounds/Second
1 Horsepower . . . . . . . . . . . . . . . . = 1.014 . . . . . . . . . Metric hp
Viscosity (mPas) . . . . . . . . . . . . . . = 1 ............ Centipoise (cP)
Viscosity (mm2/s) . . . . . . . . . . . . . = 1 ............ Centistroke (cSt)
Moisture (kg/m3) . . . . . . . . . . . . . . = 0.0624 . . . . . . . . lbm/ft3
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SUPERIOR® COMPRESSORS
Useful Calculations
Formulas:
Temperature
°C = 5/9 (°F - 32) °F = (9/5 x °C) + 32
R = (°F + 459.69) K = (°C + 273.16)
Mol/hr x SV x MW x 24 hr
= MMSCFD
1,000,000
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SUPERIOR® COMPRESSORS
Horsepower
BHP / MMCFD x Capacity
BHP =
1,000.000
Piston Speed
RPM x Stroke
Feet per minute =
6
Pipe Velocity
GPM x 0.321
V (ft/sec) =
Area (square inches)
Capacity
lbs/hr
GPM =
500 x Specific Gravity
Areas of Circles
Areas of Circles
(Diameters in inches, areas in square inches)
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SUPERIOR® COMPRESSORS
Areas of Circles
(Diameters in inches, areas in square inches)
Piston Speed
API Standard states that the average inlet valve gas velocity shall be
computed as follows:
D
V = 288 x
A
Where:
Miscellaneous Information
The following information provides assistance in fitting frame and
cylinder components to the specific requirements of the compressor
application.
Information includes:
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SUPERIOR® COMPRESSORS
Glossary of Definitions
Actual Capacity
The quantity of gas actually compressed and delivered to the discharge
system by the machine at rated speed and under rated inlet and discharge
conditions (and under rated interstage conditions in a multi-stage machine).
Actual capacity is usually expressed in cubic feet per minute, referring to
first stage inlet flange temperature and pressure.
Air Speed
An industry term denoting the average velocity of the gas flowing through
the valve lift area. It assumes that the valves are wide open at full stroke
and that the piston moves at a constant velocity. It is thus a “rating” velocity
expressed in ft/min. It is most accurately obtained by dividing the net
piston area (sq in) by the inlet valve lift area of one cylinder end (sq in)
and multiplying by piston speed (ft/mm). Some evaluators divide the total
cylinder piston displacement (cfm) by the total cylinder inlet valve lift area
(sq in) and multiply by 144.
Clearance
The volume present in one end of the cylinder in excess of the net volume
displaced by the piston during the stroke toward that end. It may not be
the same for the two ends in a double acting cylinder. An average is
usually used.
Compressibility
A volume ratio which indicates the deviation (as a multiplier) of the actual
volume from the volume as determined by perfect gas laws.
Compression Efficiency
The ratio of the theoretical work requirement (using a stated process) to
the actual work required to be done on the gas for compression and
delivery. Expressed as a percentage, compression efficiency accounts for
leakage, fluid friction losses, and thermodynamic variations from the
theoretical process.
Compression Ratio
The ratio of the absolute discharge to the absolute intake pressure. It usually
applies to a single stage of compression but may be applied to a complete
multistage compressor as well.
i The words “corrosive”
and “non-corrosive” are
not exact terms and Corrosive Gas
there are differences of
degree in their application. One which attacks normal materials of construction. Water vapor, when
Specifications must clarfy mixed with most gases, does not make them corrosive within the sense of the
what is meant when these
terms are used. Refer to above definition. In other gases (C02 for example) it makes them corrosive.
Superior’s Engineering
Standard #13 for further
information.
Critical Pressure
The saturation pressure at the critical temperature. It is the highest vapor
i Critical conditions
must be experimentally
pressure the liquid can exert.
determined for each
pure gas. When they are Critical Temperature
calculated for a mixture,
they are called pseudo The highest temperature at which a gas can be liquified.
(pretended) critical
conditions.
Density
The weight of a given volume of gas, usually expressed in lb/cu ft at SPT
conditions.
Design Pressure
A term also frequently used to denote Maximum Allowable Working
Pressure.
Dew Point
The temperature of a gas at which the vapor (at a given pressure) will start
to condense (or form dew). Dew point of a gas mixture is the temperature at
which the highest boiling point constituent will start to condense.
1-22 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
Dry Gas
Any gas or gas mixture which contains no water vapor and also in which i In commercial com-
pressor work, a gas
may be considered
all of the constituents are substantially above their respective saturated vapor dry (even though it contains
pressures at the existing temperature. water vapor) if its dew point
is low at the inlet condition
(say, minus 50°F to minus
Energy 60°F).
Heat
Energy transferred because of a temperature difference. There is no transfer
of mass.
Inert Gas
To a chemist, one which does not enter into known chemical combination,
either with itself or another element. There are four known gases of this type:
helium, neon, argon and krypton. To the engineer, however, the term usually
means a gas which does not supply any of the needs of combustion.
Inlet Pressure
The total gas pressure (static plus velocity) at the inlet flange of a
compressor. Velocity pressure is usually too small to be considered at any
point in a reciprocating compressor.
Inlet Temperature
The gas temperature at the inlet flange of the compressor.
Isothermal Process
One during which there is no change in the temperature.
Kinetic Energy
The energy a substance possesses by virtue of its motion or velocity. It enters
into a reciprocating compressor calculation.
1-24 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
Rod Reversal
A change in direction of force in the piston rod loading (tension to
compression, or vice-versa) which results in a load reversal at the crosshead
pin during each revolution.
Safety Valve
Setting is to be no higher than the Maximum Allowable Working Pressure.
i Cylinders are not
always installed to
operate at their
maximum “rated discharge
Saturated Vapor Pressure pressure.”
This is due to specific
The pressure existing at a given temperature in a closed vessel containing conditions involved in
a specific compressor
a liquid and the vapor from that liquid after equilibrium conditions have design. Limitations other than
been reached. It is dependent only on temperature and must be determined maximum cylinder design
experimentally. pressure are in control. The
proper safety valve setting
may be substantially below
Saturation Pressure the Maximum Allowable
Working Pressure.
Another term for Saturated Vapor Pressure.
Saturation Temperature
The temperature corresponding to a given saturated vapor pressure for a
given vapor.
Specific Gravity
The ratio of the density of a given gas to the density of dry air, both
measured at the same specified conditions of temperature and pressure
(usually 14.696 PsiA and 60°F). It should also take into account any
compressibility deviation from a perfect gas.
Specific Volume
The volume of a given weight of gas, usually expressed as cu ft/lb at SPT
conditions.
SF12
Means standard pressure and temperature. As used herein it is 14.696PsiA
and 6O°F.
Supercharging
Occurs when the pressure in the cylinder at the end of the suction stroke is
higher than the rated inlet pressure at the cylinder inlet flange. This occurs
when a resonant condition exists in the inlet pipe which brings a pressure
peak at the end of the suction stroke. It results in greater than normal actual
capacity and a greater power requirement. It can seriously over-load a driver.
Temperature
The property of a substance which gauges the potential or driving force for
the flow of heat.
Trip Speed
The speed (in revolutions per minute) at which the independent emergency
overspeed device operates to shut down the compressor driver. It is normally
10 percent of the Rated Speed.
1-26 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
Volumetric Efficiency
The ratio of the actual capacity to the piston displacement, expressed as a
percentage.
Wet Gas
Any gas or gas mixture in which one or more of the constituents is at its
i DRY or WET GAS
terminology has
different meanings
saturated vapor pressure. The constituent at saturation pressure may or may in different applications.
not be water vapor. One must be very careful
when using these terms to
be sure that the meaning
Work intended is actually
conveyed.
Is energy in transition and is defined as Force times Distance. Work cannot
be done unless there is motion.
1-28 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
1-30 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
Hydrocarbon Synonyms
Ethene — Ethylene
Propene — Propylene
2-methylpropane — Iso-butane
1-butene — 1-butylene
Cis-2-butene — 2-butene, 2-butylene, Cis-2-butylene
i "ISO" Is Sometimes
Abreviated as "I".
2-methylpropene — Iso-butene, Iso-butylene
2-methylbutane — Iso-pentane
2,2-dimethylpropane — Neo-pentane
1-pentene — 1-pentylene, Iso-pentene, Propylethylene
Cis-2-n-amylene — 2-pentene
N-hexane — Dipropyl
2-methylpentene — Iso-hexane
2,2-dimethylbutane — Neo-hexane
2-methylhexane — Iso-heptane
2,2,3-trimethylbutane — Triptan
2,2,4-trimethylpentane — Iso-octane
N-hexadecane — Cetane
Propadiene — Allene
Benzene — Benzol
Iso-propylbenzene — Cumene
1,2-dimethylbenzene — Ortho-xylene, O-xylene
1,3-dimethylbenzene — Meta-xylene, M-xylene
1,4-dimethylbenzene — Para-xylene, P-xylene
Acetylene — Ethyne
Methylacetylene — Propyne
Ethylene Oxide — Oxirane
1-32 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
1-34 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
Gas Properties
Empirical Properties of Specific Gases
1-36 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
SG Tc Pc Cpa Cpb Ax Bx
0.56 -113.17 672.84 8.19862 7.07604E-03 37.6845 4.46207E-02
0.57 -110.05 672.38 8.28132 7.22213E-03 38.1221 4.50533E-02
0.58 -106.93 671.92 8.36415 7.36822E-03 38.5610 4.54864E-02
0.59 -103.81 671.46 8.44710 7.51431E-03 39.0011 4.59202E-02
0.60 -100.69 671.00 8.53020 7.66040E-03 39.4425 4.63545E-02
0.61 -97.57 670.54 8.61342 7.80649E-03 39.8851 4.67895E-02
0.62 -94.45 670.08 8.69677 7.97258E-03 40.3290 4.72250E-02
0.63 -91.33 669.62 8.78025 8.09867E-03 40.7740 4.76611E-02
0.64 -88.21 669.16 8.86387 8.24476E-03 41.2204 4.80978E-02
0.65 -85.09 668.70 8.94761 8.39085E-03 41.6679 4.85352E-02
0.66 -81.97 668.24 9.03149 8.53694E-03 42.1167 4.89731E-02
0.67 -78.85 667.78 9.11550 8.68303E-03 42.5666 4.94116E-02
0.68 -75.73 667.32 9.19964 8.82912E-03 43.0178 4.98508E-02
0.69 -72.61 666.86 9.28391 8.97521E-03 43.4701 5.02905E-02
0.70 -69.49 666.40 9.36831 9.12130E-03 43.9237 5.07309E-02
0.71 -66.37 665.94 9.45285 9.26739E-03 44.3785 5.11718E-02
0.72 -63.25 665.48 9.53751 9.41348E-03 44.8345 5.16134E-02
0.73 -60.13 665.02 9.62231 9.55957E-03 45.2916 5.20556E-02
0.74 -57.01 664.56 9.70723 9.70566E-03 45.7499 5.24984E-02
0.75 -53.89 664.10 9.79229 9.85175E-03 46.2095 5.29418E-02
0.76 -50.77 663.64 9.87748 9.99784E-03 46.6702 5.33858E-02
0.77 -47.65 663.18 9.96280 1.01439E-02 47.1320 5.38305E-02
0.78 -44.53 662.72 10.0483 1.02900E-02 47.5951 5.42757E-02
0.79 -41.41 662.26 10.1338 1.04361E-02 48.0593 5.47216E-02
0.80 -38.29 661.90 10.2196 1.05822E-02 48.5247 5.51681E-02
0.81 -35.17 661.34 10.3054 1.07283E-02 48.9912 5.56152E-02
0.82 -32.05 660.88 10.3914 1.08744E-02 49.4589 5.60629E-02
0.83 -28.93 660.42 10.4775 1.10205E-02 49.9277 5.65113E-02
0.84 -25.81 659.96 10.5637 1.11666E-02 50.3977 5.69603E-02
0.85 -22.69 659.50 10.6501 1.13126E-02 50.8689 5.74099E-02
0.86 -19.57 659.04 10.7366 1.14587E-02 51.3412 5.78601E-02
0.87 -16.45 658.58 10.8232 1.16048E-02 51.8146 5.83110E-02
0.88 -13.33 658.12 10.9100 1.17509E-02 52.2892 5.87625E-02
0.89 -10.21 657.66 10.9969 1.18970E-02 52.7649 5.92146E-02
0.90 -7.09 657.20 11.0839 1.20431E-02 53.2417 5.96674E-02
SG Tc Pc Cpa Cpb Ax Bx
0.91 -3.97 656.74 11.1711 1.21892E-02 53.7197 6.01208E-02
0.92 -0.85 656.28 11.2584 1.23353E-02 54.1988 6.05748E-02
0.93 2.27 655.82 11.3458 1.24814E-02 54.6790 6.10295E-02
0.94 5.39 655.36 11.4333 1.26275E-02 55.1604 6.14848E-02
0.95 8.51 654.90 11.5210 1.27735E-02 55.6429 6.19408E-02
0.96 11.63 654.44 11.6088 1.29196E-02 56.1264 6.23973E-02
0.97 14.75 653.98 11.6968 1.30657E-02 56.6112 6.28546E-02
0.98 17.87 653.52 11.7849 1.32118E-02 57.0970 6.33125E-02
0.99 20.99 653.06 11.8731 1.33579E-02 57.5839 6.37710E-02
1.00 24.11 652.60 11.9614 1.35040E-02 58.0720 6.42302E-02
1.01 27.23 652.14 12.0499 1.36501E-02 58.5611 6.46900E-02
1.02 30.35 651.68 12.1385 1.37962E-02 59.0513 6.51504E-02
1.03 33.47 651.22 12.2272 1.39423E-02 59.5427 6.56115E-02
1.04 36.59 650.76 12.3161 1.40884E-02 60.0352 6.60733E-02
1.05 39.71 650.30 12.4051 1.42344E-02 60.5287 6.65357E-02
1.06 42.83 649.84 12.4942 1.43805E-02 61.0234 6.69988E-02
1.07 45.95 649.38 12.5835 1.45266E-02 61.5191 6.74625E-02
1.08 49.07 648.92 12.6728 1.46727E-02 62.0159 6.79269E-02
1.09 52.19 648.46 12.7624 1.48188E-02 62.5139 6.83920E-02
1.10 55.31 648.00 12.8520 1.49649E-02 63.0129 6.88577E-02
1.11 58.43 647.54 12.9418 1.51110E-02 63.5129 6.93241E-02
1.12 61.55 647.08 13.0317 1.52571E-02 64.0141 6.97911E-02
1.13 64.67 646.62 13.1218 1.54032E-02 64.5164 7.02588E-02
1.14 67.79 646.16 13.2119 1.55493E-02 65.0197 7.07271E-02
1.15 70.91 645.70 13.3023 1.56954E-02 65.5241 7.11962E-02
1.16 74.03 645.24 13.3927 1.58414E-02 66.0296 7.16659E-02
1.17 77.15 644.78 13.4833 1.59875E-02 66.5362 7.21362E-02
1.18 80.27 644.32 13.5740 1.61336E-02 67.0438 7.26073E-02
1.19 83.39 643.86 13.6648 1.62797E-02 67.5525 7.30790E-02
1.20 86.51 643.40 13.7558 1.64258E-02 68.0623 7.35514E-02
1.21 89.63 642.94 13.8469 1.65719E-02 68.5732 7.40244E-02
1.22 92.75 642.48 13.9381 1.67180E-02 69.0850 7.44982E-02
1.23 95.87 642.02 14.0294 1.686411E-02 69.5980 7.49726E-02
1.24 98.99 641.56 14.1209 1.70102E-02 70.1121 7.54477E-02
1.25 102.11 641.10 14.2126 1.71563E-02 70.6272 7.59235E-02
1-38 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
SG Tc Pc Cpa Cpb Ax Bx
1.26 105.23 640.64 14.3043 1.73023E-02 71.1433 7.64000E-02
1.27 108.35 640.18 14.3962 1.74484E-02 71.6606 7.68771E-02
1.28 111.47 639.72 14.4882 1.75945E-02 72.1788 7.73549E-02
1.29 114.59 639.26 14.5803 1.77406E-02 72.6982 7.78335E-02
1.30 117.71 638.80 14.6726 1.78867E-02 73.2185 7.83127E-02
1.31 120.83 638.34 14.7650 1.80328E-02 73.7400 7.87926E-02
1.32 123.95 637.88 14.8576 1.81789E-02 74.2625 7.92732E-02
1.33 127.07 637.42 14.9502 1.83250E-02 74.7860 7.97545E-02
1.34 130.19 636.96 15.0430 1.84711E-02 75.3106 8.02364E-02
1.35 133.31 636.50 15.1360 1.86172E-02 75.8362 8.07191E-02
1.36 136.43 636.04 15.2290 1.87632E-02 76.3629 8.12025E-02
1.37 139.55 635.58 15.3222 1.89093E-02 76.8906 8.16366E-02
1.38 142.67 635.12 15.4156 1.90554E-02 77.4194 8.21714E-02
1.39 145.79 634.66 15.5090 1.92015E-02 77.9492 8.26568E-02
1.40 148.91 634.20 15.6026 1.93476E-02 78.4801 8.31430E-02
1.41 152.03 633.74 15.6963 1.94937E-02 79.0120 8.36299E-02
1.42 155.15 633.28 15.7902 1.96398E-02 79.5449 8.41175E-02
1.43 158.27 632.82 15.8842 1.97859E-02 80.0789 8.46058E-02
1.44 161.39 632.36 15.9783 1.99320E-02 80.6139 8.50949E-02
1.45 164.51 631.90 16.0725 2.00780E-02 81.1499 8.55846E-02
1.46 167.63 631.44 16.1669 2.02241E-02 81.6870 8.60750E-02
1.47 170.75 630.98 16.2614 2.03702E-02 82.2251 8.65662E-02
1.48 173.87 630.62 16.3561 2.05163E-02 82.7643 8.70581E-02
1.49 176.99 630.06 16.4508 2.06624E-02 83.3045 8.75507E-02
1.50 180.11 629.60 16.5457 2.08085E-02 83.8456 8.80440E-02
1.51 183.23 629.14 16.6408 2.09546E-02 84.3879 8.85380E-02
1.52 186.35 628.68 16.7359 2.11007E-02 84.9311 8.900328E-02
1.53 189.47 628.22 16.8312 2.12468E-02 85.4754 8.95283E-02
1.54 192.59 627.76 16.9266 2.13929E-02 86.0208 9.00245E-02
1.55 195.71 627.30 17.0222 2.15389E-02 86.5672 9.05214E-02
1.56 198.83 626.84 17.1179 2.16850E-02 87.1145 9.10191E-02
1.57 201.95 626.38 17.2137 2.18311E-02 87.6629 9.15175E-02
1.58 205.07 625.92 17.3097 2.19772E-02 88.2124 9.20166E-02
1.59 208.19 625.46 17.4057 2.21233E-02 88.7627 9.25165E-02
1.60 211.31 625.00 17.5020 2.22694E-02 89.3143 9.30171E-02
SG Tc Pc Cpa Cpb Ax Bx
1.61 214.43 624.54 17.5983 2.24155E-02 89.8667 9.35184E-02
1.62 217.55 624.08 17.6948 2.25616E-02 90.4203 9.40205E-02
1.63 220.67 623.62 17.7914 2.27077E.02 90.9748 9.45233E-02
1.64 223.79 623.16 17.8881 2.28538E-02 91.5304 9.50269E-02
1.65 226.91 622.70 17.9850 2.29998E-02 92.0869 9.55312E-02
1.66 230.03 622.24 18.0820 2.31459E-02 92.6445 9.60362E-02
1.67 233.15 621.78 18.1791 2.32920E-02 93.2031 9.65420E-02
1.68 236.27 621.32 18.2764 2.34381E-02 93.7627 9.70486E-02
1.69 239.39 620.86 18.3738 2.35842E-02 94.3234 9.75559E-02
1.70 242.51 620.40 18.4713 2.37303E-02 94.8851 9.80639E-02
1.71 245.63 619.94 18.5690 2.38764E-02 95.4477 9.85727E-02
1.72 248.75 619.48 18.6668 2.40225E-02 96.0114 9.90823E-02
1.73 251.87 619.02 18.7647 2.41686E-02 96.5761 9.95926E-02
1.74 254.99 618.56 18.8627 2.43147E-02 97.1417 1.00104E-01
1.75 258.11 618.10 18.9609 2.44607E-02 97.7085 1.00616E-01
1.76 261.23 617.64 19.0592 2.46068E-02 98.2763 1.01128E-01
1.77 264.35 617.18 19.1577 2.47529E-02 98.8450 1.01641E-01
1.78 267.47 616.72 19.2563 2.48990E-02 99.4148 1.02156E-01
1.79 270.59 616.26 19.3550 2.50451E-02 99.9856 1.02670E-01
1.80 273.71 615.80 19.4538 2.51912E-02 100.557 1.03186E-01
1.81 276.83 615.34 19.5528 2.53373E-02 101.130 1.03703E-01
1.82 279.95 614.88 19.6519 2.54834E-02 101.704 1.04220E-01
1.83 263.07 614.42 19.7511 2.56295E-02 102.279 1.04738E-01
1.84 286.19 613.96 19.8505 2.57756E-02 102.855 1.05257E-01
1.85 289.31 613.50 19.9500 2.59216E-02 103.431 1.05776E-01
1.86 292.43 613.04 20.0496 2.60677E-02 104.009 1.06296E-01
1.87 295.55 612.58 20.1493 2.62138E-02 104.588 1.06817E-01
1.88 298.67 612.12 20.2492 2.63599E-02 105.168 1.07339E-01
1.89 301.79 611.66 20.3493 2.65060E-02 105.749 1.07862E-01
1.90 304.91 611.20 20.4494 2.66521E-02 106.331 1.08385E-01
i Ax and Bx are
constants for
Redlich-Kwong
equation of state.
1-40 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
Specific Specific
Cp/CV @ Gravity Vol. Cu. ft.
150 deg. F @ 14.7 Gas @
Molec. & 14.7 PsiA & Pc 14.7 PsiA
Gas Formula Wt. PsiA 60 deg F (PsiA) Tc (deg. R) 60 deg F
Hydrogen H2 2.016 1.40 .0700 188.00 60.20 188.6790
Oxygen O2 32.000 1.39 1.1047 730.00 277.85 11.8480
Nitrogen N2 28.016 1.40 .9672 492.00 226.91 13.5320
Carbon Monoxide CO 28.010 1.40 .9670 510.00 241.49 13.5500
Carbon Dioxide CO2 44.010 1.27 1.5194 1073.00 547.67 8.5690
Water H2O 18.016 1.32 .6220 3206.00 1164.89 ---
Ammonia NH3 17.032 1.29 .5580 1657.00 730.08 22.1240
Sulphur Dioxide SO2 64.060 1.25 2.2116 1142.00 774.65 5.8240
Hydrogen Sulfide H 2S 34.076 1.31 1.1764 1306.47 672.41 11.0500
Air --- 28.966 1.40 1.0000 546.69 238.43 13.0890
Methane CH4 16.042 1.28 .5550 673.10 343.19 23.6100
Acetylene C2H2 26.036 1.22 .8988 905.00 557.09 14.5770
Ethene C2H4 28.052 1.21 .9684 742.10 509.51 13.5300
Ethane C2H6 30.068 1.17 1.0460 708.30 549.47 12.5200
Propene C3H6 42.078 1.14 1.4526 667.00 656.64 9.0200
Propane C3H8 44.094 1.11 1.5470 617.38 665.95 8.4710
I-Butene C4H8 56.104 1.09 1.9368 583.00 755.29 6.7640
Isobutene C4H8 56.104 1.09 1.9368 579.80 752.19 6.7640
Butane C4H10 58.120 1.08 2.0710 550.70 765.31 6.3270
Isobutane C4H10 58.120 1.08 2.0670 529.10 734.65 6.3390
Pentane C5H12 72.146 1.06 2.4906 489.50 845.61 5.2601
Isopentane C5H12 72.146 1.06 2.4906 483.00 829.69 5.2601
Neopentane C5H12 72.146 1.09 2.4906 464.00 780.77 5.2601
Benzene C6H6 78.108 1.09 2.6965 714.00 1012.70 4.8586
Hexane C6H14 86.172 1.05 2.9749 439.70 914.19 4.4039
Heptane C7H16 100.198 1.04 3.4591 396.90 972.19 3.7875
Constants used: 1 BTU = 778.16 ft-lb (Wt.) 1 Atms = 14.696 psia 0 deg. F = 459.69 deg. R
R = 1.98718 BTU per lb-mole = 10.7385 psia CF per lb-mole, deg. R
Volume of 1 lb-mole at 491.69 deg. R = 359.28 CF
25 50 75 100 125 150 175 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050 1100 1150 1200
0 60 92 119 134 145 156 165 174 189 202 216 216 224 230 236 241 247 253 257 262 266 270 274 278 281 285 289 293
10 33 59 79 97 112 122 130 138 151 163 173 182 190 199 207 215 212 216 220 225 228 232 235 239 241 245 248 251
20 40 58 72 85 98 110 117 129 140 149 158 165 173 179 185 191 197 202 209 215 210 213 215 219 222 225 228
THREE STAGE
30 27 44 58 69 79 89 99 114 124 133 141 148 155 161 166 172 177 182 187 191 193 201 205 210 214 208 211
40 33 46 57 67 75 84 99 112 121 128 135 141 147 152 158 163 167 172 176 180 184 188 191 195 199 202
50 24 38 48 57 65 72 86 98 111 118 124 131 137 142 147 151 156 161 164 168 172 176 179 182 186 189
60 30 41 49 57 64 77 88 100 110 116 122 127 133 137 142 147 150 154 158 162 165 169 172 175 178
70 23 34 43 50 57 69 80 90 101 109 114 120 125 130 135 138 142 146 150 153 157 160 163 166 169
80 28 37 44 50 62 72 83 91 101 109 113 118 123 127 132 136 139 142 146 150 152 155 159 162
90 22 32 39 46 57 67 75 85 93 101 108 112 117 122 125 129 133 137 139 143 146 149 151 154
100 26 34 41 51 61 70 78 85 93 101 108 111 116 120 124 127 131 134 137 140 143 146 149
125 23 30 41 50 59 66 72 79 85 92 98 105 109 112 115 119 122 124 127 130 133 136
150 20 33 42 49 56 62 69 74 80 85 91 96 102 106 110 112 115 118 121 124 125
TWO STAGE
250 24 31 37 43 47 52 56 60 64 68 72 75 79 82 85 88 92 95
300 21 28 33 38 43 46 50 54 58 61 64 68 71 73 77 80 83
350 20 25 31 35 39 43 46 49 53 56 59 62 65 68 70 72
Compressor Horsepower Selection Chart
400 23 29 33 36 40 43 46 49 52 55 56 59 62 65
450 21 26 30 33 37 40 43 46 48 51 54 56 59
500 20 24 28 32 35 38 41 43 46 48 50 53
550 19 23 27 30 33 36 38 41 43 46 47
600 21 25 28 32 34 36 39 41 43
650 20 24 27 30 33 35 37 39
SINGLE STAGE
700 20 23 26 28 31 33 35
750 19 22 25 27 30 32
Note: To be used only as an estimation guide. Horsepower Sizing and Engine/Generator Selection should be confirmed with Superior Marketing.
RAM-DB-05-01-2002
Chapter 1: Application and Performance Data
SUPERIOR® COMPRESSORS
7 8 9 10 20 30 40 50 60 80 100 200 300 400 600 800 1000 2000 3000 4000
10
9 9
8 8
∆P - (Psi)
7 w) 7
6 belo 6
Note: Use only when actual on
5 values are not available. uati 5
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Interstage Pressure Drop -
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:
ote
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g .5)
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.5
Pd
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.1 10
7 8 9 10 20 30 40 50 60 80 100 200 300 400 600 800 1000 2000 3000
1
DRIVE
END
1 DRIVE
END
1
DEG. 0O 90O 180 O 270O 360O 2
4 4 3
CYL. H.E. 1&2 3&4 1&2 3
4
C.E. 1&2 3&4
AUX. END
2
DRIVE
1 END
4 6 1
2
DEG. 0 O
60 O
120 O
180 O
240
O
300O
360O
6 3
CYL. H.E. 1 & 2 3&4 5&6 1&2 4
5
C.E. 5&6 1&2 3&4 5 3 6
2 AUX. END
1 DRIVE
8 END
1
DEG. 0O 90O 180 O 270O 360O 2
8 4 3 3
CYL. H.E. 1&2 3&4 7&8 5&6 1&2 5 6 4
2 7
H.E. OUTER DEAD CENTER 8
7
C.E. INNER DEAD CENTER
AUX. END
1-44 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
RAM COMPRESSORS
Chapter 1 General:
Engineering Standards
RAM Compressors Technical Data Book: RAM-DB-1-0701-0
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ENGINEERING STANDARDS
The following engineering standards are provided to further illustrate points
made throghout this manual and to provide the necessary recommendations
for packaging Superior compression equipment. By receiving these
documents, you agree not to use such confidential information for any
purpose other than for marketing and packaging of superior products.
INDEX
Standard Topic
ES-3 Venting and Draining Systems for Reciprocating Compressors
ES-5 Protection of Engines and Compressors for Domestic Shipment
of Average Storage
ES -7 Protection of Engines and Compressors for Export Shipment or
Hazardous Storage
ES-13 Trimming Superior and Ajax Compressors for Sour Gas
Applications in Lubricated Service
ES-14 Trimming Compressors for Carbon Dioxide/Natural Gas
Applications in Lubricated Service
ES-16 RAM Series Compressor Mechanical and Acoustic Packaging
Requirements
ES-19 Compressor Frame and Cylinder Assembly Criteria
ES-20 Guard and Spring Reference List for RAM, WH, MH, & W7
Assemblies
ES-23 Superior compressor Cylinder and Cylinder Class Designations
ES-27 Compressor Performance Guarantee
ES-1001 Lubrication of Superior Engines and Compressors
ES-1002 Lubrication Recommendations for Superior Reciprocating
Compressor Frames and Cylinders
ES-3001 Pipe Cleaning Engines, Compressors, Packaged Unit
ES-3002 Welded Clearance Volume Bottles for Compressors: Material
and Fabrication Requirements
ES-3004 Ajax-Superior Packager Manual
ES-3006 Compressor Cooling System Design
ES-4009 Determination of Compressor Cylinder Dead Center Position
ES-4100 Compressor Field Performance Test Specification
ES-4101 Ajax-Superior Compressor Field Performance Test
Instrumentation
ES-4102 Analysis and Interprestation of Compressor Field Performance
Test Results
ES-5011 Hydrostatic and Helium Testing of Compressor Cylinders,
Cylinder Heads and Valve Covers
ES 3
Venting and Draining Systems
for Reciprocating Compressors
1.0 Scope
1.1 This standard sheet describes the venting and drain systems
which must be provided for crosshead guides and/or distance
pieces and packings.
2.0 Requirements
2.1 Vent lines and drain lines must be separate for each crosshead guide
distance piece and each packing. The use of one line as both a drain
and vent is not acceptable. Packing vents must also be separate from
distance piece vents.
2.2 Vent piping and drain piping shall be at least 3/4 inch nominal
size. External connections and piping shall not be less than 3/4 inch
(except vent holes in packings and internal connection tubing which
may be 1/4 inch).
2.3 Vent and drain piping or tubing shall be seamless steel. Nipples,
when used, shall be Schedule 80 minimum, with steel tubing fittings
being an acceptable alternate.
2.4 To prevent “back venting” and drain plugging, it is desirable
that each vent and drain from the individual distance pieces and
packings be a separate line, especially on multistage units. If vent
lines are manifolded together, however, the cross-sectional flow area
of the manifold must be at least equal to the total of the flow areas
of the individual lines feeding into it. Drain manifolds shall be sized
in the same manner.
2.5 Vent lines and drain lines from each auxiliary distance piece must
be separate. Manifolding of these lines into any other vent or drain
is not acceptable. Different gasses should never be manifolded into
a common vent.
2.6 Vent connections are always located on the top of the distance
pieces. The proper location will always be shown on the foundation
and outline drawing. Vent lines piped from these connections must
be configured such that their level is always equal to or rising above
the connection point (i.e. - liquid traps must not be formed).
2.7 Drain connections are always located on the bottom of the distance
pieces. The proper location will always be shown on the foundation
and outline drawing. Drain lines piped from these connections must
be configured such that their level is always equal to or dropping
below the connection point (i.e. liquid traps must not be formed).
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ES 5
Protection of Engines and Compresssors
for Domestic Shipment or Average Stor-
age
1.0 Scope
1.1 This procedure explains the necessary steps required to protect
engines and compressors from rust and oxidation during
domestic shipment and/or average storage before start-up.
Domestic shipment applies to transport within North America
when not subject to a salt-laden atmosphere for a significant time
(offshore service). Average storage applies to a salt and sand-free
and otherwise non-highly corrosive atmosphere. (Units to be
exported should be protected in accordance with the requirements
of ES7. Non-lube compressor cylinders should be protected
according to the requirements of ES2).
3.0 Requirements
3.1 Compressor Frames
3.1.1 Pump a good rust inhibiting oil such as Tectyl 940
through the oil lines for a period long enough to insure
that a good distribution of oil to all necessary locations
(bearings, rods, etc.) is attained. Once completed,
drain the oil. When units have cylinders mounted, this
protective oil shall be pumped throughout the cylinder
lubrication lines as well.
3.1.2 With crosshead guide covers, distance piece covers and
frame top cover removed, spray Tectyl 843 or equal
on packings, piston rods, crossheads, crosshead guides,
inside the crankcase frame including the crankshaft,
connecting rods and gears. Replace all the above covers.
3.1.3 Plug all holes using pipe plugs where threaded, or
plastic plugs. Breather caps should be covered with
6 mil plastic bags secured with waterproof tape or a
draw string.
3.1.4 If compressor cylinders are not on the frame, seal
crosshead guide cylinder end openings with 1/2" marine
plywood and 1/8" thick flat neoprene gasket sheet
installed with at least 50% bolting. After painting,
Tectyl 506 shall be brushed between the wood cover
and crosshead guide cylinder mounting face to inhibit
moisture from penetrating past the rubber gasket.
3.1.5 The compressor should not be barred over after the rust
proofing has been accomplished as this will remove the
protective film.
3.1.6 Caution tags should be attached to the frame to indicate
the treatment performed (see last page for example).
3.1.7 Cover the unit with a heavy waterproof tarp
during transportation and outdoor storage. IF THE
ABOVE PROCEDURES HAVE BEEN FOLLOWED
BUT TARP IS NOT USED, CES WILL NOT
BE RESPONSIBLE FOR ACCELERATED BREAK
DOWN OF RUST PROTECFION.
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3.2.7 For piston & rod assemblies shipped in the cylinders, the
piston, piston rod and cylinder bore shall all be coated with
Tectyl 843 prior to assembling. The piston and rod should
be placed in the cylinder as soon as possible after coating
while the coating is still liquid. After the head is installed,
the piston shall be positioned at the head end. The exposed
piston rod, packing and end cover shall be coated with
Tectyl 506 and wrapped in moisture resistant paper. In
order to avoid shipping damage to the exposed piston rod,
a box shall be constructed of 1/2" marine plywood to cover
the rod. The box shall have center supports for the rod to
insure against movement or shifting or the rod and piston
which could damage the packing. The box shall be securely
fastened to the cylinder by use of metal banding.
3.2.8 If valve covers are shipped loose, the cylinder openings
shall be covered with 1/2" marine plywood and sealed with
1/8" thick flat neoprene gasket sheet or RTVsealant with at
least 50% bolting. Before applying RTV sealant, a coating
of Tectyl 843 should be applied to the metal surface
to minimize problems of cover removal. When shipping
valve covers, unloaders, retainers, etc. separately, treat
with Tectyl 843 or equal and pack in water resistant
wooden boxes.
3.2.9 After final painting, coat the assembled valve cap/cylinder
interfaces with Tectyl 506.
3.2.10 After final painting, all exposed stud threads shall be coated
with Tectyl 506.
3.2.11 After final painting, the variable volume adjusting screw
and adjacent components shall be sprayed with Tectyl 843.
3.2.12 Cylinders shipped loose or stored outdoors shall be
covered with a heavy waterproof tarp. IF THE ABOVE
PROCEDURES HAVE BEEN FOLLOWED BUT TARP
NOT USED, CES IS NOT RESPONSIBLE FOR
ACCELERATED BREAKDOWN OF RUST
PROTECTION.
3.2.13 Pistons, rods, and piston and rod assemblies shipped loose
shall be sprayed or brushed with Tectyl 506 or equal and
shipped in a waterproof wooden box.
3.2.14 Assembled valves shipped separately should be dipped in
K-450 or equal and sealed in 6 mil plastic bags.
3.2.15 Caution tags should be attached to the cylinders to indicate
treatment performed (see last page for example).
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3.3 Engines
3.3.1 Production tests on engines shall be performed
using Tectyl 940 rust preventive
lubricating oil.
3.3.2 Drain the unit of oil and water. On Vee engine heads,
two 1/4" pipe plugs must be removed on each head
in order to completely drain them of water. The plugs
should then be placed in a plastic bag and shipped with
the engine.
3.3.3 On all Superior stock engines, Tectyl 843 shall be
sprayed inside each power cylinder as well as all
exposed surfaces inside the crankcase including crank
shaft, connecting rods, liners, piston skirts, camshafts,
chain drives and gear drives.
3.3.4 Plug all small holes using pipe plugs or plastic caps.
3.3.5 Remove all belts prior to finish painting to insure good
paint coverage on sheaves. Place the belts in a plastic
bag and attach to engine.
3.3.6 The engine should not be barred over after the rust
proofing has been accomplished as this removes the
protective film.
3.3.7 Cover flange holes (i.e. air, water, and oil inlets &
outlets) with 1/2" marine plywood and either 1/8" thick,
flat, neoprene gasket sheet or RTV sealant. Use at least
50% bolting to secure the covers. Before applying RTV
sealant, a coating of Tectyl 843 should be applied to the
metal surface to minimize problems of cover removal.
3.3.8 The Governor shall be wrapped in PC75D VCI paper or
equal and then securely covered with a plastic bag. Use
Tectyl 940 when filling governor.
3.3.9 Wrap the magneto in PC7SD VCI paper and securely
cover with a plastic bag. For Superior stock units, the
magneto shall be removed from the engine wrapped in
PC75D VU paper and placed in a waterproof box.
3.3.10 Brush Tectyl 502-C or equal on all external movements
such as springs or linkages.
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ICAUTION
During the first hour of oper-
ation the differential pressure
across the oil filters should be
monitored closely to assure
the oil filters are not clogged.
If the filters appear to be
clogging, the engine should
be stopped and the filters
changed.al fill of lubricating
oil.
ICAUTION
This compressor cylinder has
been treated with Tectyl
rust preventives. Prior to
start-up, this preventive must
be removed from inside the
cylinder, including the valve
pockets, with stoddard
solvent or mineral spirits.
ES7
Protection of Engines and Compressors
for Export Shipment or Hazardous Stor-
age
1.0 Scope
1.1 This proccdure explains the necessary steps required to protect
engines and compressors from rust and oxidation during export
shipment or hazardous storage. Export shipment applies to
transport in a salt-laden atmosphere or to anywhere outside
North America. Hazardous storages applies to a highly damaging
atmosphere (such as salt-laden, sand-laden, or high humidity)
typical of offshore platform service.
1-56 RAM-DB-05-01-2002
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3.0 Requirements
3.1 Compressor Cylinders
3.1.1 Standard Lube and Mini-lube Cylinders
Coat the compressor cylinder bore, gas passages, under
the valve caps, head, valve retainers, valves, suction
and discharge flanges, V.V. pocket screws and any other
unpainted metal surfaces per Engineering Standard ES5
except that Tectyl 502-C replaces Tectyl 843.
All cylinders are to be shipped in a waterproof box after
coating as well as all related parts which are shipped
loose.
3.1.2 Non-Lube Cylinders
Prepare per Engineermng Standard ES2.
3.2 Compressor Frames
Follow the Engineering Standard ES5 storage requirements
except that Tectyl 502-C replaces Tectyl 843 and also the
protective coatings must be removed prior to start.
Box the entire unit in a waterproof box.
3.3 Engines
Follow the storage requirements of Engineering Standard ES5
with the following additions:
3.3.1 Protective coatings must be removed prior to start
except Item 3 below.
3.3.2 Pump a mixture of 50/50 Tectyl 843 and diesel fuel into
the fuel lines for diesel and dual fuel engines.
3.3.3 Spray a very light film of Tectyl 843 inside the power
cylinders and reinstall the spark plugs/injector nozzles/
clean burn nozzles. i Normally,Tectyl 843
will not have to be
removed from the
3.3.4 After removing sidecovers, spray all exposed machined power cylinders prior to
surfaces inside the crankcase with Tectyl 843 or equal, start as it is a combustible
including crankshaft, connecting rods, liners, piston and will burn cleanly inside
the combustion chamber.
skirts, camshafts, chain drives and gear drives. BEFORE STARTING THE
UNIT, however, the power
cylinders should be visually
inspected using a bore-
scope to assure that there
is no water collection, rust
damage or a large accumu-
lation of Tectyl. Flush large
accumulations of Tectyl with
a stoddard solvent prior to
start.
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ES 13
Trimming Superior And Ajax
Compressors For Sour Gas Applications
In Lubricated Service
1.0 Purpose
1.1 To define and clarify the compressor design criteria to be used
in applying compressors in sour gas service to prevent the
occurrence of sulfide stress corrosion cracking and untimely
failure of compressor components.
1.2 To establish compressor design criteria that follow the guidelines
of API 11P and NACE MR0175 for sour gas service.
1.3 To establish Ajax and Superior Packaging design criteria that
follow the guidelines of API 11P and NACE MR0175.
1.4 To establish and define different levels of protection depending
upon the customer’s requirements.
1.4.1 The standard protection level will be per guidelines
established by API 11P and described in Section 4.0.
1.4.2 For more rigid protection requirements the guidelines
used will be NACE MR0175, described in Section 5.0.
This stricter protection may be needed to comply with
stricter regulatory controls or customer requirements.
1.4.3 Since the customer knows the application details of
his process much more thoroughly than does CES, the
customer may determine that higher levels of H2S trim
are required and opt to buy these. CES will make every
effort to accommodate these special requirements.
2.0 Application
2.1 These guidelines apply only to lubricated compressor units;
requirements will be different on a non-lube compressor and will
be decided on an individual basis.
ES 13
2.2 Section 4.0 designates the trim requirement when units are
designed to the guidelines of API 11P.
a. Section 4.1 for H2S concentrations up to and including 2%
by volume applies to Ajax and Superior model compressors,
including RAM and JOY.
b. Section 4.2 for H2S concentrations between 2% and 5%
(Level 1-11P) applies only to Ajax and Superior model
compressors, including RAM.
c. Section 4.3 for H2S concentrations greater than 5%
(Level 2-11P) applies only to Ajax and Superior model
compressors, including RAM.
2.3 Section 5.0 designates the trim requirements when units are
designed to more nearly meet the guidelines of NACE MR0175
and applies only to Ajax and Superior model compressors,
including RAM.
2.4 Section 6.0 designates the trim requirements for Ajax Packaging
when it is designed to meet the guidelines of API 11P.
2.5 Section 7.0 designates the trim requirements for Ajax Packaging
when it is designed to more nearly meet the guidelines of NACE
MR0175 and more stringent customer requirements.
2.6 When CO2 concentrations greater than 5% are present with an
H2S concentration greater than 2%, the units should be trimmed
per the Level 2-11P requirements in Section 4.3 as a minimum.
In addition, the requirements in Section 7.0 of CO2 trim standard
(ES14—contact CES Marketing) will be required.
3.0 Responsibilities
3.1 Marketing’s responsibilities are:
3.1.1 To acquire reliable gas analysis; and to identify,
to both engineering and the customer, all sour gas
applications as early as possible (hopefully in the
pre-quotation stage).
3.1.2 To be familiar with the various requirements set herein.
3.1.3 To price all sour gas units appropriately.
3.1.4 To educate the involved customers and end-users
ES 13
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ES 13
Exceptions to this can occur on an individual basis when either high H2S
levels exist or other constituents are present which affect the trim.
4.1 Hydrogen sulfide (H2S) concentrations up to and including 2%
by volume:
4.1.1 For any concentration of H2S below .005% (50 ppm)
no special requirements are necessarily relative to the
trimming of the equipment.
4.1.2 For any concentration of H2S from .005% (50 ppm)
up to and including 2% by volume in lubricated
service special trim will not be required. Standard
material is acceptable and special lubrication practices
are recommended.
4.1.3 The frame lubricant used must have a total base number
(TBN) of 15 or higher to help prevent the lubricant from
turning acid and damaging bearings and bushings. This
alkalinity must be maintained during operation in the
machine by appropriate timely makeup or complete oil
changes. At no time should the lubricant TBN be less
than approximately 30% of the original TBN number.
4.1.4 The frame lubricant must meet or exceed the
requirements of MIL-L-2104B, Supplement No. 1.
4.1.5 A complete oil analysis program on the frame lubricant
is required to determine proper oil change intervals as
well as to monitor the condition of the lubricant and
the unit.
4.1.6 Compressor cylinder lubricants must adhere to the
requirements of Ajax-Superior Engineering Standard
ES1002 for Superior models and ESS-L-811 and
ESS-L-168 for Ajax models. Viscosities are to
be on the high side of the pressure conditions
normally required and a 3 to 8% compounding with
acidless tallow (similar to steam cylinder oils) is
also required.
4.1.7 The compressor cylinder lubricant rate is to be
double the normal rate for equivalent non-sour gas
applications.
ES 13
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ES 13
ES 13
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ES 13
ES 13
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ES 13
ES 13
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ES 13
ES 13
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ES 13
ES 13
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ES 13
ES 13
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ES 13
ES 13
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ES 14
Trimming Compressors for Carbon
Dioxide/Natural Gas Applications in
Lubricated Service
1.0 Scope
1.1 This specification is to be used as a guide in trimming CES
Superior manufactured compressors for the compression of gas
having various percentages of carbon dioxide (CO2).
1.2 These guidelines apply only to lubricated compressor units;
requirements will be different on a non-lube compressor and will
be decided on an individual basis.
1.3 This specification follows the guidelines established in the
latest edition of API Specification 11P. Where this specification
deviates from 11P it will be noted. Some of the wording and
graph data is taken directly from this API publication.
Special trimming and materials other than those specified in this
specification will be negotiated on an individual basis in order to
meet a customer’s specific requirements.
1.4 Figure 1 in this specification shows the pressure and CO2
concentration parameters where special trimming is required.
2.0 Purpose
2.1 Carbon dioxide is soluble to some degree in water and will form
a weak carbonic acid solution. The solubility of CO2 in water
increases with increasing pressure and decreases with increasing
temperature. Water droplets are normally present in gas streams
handled by Ajax-Superior equipment, and even when separation
and dehydration equipment is used it is subject to system upsets.
Therefore, this specification is written to limit the susceptibility
of this equipment to potential carbonic acid corrosion. (See
Section 5.2 on the following pages).
ES 14
3.0 Responsibilities
3.1 Marketing’s responsibility:
3.1.1 To acquire reliable gas analysis and to identify, to
both Engineering and the customer, gas concentrations
requiring special trim as early as possible (hopefully in
the pre-quotation stage).
3.1.2 To be familiar with the various requirements set herein.
3.1.3 To price all units requiring the special trim
appropriately.
3.1.4 To educate the involved customers and end-users on
their responsibility concerning the maintenance and
operational procedures to be used for CO2 compression.
3.2 Engineering’s responsibility:
3.2.1 To define and specify properly-designed components in
accordance with the guidelines set herein.
3.2.2 To review all CO2 applications forwarded by Marketing
and assist them, as required, in tailoring individual
applications to requirements.
3.2.3 To set the standards for design and proper
maintenanace, and to keep them updated as the “state of
the art” advances.
3.2.4 To assure that copies of this standard, as well as
Engineering Standard ES 1002, are properly distributed
in instruction manuals for CO2 units.
3.3 Responsibility of the customer:
3.3.1 To maintain the CO2 compressors in accordance with
the standards set herein.
ES 14
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ES 14
ES 14
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Figure I – Trimming Curve for CO2 Concentrations (Lubricated Units with < 2% H2S)
Suction Pressure
1200
900
300
Special trim not required
0
5 10 20 30 40 50 60 70 80 90 100
Percent CO2
ES 14
ES 16
RAM Series Compressor Mechanical
and Acoustic Packaging Requirements
1.0 Scope
This standard provides the limitations and requirements for design of
the skid, pulsation bottles and cylinder supports to minimize mechanical
and pneumatic vibrations on RAM Series compressor packages. For
applications requiring vibration or performance guarantees, refer to ES3005
for requirements.
2.0 Responsibilities
2.1 Marketing
2.1.1 Convey this standard to the packager.
2.1.2 Coordinate design review and testing of package.
2.1.3 Inform packager of the need to test the package for
special applications.
2.2 Engineering
2.2.1 Review package design, approve or disapprove, and
suggest where improvements could be made.
2.2.2 Participate in package testing and approve results where
applicable.
2.2.3 Review customer specifications to determine when
testing is necessary.
2.3 Packager
2.3.1 Design the package to the requirements in this standard.
2.3.2 Test the package when necessary.
3.0 Requirements
3.1 Unless otherwise required by customer specifications, cylinder
bottles are to be designed to achieve maximum pulsation level of
5% peak-to-peak.
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3.2 The structural mounting for the RAM cylinder and frame assembly
shall be massive and stiff enough to achieve a maximum vibration
level on the cylinder and frame assembly of 15 mils peak-to-peak.
3.3 Completed packages will be tested as needed to confirm acceptable
vibration and pulsation characteristics.
4.0 Procedure
4.1 The packager is to use the following inertia and stiffness guidelines
in designing the mounting structure.
4.1.1 The RAM compressor assembly shall be mounted to
a structure and concrete pad that has a total inertia
(not including that for prime-mover) about the vertical
centerline no less than 17,000 lb-ft-sec2 for a RAM two-
throw and 26,500 for a RAM four-throw.
4.1.2 The RAM compressor assembly shall be mounted to
a structure with a torsional stiffness about the vertical
centerline of no less than 6 x 109 in-lb/rad for a RAM two-
throw, and 12 x 109 in-lb/rad for a RAM four-throw.
4.1.3 The packager is to design head-end cylinder supports
for cylinder Classes H, I, J, and K (131⁄2” through 20”
diameter) and units employing an auxiliary distance piece.
The cylinder supports should be designed similar to the
sketch in Figure 1 and mounted to a concrete pad, skid,
or piling. For lowest vibration, supports may also be
required for smaller cylinder classes.
4.2 First-time packagers of RAM compressors, must submit the design
drawings for review by CES Engineering and approval signature of
the Manager, Product Engineering.
4.3 After approval, the design will be tested.
4.3.1 A no-load mechanical vibration test will be conducted.
4.3.2 A bump test will be performed to determine natural
frequencies in the operating speed range.
4.4 If the design proves adequate, no further testing or review would be
needed on subsequent units, except for special applications such as
offshore platforms and trailer-mounted units.
4.5 Packages for offshore platforms will always be tested with a bump
test and a no-load mechanical vibration test even if not required by
the customer specifications.
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ES 19
Compressor Frame and Cylinder
Assembly Criteria
1.0 Scope
This standard lists the assembly criteria for the MW, SW, W7, WH, MH,
RAM and JOY frames and cylinders, along with the RAM, JOY, Superior
(traditional and WH), Ajax, and pipeline cylinders.
2.0 Purpose
This standard defines the assembly criteria that establish a machine to be an
acceptable product to be shipped to the customer.
3.0 Procedures
Machines are to be assembled and tested using the following:
3.1 Torque Table (pages 3 and 4).
3.2 Clearance Table (page 8).
3.3 Pressure testing of components.
3.3.1 Hydrotests are performed on all cylinder bodies,
heads, bonnets, and valve covers per Engineering
Standard ES 5011. Test procedures are determined from
individual part drawings.
3.3.2 Helium tests are performed per ES 5011 when required
by the sales release or for gases with molecular weights
below 12.
3.4 Valve leak testing is done per ES 4023.
3.5 Assembly inspections are performed per General Operating
Procedure 10.1003; included in this standard are the following:
3.5.1 Frame bar over test per ES 5029.
3.5.2 Recording of torques and clearances per Form SI-418,
SI-400, SI-461, SI-402, and SI- 468 found in Procedure
10.1003.
3.5.3 Recording reciprocating part weights per Form SI-417
found in Procedure 10.1003. See Section 3.6 of this
procedure (ES 19) for balancing details.
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Connecting 1-1/8"-12 UNF nut 1"-14 UNS nut 1"-14 UNS nut 1"-8 UNJ bolt 1"-8 UNJ bolt 1"-14 UNS bolt
Rod 430-460 320-330 250-260 500 430-450 520
Main Bearing 1-1/8"-12 UNF nut 3/4"-10 UNC nut 3/4"-10 UNC nut 3/4"-10 UNC nut 3/4"-10 UNC nut 1"-8 UNC bolt
Cap 430-460 180-200 180-200 185-200 185-200 350
Base Spacer 1-1/4"-12 UNF 1-1/8"-12 UNF 1-1/8"-12 UNF 1-1/8"-7 bolt 1-1/8"-7 bolt 7/8"-9 UNC bolt
Bolt/Nut 640-700 380-410 380-410 380-400 380-400 300
Crosshead Pin 3/4"-16 UNF UNF 3/4"-16 UNF N/A N/A N/A
Nut 105-115 105-115 105-115
Soc. Head 5/8"-11 UNC Allen Screw Allen Screw 5/8"-11 5/8"-11 3/4-10
Capscrews Allen Soc. Head
Screws-Rod 60-70 Grade 5 60-65 60-65 60-70 60-70 120-140
Packing
Crosshead 1-1/2"-20 UNF- Flat Head Flat Head 3/8"-16 UNC 1/2"-20 UNF 1/2"-20 UNF
Shoe Flat Head Capscrew
35-45 25-30 25-30 18-20 30-35 20-25
W7 SW MW WH MH RAM
Balance Nut 2-1/2"-10 UN 2-1/2"-10 UNS 2-1/4"-8 UN 2-1/2"-10 UNS 2-1/2"-10 UNS 2"-8 UN
or Crosshead 2650-3250 2650-3250 1500-2000 2650-3250 1900-2300 1100
Jam Nut
Piston-to- 2"-8 UNF 2"-12 UN 2"-12 UN 7/8"-9 UNRC 7/8"-9 UNRC 1-1/2"-12 UN
Piston Rod 1180-1265 1760-2150 1760-2150 Capscrew Capscrew 1100
Nut (for thru rod) 200-220 200-220
For Multi-bolt, 2"-8 UN 2"-8 UN
see misc. fasteners. 1500-1600 1500-1600
(for Thru Rod) (for Thru Rod)
Cyl/Crosshead 7/8"-9 UNC 7/8"-9 UNC 7/8"-9 UNC 7/8"-9 UNC 7/8"-9 UNC 7/8"-9 UNC
Guide Capscrew 200 200 200 200-220 200-220 200
Valve Caps See Note 1 See Note 1 See Note 1 See Table for See Table for See Misc.
Valve Caps Valve Caps Nuts
WH6 Cylinder N/A N/A See Table for See Table for N/A
Half Bolting WH6 Half WH6 Half
Bolting Bolting
2.375" 3-5
3.25" 3-5
4.00" Slotted Seat 13-15 5/16"-24 22-26
Center Bolt 4.00" Drilled Seat 29-32 3/8"-24 41-45
Torque 5.25" 13-15 7/16"-20 58-62
All Models 5.75" 18-20
7.00" 18-20
8.00" 18-20
9.125" 18-20
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Notes:
1. On the W7, SW, and MW cylinders, torque valve cap nuts on 3-3/4" and
smaller diameter cylinders or cylinders with working pressure of 4,000
psi or greater to 300 ft-lbs (all others use miscellaneous fastener table).
2. On the W7, SW, and MW, each crosshead pin to be checked two (2)
hours after first being placed in service, re-torquing bolt nut to
105 - 115 ft/lb. This procedure to again be followed at the end of
one (1) week's service, at which time each pin should be in a stable
and permanent position.
3. Torque figures are for threads lubricated with lubriplate or petroleum-
based oil. Do not use any compounds containing molybdenum
disulfide as a thread lubricant.
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Running Clearances
Joy Compressor Class
Description W7 MW/SW MH6 WH6 RAM 72XHD 74XHD 76XHD
Crankshaft Thrust .012/.017 .011/.022 .011/.022 .011/.022 .006/.014 .040/.055 .011/.028 .026/.042
Main Bearing .004/ .004/ .004/ .004/ .004/.008 .003/.006 .003/.006 .003/.006
.0094 .0084 .0084 .0084
Connecting Rod .016/.031+ .014/.027 .017/.029 .014/.027 .018/.032 .018/.022 .018/.022 .018/.022
Thrust .016/.031+
Connecting Rod .004/ .004/ .004/ .004/ .004/.008 .003/ .003/ .003/
Bearing .0094 .0084 .0094 .0084 .0068 .0068 .0068
Crosshead Pin to .003/.006 .003/.006 .003/.004 .003/ .003/ .005/.006 .005/.006 .005/.006
Bushing .0065 .0045
Crosshead to Guide .010/.015 .010/.015 .011/.020 .008/.020 .008/.014 .007/.012 .007/.012 .007/.012
Crosshead Pin to * * .0015/ .0015/ .0015/ .0003/ .003/ .003/
Crosshead .003 .0035 .0035 .0010 .0010 .0010
Crosshead Pin Bushing .0025/ .0025/ .004/.008 .004/.008 .0035/ .004/.007 .004/.007 .004/.007
Interference Fit .004 .004 .0060
Drive Gear - Stub .0035/ .0035/ .0005/ .0005/ .0005/ N/A N/A N/A
Shaft Interference Fit .005 .005 .0020 .0020 .0020
Lube Oil Pump Drive .010/.014 .005/.007 .006/.010 .006/.010 .006/.010 N/A N/A N/A
Gear Backlash
Lube Oil Pump Rotor N/A N/A N/A N/A N/A .004 .004 .004
Gear Max. Tip
Clearance
Lube Oil Pump Gear W72 M/SW62
End Play .004/.007 .004/.007
74/76 64/66/68 .003/.007 .003/.007 Later .004/.010 .005/.010 .005/.010
.005/.008 .005/.008
Piston End HE .080*** .080*** .080*** .080*** .080*** .070*** .070*** .070***
Clearance CE .040*** .040*** .040*** .040*** .040*** .060*** .060*** .060***
+ .001 allowed from print dimension for oil film on low tolerance
* Uses tapered pin and as such is a metal-to-metal fit.
** It may not be possible to achieve these values in all cylinders; however, the head end clearance is to be .010
greater than the crank end clearance.
*** It may not be possible to achieve these values in all cylinders; however, the clearances are to be divided 1/3
on the crank end and 2/3 on the head end.
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Register Number
Compressor Frame
Cylinder Class/Type
Customer
Date
Issued by Date
(Engineering Representative)
Checked by Date
(Engineering Representative)
Approved by
(Test Supervisor)
ES 20
Guard And Spring Reference List For
RAM, WH, MH, & W7 Assemblies
1.0 Scope
This list has been put together to allow for the identification of parts required
to convert one valve assembly to another.
2.0 Background
For any given size or type of valve listed, only two possible parts can
change: the guard and/or the spring. In a lot of cases, only the spring
changes. Guard assembly part numbers are listed, but they differ from
the guard in that they include one or two locating pins, Part Number
757-135-001. Some guard assemblies use pins 757-135-004; these are
marked by **.
3.0 Responsibilities
After using this chart to change over a valve assembly, the party making
the change has to re-identify the assembly (stamp-over or cover the original
assembly part number with Xs and re-mark the valve with the new assembly
part number).
RAM Valve Assembly Guard and Spring Reference List
Valve Assembly Guard Spring Spring Guard Assembly*
Size Type Part No. Part No. Part No. Qty. Part No.
4" (S) 9OCFT 600-394 757-830-179 757-833-051 18 758-134-086
4" (S) 9OCFT 600-389 757-830-179 757-833-050 18 758-134-086
4" (S) 9OCFT 600-392 757-830-179 757-833-041 18 758-134-086
4" (D) 9OCFT 600-395 757-830-180 757-833-050 18 758-134-087
4" (D) 9OCFT 600-393 757-830-180 757-833-041 18 758-134-087
4" (D) 9OCFT 600-390 757-830-180 757-833-003 18 758-134-087
4-7/8" (S) 116CGT 600-352 757-830-149 757-833-045 12 758-134-051
4-7/8" (S) 116CGT 600-354 757-830-149 757-833-012 12 758-134-051
4-7/8" (S) 116CGT 600-356 757-830-149 757-833-003 12 758-134-051
4-7/8" (D) 116CGT 600-353 757-830-150 757-833-045 24 758-134-052
4-7/8" (D) 116CGT 600-355 757-830-150 757-833-012 24 758-134-052
4-7/8" (D) 116CGT 600-357 757-830-150 757-833-003 24 758-134-062
5-1/4" (S) 127CGT 600-287 757-830-109 757-833-008 13 758-134-011
5-1/4" (S) 127CGT 600-289 757-830-110 757-833-044 13 758-134-013
5-1/4" (S) 127CGT 600-291 757-830-110 757-833-045 13 758-134-013
5-1/4" (S) 127CGT 600-408 757-830-110 757-833-012 13 758-134-013
5-1/4" (D) 127CGT 600-288 757-830-111 757-833-008 26 758-134-012
5-1/4" (D) 127CGT 600-290 757-830-112 757-833-044 26 758-134-014
5-1/4" (D) 127CGT 600-292 757-830-112 757-833-045 26 758-134-014
5-1/4" (D) 127CGT 600-409 757-830-112 757-833-012 26 758-134-014
S = Suction Valve
D = Discharge Valve
* Includes Locating Pin 757-135-001; quantity varies.
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ES 23
Superior Compressor Cylinder And Cyl-
inder Class Designations
1.0 Scope
This standard describes the formats used for designating the compressor
cylinder numbers and cylinder class names.
2.0 Purpose
The purpose of this standard is to explain the appropriate designations which
are used to identify existing cylinders or cylinder classes, or which may be
combined to identify a new cylinder or cylinder class.
ES 23
ES 23
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ES 23
ES 27
Compressor Performance Guarantee
1.0 Scope
This standard covers the acceptable compressor performance guarantee for
all Superior compressors manufactured.
2.0 Requirements
The following information is required to guarantee an operating condition:
• Suction pressure
• Discharge pressure
• RPM
• Gas analysis
• Site Conditions (ambient pressure and temperature)
• Suction temperature
• All pressure drops due to interstage & after-cooling, pulsation
bottle, and any other external equipment.
For gases with a specific gravity greater than 1.0 (29 MW) add an additional
1% to the above numbers.
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ES1001
Lubrication of Superior Engines and
compressors
1.0 Responsibility for Lubricant Performance
Lubricating oils are extremely complex with many variations in
additive packages and base stocks. No specific formulation can
guarantee completely satisfactory performance.
Therefore, all major refiners conduct extensive laboratory and
field tests to substantiate the performance of their products.
Selection of the proper lubricant is the responsibility of the
supplier and the best assurance of obtaining a suitable oil is to
use only products of well-known merit produced by responsible
concerns, and used in accordance with their recommendations.
Engine design, operating conditions, and fuels all have a
significant effect on how a lubricant performs in a given situation:
therefore, the lubricant must be matched to its application. To
assist our customer, Ajax-Superior has formed a list of qualities
of lubricants that have consistently performed well in our
products under specified field conditions. This list of minimum
qualities is presented herein to assist the customer when selecting
a lubricant.
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7.0 Fuels
7.1 The lubricant must be capable of operating with the type or
quality of fuel supplied to the engine. Most refiners supply
different oils for diesel engines than for gas engines. In addition,
sulfur content in the fuel requires a lubricant with higher
TBN and/or a method of retaining its TBN when operating
on such fuels.
7.2 The maximum sulfur content allowable in the fuel for normally
acceptable maintenance levels and operation is: 100 grains H2S
per 100 standard cubic feet of gas or 1% by weight of sulfur for
diesel fuel (by ASTM D-129).
7.3 Ajax-Superior does not recommend any particular brand of
oil. However, a file of the specifications of many widely used
lubricating oils is maintained in our Engineering Department and
we invite our customers to advise us as to what brand, or brands,
of oils they prefer to use. Given this information, we can then
advise the customer regarding those companies’ oils, by brand
name or manufacturer’s code, which have given best service in
similar applications.
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ES 1002
Lubrication Recommendations For
Superior Reciprocating Compressor
Frames And
Cylinders
1.0 Basic Requirements
1.1 The responsibility for selecting the proper lubricant is primarily
that of the supplier. Use of only products with field-proven
reliability and merit, produced by responsible concerns will
provide the best assurance for achieving effective lubrication.
Use of such products should always be accomplished according
to the manufacturer's recommendations.
1.2 Compressor design, operating conditions, and the gases being
handled all have a significant effect on how well a lubricant
performs in the given application. This standard has been
prepared to assist users in selecting the proper lubricant for
each application.
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Service Recommendations
d. Natural Gases, Methane, Use viscosity table and 3% - 5% compounding with tallow if
Ethane the gas is “wet” and/or water saturated.
f. Butane, Propane, Ethylene, These gases are diluents of oil. Use next higher viscosity
Carbon Dioxide over Table 1 recommendations. Increase supply quantities
over normal. Lubricant must be dry.
g. Hydrogen, Nitrogen, Helium, These are inert gases relative to lubricating oils. Use
Carbon Monoxide, Exhaust Gas, Viscosity Table.
Ammonia Synthesis
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Table 1
Viscosity Requirements for Superior
Reciprocating Compressor Cylinders
Minimum Viscosity (SSU @ 210° F)
Pressure Cylinder Diameters
(psig)
0 - 10" 10" - 15" 15" - 20" above 20"
0 - 500 60 - 70 60 -75 65 - 75 65 - 80
500 - 1,000 70 - 80 70 -85 75 - 85 75 - 90
1,000 - 2,000 80 - 100 85 - 100 — —
2,000 - 4,000 100 - 150 — — —
4,000 & up 150 - 200 — — —
6.1 For wet and saturated gas conditions, 0-1,000 psig, use a
minimum viscosity of 85 SSU @ 210° F with 3% - 8%
compounding with acidless tallow, or two grades heavier than
normally used for the pressure conditions involved.
6.2 For heavy hydrocarbon and sour gases, use the next higher
viscosity over that shown in the table with a minimum of
85 SSU @ 210° F.
6.3 For refrigeration service, use the highest possible viscosity that
should be used, while still retaining the pour point 15° F below
gas suction temperature.
6.4 For chemically active gases, consult Cooper Energy Services.
6.5 Whenever there is any question as to viscosity selection, always
use the heavier oil.
6.6 For oil viscosities over 100 SSU @ 210° F, measures should be
taken to maintain lubricator pump inlet oil temperatures at or
above 120° F.
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ES 3001
Pipe Cleaning Engines, Compressors,
Packaged Unit
1.0 Scope
This standard covers cleaning of pipe used on all Superior
engines, compressors, and packaged units.
2.0 Requirements
All piping used on Superior engines and compressors must meet
the following requirements by those packaging or installing the
equipment:
2.1 Lube oil, gas, diesel & gas fuel, and air inlet piping must be free
of all rust, scale, dirt, and other foreign materials.
2.2 Water piping must be free of scale, dirt, and other foreign
materials.
2.3 Piping utilized in special services (such as oxygen compression)
must be prepared in accordance with instructions issued on these
special jobs.
2.4 Vent and drain piping (and other systems which transport waste
material away from the equipment) are not required to have
special cleaning. Piping carrying expelled matter must, however,
be free of any loose foreign substances to prevent clogging.
2.5 Recirculating vent and drain piping (systems which reprocess
waste material) must be cleaned according to the requirements of
Paragraph A above.
3.1.4 When possible, strip and pickle all lube oil, gas, and air
inlet piping as follows:
a. Strip in a hot alkaline solution. Thc alkaline
solution should be composed of:
40% volume of water
60% volume of 50% caustic soda*
* 0.6 - 0.65 lbs. of sodium gluconate per
gallon of the water - caustic soda solution
b. Thoroughly wash the inside and outside of the
piping using a hot water or steam spray to
remove the loosened material.
c. Inspect and repeat a & b if all foreign particles
have not been removed.
d. While not required, it is recommended that the
pipe be pickled in a phosphoric acid solution
using the concentration, temperature and
time recommended by the pickling solution
manufacturer.
e. Water rinse using the immersion technique.
f. Dry with air and inspect.
g. Protect clean pipe by coating with a
rust preventative or corrosion inhibitor per
MIL-C-23411.
3.1.5. Piping and fabricated assemblies too large to be stripped
in a tank should be shot blasted, brushed using a wire
wheel, and flushed with a good industrial solvent.
3.1.6 The integrally cast oil header on all compressor frames
must be deburred, ground, wire wheel brushed and
washed using a good industrial solvent.
3.2 All water piping must have all loose scale and foreign material
removed. Water piping need not be stripped and coated internally
with a rust preventative.
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ES 3002
Welded Clearance Volume Bottles for
Compressors: Material and Fabrication
Requirements
1.0 Scope
This standard covers bottle component material specifications and welding
procedure requirements for all compressor clearance volume bottles.
2.0 Requirements
(Ref: Tube Turn #311 Catalog & CA 3994)
2.1 All bottle component material shall be as follows and shall be
called for on all bottle drawings. (Ref. Sheet 1342)
Yield Strength
Minimum PSI
a. All straight pipe sections ASTM-A53, Type S Grade B 35,000
b. All reducers and caps ASTM-A234 Grade B 35,000
c. Adaptor 3" - 600# WNF ASTM-A105 — 35,000
d. Adaptor 6" - 150# WNF ASTM-A105 — 35,000
e. Adaptor 1 1/2" - 300# WNF ASTM-A105 — 35,000
f. Adaptor B904-891 & B904-901 ASTM-A181 Grade 11 35,000
g. Adaptor B907-351 & B936-661 ASTM-A515 Grade 70 35,000
2.2 The allowable pressure data shall be included on all MAXIMUM ALLOWABLE
drawings as shown in the example to the right for WORKING PRESSURE
corrosion allowance. The data should be entered in CORR. ALLOWANCE
the appropriate spaces. 0" .062" .125"
2.3 All drawings shall include the following note:
This bottle for use on a cylinder
“A.S.M.E. Code Construction of lower MAWP than the above
pressures.
(No Stamping)”
The above note will have the “No Stamping” words deleted only
when a customer has requested complete ASME certification.
ES 3002
ES 3002
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ES 3004
Ajax-Superior Packager Manual
1.0 Scope
This specification provides guidelines and requirements for packaging and
interfacing with Ajax-Superior engines and compressors. It is not intended
to encompass all necessary aspects of properly designed and constructed
engine and compressor packages.
2.0 Requirements
2.1 Packagers of Ajax-Superior equipment are expected to follow
good, generally accepted industry practices and applicable codes,
as well as local, state and federal regulations for the design
and construction of the packaged product. In addition, and for
full warranty consideration, the packager is expected to follow
application and safety guidelines as proposed herein, and to pass
on to the customer appropriate warnings and safety procedures
associated with the equipment.
2.2 A label with operator warning statements will be issued for
mounting on the equipment control panel where start-up of the
unit is controlled. The label is to be mounted on the front face of
the panel as close to operator eye level as practical.
2.3 When specified by the customer or dictated by location, the
safety guidelines of OSHA, NFPA, API or other governing
codes are to be followed. It is intended that for non-refinery
applications API-11P is the governing specification. Certain
piping on Ajax-Superior engine and compressor fuel, oil, and
water systems do not meet ANSI B.31.3 but are allowable
exceptions due to their proprietary design.
2.4 Cleanliness of piping is very important. The requirements of
ES 3001 and ES 3001A, or a mutually agreed upon alternative
procedure approved by Ajax-Superior, should be followed
by packagers.
2.5 Other technical information relating to specific engine or
compressor models can be found in the Engineering Technical
Data Books and in Ajax-Superior Engineering Standards
provided to packagers. When in doubt, consult the CES
Engineering Department for recommendations.
3.0 Compressors
3.1 Unit ratings for speed, torque, rod load, cylinder pressure, rod
load reversal, etc. are not to exceed the values specified in the
Engineering Data Books, Engineering Standards, or equipment
nameplates.
3.2 While it is current industry standard to quote capacity and
performance from compressor cylinder inlet flange to compressor
cylinder discharge flange, it is the packager’s responsibility
to ensure that the design and construction of the package
accommodates the system pressure drops. The interstage pressure
drops (consistent with the pressure drops represented in the
customer proposal and/or contract) and suction and discharge
pressure drops must not overload the equipment or exceed
pressure and temperature limits that would cause premature wear
or dangerous operating conditions. If such pressure drops do
not impose equipment problems but do adversely affect the
compressor capacity or power required, it is the packager’s
responsibility to advise the customer accordingly.
3.3 All vent connections for crankcase, crosshead guides, distance
pieces, unloaders, etc. must be piped to edge of skid, marked
for customer connection, or clearly noted on the equipment
outline drawing. Manifolding of vents must meet API-11P
standards and comply with Ajax-Superior Engineering Standards
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9.3 Skid design must include proper guards for flywheel, pumps,
pulleys, drive shafts, etc. to protect operators from moving
components. Guard designs are to comply with OSHA 1910.219.
9.4 Provision for shims must be included under the driver and/or
driven equipment to allow for field alignment. Fixed location of
properly aligned compressors by grouting is acceptable.
9.5 Where fixed ladders and platforms are used, they must comply
with OSHA Standard 1910.27 and applicable local codes.
Placement of components on skid must not void compliance of
ladders and platforms furnished by Ajax-Superior.
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ES 3006
Compressor Cooling System Design
1.0 Scope
1.1 The scope of this Engineering Standard is to present the
requirements and tools to design a satisfactory cooling system.
2.0 Requirements
2.1 Cylinders
2.1.1 No cooling is required when the gas discharge
temperature is below 140°F and the gas inlet
temperature is greater than 60°F.
2.1.2 Either forced liquid cooling or thermal siphon or
stand pipe cooling is required when the gas discharge
temperature is between 140°F and 250°F and the gas
temperature rise is less than 170°F.
2.1.3 Forced liquid cooling is required when the gas
discharge temperature is greater than 250°F or the gas
temperature rise is greater than 170°F.
2.2 Frame Lube Oil Coolers
2.2.1 All Superior medium and high speed compressor frames
require coolant between 140° and 160°F for the oil
coolers.
2.3 Piston Rod Packing Cooling
2.3.1 Lubricated packing must have cooling when cylinder
discharge pressures are above 2000 psig.
2.3.2 All non-lube packings require cooling.
2.4 Coolers
2.4.1 Heat rejection from the cylinders and compressor frame
oil cooler and packing will vary with operating and
ambient conditions. Add l0%, not including fouling
factor, to the heat transfer requirements to select the
coolers and chillers.
Page 1 of 15
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3.0 Procedure
3.1 General
3.1.1 This cooling design procedure will apply to a wide
range of compressor cooling systems, including the
following:
System Figure
1. Motor or Turbine Drive 1
2. Generic Engine Drive 2
3. Matched Engine/Compressor Set 3
All of the systems considered in this Engineering
Standard are for ambient air cooling and a thermostatic
coolant control to 180° F. The ambient air can vary from
very cold to extremely hot. In very cold climates, the
thermostat allows recirculation of coolant through the
bypass to warm the fluid coming from the air cooler.
The compressor will warm up faster and will start up
with warmer oil. When the ambient temperature is very
hot, the compressor oil temperature becomes hot also.
All the systems include a compressor lube oil shut down
at 190°F.
3.1.1.1 The Motor or Turbine Drive compressor
cooling system will have a coolant
temperature shutdown in addition to all of the
above system features.
3.1.1.2 The Generic Engine Drive compressor
cooling system is configured for engines that
lack sufficient jacket coolant capacity in head
or flow to supply cooling for the compressor.
Diesel and gas engines developed from diesels
are likely to have pumps too small to handle
requirements of the compressor. If there is no
pump information available, please use this
system. In this case, a coolant pump and
source of power will be required to cool the
compressor. The existence of the compressor
will add to the engine jacket heat load and
coolant flow. An air cooler will need to be
selected for the additional requirements.
Page 2 of 15
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Table 1
Coolant Temperature “Tc” Density “DC” Specific Heat “Cp”
80° 66.2 .797
100° 65.7 .813
120° 65.3 .828
140° 64.8 .842
160° 64.4 .854
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Equation 4.
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Frame BTU/ hr RPM Cooler Part # Flow* Allowable Design Pipe Size**
Resistance Flow Range Flow
(gpm) (gpm)
MH & WH62 42,000 1200 620-162-001 0.00107 30 - 50 40 1-1/2"
MH & WH64 51,000 1200 620-162-002 0.00107 30 - 50 40 1-1/2"
MH & WH66 96,000 1200 620-162-003 0.00227 50 - 70 60 1-1/2"
MW & SW62 23,100 900 919-142 0.00790 8 - 15 12 3/4"
MW & SW64 46,200 900 919-144 0.00107 30 - 50 40 1-1/2"
MW & SW66 68,100 900 919-141 0.00117 30 - 50 40 1-1/2"
MW & SW68 92,100 900 919-141 0.00117 60 - 80 70 1-1/2"
W72 37,500 900 919-144 0.00107 30 - 50 40 1-1/2"
W74 75,000 900 919-144 0.00107 50 - 70 60 1-1/2"
W76 112,500 900 919-169 0.00227 50 - 70 60 1-1/2"
RAM52 16,000 1200 919-142 0.00790 8 - 15 12 3/4"
RAM54 32,000 1200 919-144 0.00107 30 - 50 40 1-1/2"
* The resistance includes 10 feet of pipe and two (2) ball valves.
** From Header to Cooler.
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3.3.2 Cylinders
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Table 3, Continued
W6 Number WH6 Number Cylinder Class Heat Transfer * Coolant Flow
Diameter Range Coefficient “H” Resistance “R”
BTU/hr-deg F psi/gpm2
671 - 672, 637 - 640 11.0 - 13.0 HD/HDA 1200 0.011
63-66, 133 13.5 - 15.3 JD 1200 0.011
112, 137-136 15.0 - 15.8 JD 1200 0.011
109 - 111 13.5 - 14.5 JD 1200 0.011
641 - 644, 673 - 674 14.0 15.8 JD/JDA 1200 0.011
108, 68 18.0 - 18.5 KD 1500 0.011
135 - 134 17.5 - 18.5 KD 1500 0.011
78 - 80 18.0 - 19.0 KLA 1500 0.011
70, 82, 129 20.0 - 22.0 KLD 1500 0.011
71, 72, 77 22.0 - 23.0 LD 1500 0.011
73 - 75, 130 24.5 - 26.0 MD 1500 0.011
141, 132 22.5 - 26.5 MD 1500 0.011
662 - 663
618 - 621 5.75 - 7.25 ND/NDA** 1200 0.020
659 - 661, 664 -
666, 625 - 626 6.00 - 8.00 PD/PDA** 660 0.020
668 - 670
630 - 670 9.00 - 12.00 QD/QDA** 1080 0.011
645 - 646 17.0 - 18.0 RD/RDA 1320 0.011
648 - 649 19.5 - 20.5 SD 1500 0.011
650 - 651 22.5 - 23.5 TD 2160 0.011
652 - 653 23.5 - 26.5 TD 1920 0.011
* The resistance includes ten (10) feet of pipe and two (2) ball valves.
** These cyls. have been converted to non-cooled, but remain here for service requirements.
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ES 4009
Determination of Compressor Cylinder
Dead Center Position
1.0 Scope
This procedure describes the correct way to locate the head end dead center
position for any compressor cylinder. It should be used to mark the flywheel
wherever cylinders are indicated with a balance pressure indicator or an
analyzer. Analyzers use a pulse from a magnetic pickup to signal out dead
center. The pulse is generated from a pin or a hole, which should be located
in the largest diameter available on the flywheel.
2.0 Procedure
2.1 Remove a crosshead cover on either #l or #2 throw cylinders.
These cylinders are chosen for convenience, since they are
closest to the flywheel.
2.2 Manually bar over the unit until the selected (#l or #2) cylinder is
approximately dead center.
2.3 Install a dial indicator on the crosshead guide in such a manner
that the stylus of the indicator rests squarely on one of the ends
of the crosshead. On some units, it may be easier to install the
indicator on the crosshead rather than the crosshead guide. In
this arrangement, adjust the stylus so that it rests squarely on a
vertical surface of the crosshead guide.
2.4 Bar the unit over first in the actual
direction of rotation until the piston is at
the approximate head end (HE) dead center
point (the dial indicator will stop moving at
this point). With the cylinder resting on the
approximate HE dead center, set the dial
indicator to a zero reading.
2.5 Back the crosshead away from HEDC
by barring over the unit in the direction
opposite normal rotation until the indicator
reading exceeds +0.030".
Then bar over the unit in the normal
rotation until the indicator reads +0.015".
Page 1 of 3
2.6 With the dial indicator reading +0.015, scribe a line on the
flywheel (either the engine flywheel or the compressor flywheel,
whichever is easier) in line with the pointer. (See “Line 1” in
previous sketch in Paragraph 2.5.)
2.7 Continue to bar over the
unit in the normal rotational
direction until the crosshead
travels through HEDC and
the indicator reads +0.030"
again. (The indicator reading
will decrease to zero and then
increase to +0.030).
Then bar over the unit in
the direction opposite normal
rotation until the indicator reads +0.015".
2.8 With the dial indicator reading +0.015, scribe a second line on the
flywheel opposite the pointer. (See “Line 2” in previous sketch
in Paragraph 2.7.)
2.9 Now measure the
distance between the
two scribed lines and
then scribe a third
line on the flywheel
exactly equidistant
between the first two
lines. This third line is the head end dead center (HEDC) point
and should be labeled “#l HEDC” or “#2 HEDC”, depending on
the cylinder that was checked.
2.10 To check the accuracy of
the HEDC line, the process
should be repeated using
2.10 through 2.14. Bar the
unit over in the direction
opposite normal rotation to
align the third line (see
2.9), HEDC mark, with the
pointer. Set the indicator to
a zero reading.
Page 2 of 3
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ES 4100
Compressor Field Performance
Test Specification
1.0 Scope
This standard outlines the requirements, procedures and calculations
necessary to perform, interpret and properly report field performance tests on
Ajax, Superior or Joy reciprocating compressors and to ensure that results
are valid.
2.0 Purpose
2.1 The requirements of this specification are mandatory where
verification of guaranteed compressor capacity and/or power by
field testing is required by the customer.
2.2 This test procedure is to be used for accurate assessment of:
2.2.1 The capacity of the individual compressor cylinders,
2.2.2 The brake horsepower demand of the individual gas
compressor cylinders,
2.2.3 Overall compressor capacity, horsepower and
efficiency.
2.3 This procedure is also recommended for diagnosis of actual
or suspected operating problems or discrepancies, such as
valve plate or spring failures, pulsation-induced vibration,
high discharge temperature, low capacity, low efficiency
(BHP/MMSCFD) or driver overload.
2.4 Supplemental specifications ES4101 and ES4102 provide general
requirements for field performance test instrumentation and for
analysis and interpretation of results.
ES 3003
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ES 3003
ES 3003
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ES 3003
ES 3003
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ES 3003
ES 3003
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ES 3003
3.5 Safety
3.5.1 Prior to conducting any type of tests, review all
customer’s, operator’s and owner’s safety procedures
with cognizant site personnel.
3.5.2 Always make sure that the above safety procedures are
followed during the actual testing.
3.5.3 Prior to testing, review equipment instruction manuals
and become generally familiar with the operation of the
equipment to be tested and its operating systems.
3.5.4 Avoid specifying or running at any operating conditions
that might expose personnel to risk of injury or death, or
plant machinery or other equipment to damage.
ES 3003
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ES 3003
Table 1
Allowable Deviations
Variable Allowable
Deviations
Average suction pressure +/- 1%
Average discharge pressure +/- 1%
Suction temperature +/- 2°F
Speed +/- 0.5%
Cooling water inlet temperature +/- 2°F
Cooling water flow rate +/- 3%
Metering temperature +/- 3°F
ES 3003
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ES 3003
ES 4101
Ajax-Superior Compressor
Field Performance Test Instrumentation
1.0 Scope
1.1 This standard defines the instrumentation required to accurately
do field performance tests on Ajax, Superior, or Joy reciprocating
compressors. Calibration procedures for the instrumentation are
also listed.
1.2 This standard is a supplement to ES4100, Ajax-Superior
Compressor Field Performance Test Specification.
2.0 Purpose
2.1 This supplement lists the instrumentation accuracies and
calibration methods required for field tests that involve
compressor capacity or horsepower guarantees. These
requirements are also recommended for maintenance testing.
2.2 Testing procedures are listed that will insure accurate
performance data.
2.3 Techniques for operating analyzers vary between analyzer
manufacturers. Unless otherwise noted, the procedures listed are
for the Entronics En-Spec 1400 and En-Spec 3000 analyzers. The
required accuracies and calibrations apply, however, to indicating
testing done with analyzers from any manufacturer.
ES 4101
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5.0 Encoder
5.1 The speed of a compressor changes throughout each revolution
due to the torque change within each revolution. To obtain
accurate pressure-volume cards, an encoder must be used to
phase the pressure readings to the crankshaft position. Analyzers
that use a one-per-revolution signal and divide each revolution
into equal time intervals cannot compensate for the speed change
within each revolution.
5.2 The encoder drive must be attached to the compressor
crankshaft; friction drives can slip and cause errors. A torsionally
rigid coupling is used to connect the encoder to the compressor
crankshaft drive. Sections of rubber or plastic tubing will not
allow accurate phasing. The encoder shaft must be parallel to the
ES 4101
Table 1
Bill of Materials
ES 4101
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Figure 1. Encoder drive arrangement when lubricator is driven from the crankshaft.
ES 4101
ES 4101
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ES 4101
Table 2
Bill of Materials
ES 4101
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1 2 4 5 6 7
7.2 The indicator tube valving must not be partially closed to reduce
tube resonance and “smooth” the pressure traces. This restriction
will distort the card and result in inaccurate data.
7.3 Warning: Many ball valves will not be suited for long term
use in this service. They should therefore be removed at the
conclusion of the indicator test. This must be done with the
compressor shut down and depressurized.
ES 4101
10.0 Thermometers/Thermocouples
10.1 Thermocouples are available that are accurate to within one
degree of the measured temperature and are the preferred
method of measuring temperatures for performance testing.
Glass thermometers, although fragile, can also be used.
Metallic dial thermometers should not be used.
Elevation (ft) Correction (in. Hg) Elevation (ft) Correction (in. Hg)
100 .108 3,000 3.105
200 .216 5,000 5.025
500 .537 8,000 7.696
1,000 1.066 10,000 9.344
2,000 2.100
ES 4101
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13.0 Summary
The accuracy of performance testing requires accurate equipment,
careful calibration and diligent testing. It is the responsibility of the
analyzer operator to insure that the testing is properly done and that the
instrumentation is in good working condition. Any required maintenance
should be completed before testing is started.
ES 4101
ES 4102
Analysis And Interpretation Of Com-
pressor Field Performance Test Results
1.0 Scope
This standard provides guidelines for analyzing and interpreting the results
of compressor field performance tests. Section 3.0, On-Site Review of
Indicator Cards, is an in-process check to assure that accurate, high quality
data is generated during the testing process. Regardless of how the data
will be analyzed it is highly recommended that this in-process check be
performed so that data quality problems may be quickly resolved and
repeat testing avoided. Section 4.0, Indicator Test Data Analysis and
Troubleshooting, is a basic approach to interpretation of indicator cards.
A step-by-step procedure is provided for preparing the measured indicator
card for comparison to the ideal case and sample indicator cards illustrating
more common problems.
2.0 Purpose
2.1 Section 3.0 shall be used during all compressor performance
tests.
2.2 Section 4.0 should be used for basic interpretation of indicator
cards. If an unusual or special condition exists that is beyond the
scope of this standard, the CES Engineering Department should
be consulted.
ES 4102
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ES 4102
ES 4102
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Time
Stage
DA/SAHE/SACE
HE/CE
VVP opening
PS (PSIG - D.W.T.)
PS (PSIG - D.W.T.)
TS (°F)
TS (°F)
PB (PSIA)
Speed (rpm)
ES 4102
Clearance Volume
(including pockets)
Discharge Volume
2
Pd 3
— Discharge valve Discharge
closes valve opens
— Minimum
cylinder volume
PRESSURE
Re-expansion Compression
VOLUME
ES 4102
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Figure 3.3. P–V Diagram with rounded corners, indicating excessive channel restriction or
pressure transducer with a slow response time
Pd
Discharge
—Discharge valve valve
—closes opens
—Minimum cylinder
—volume
PRESSURE
Compression
Re-expansion
VOLUME
ES 4102
Figure 3.4. P–T Curve with channel pulsations/resonance manual correction shown by drawing envelope lines
and finding average curve
Envelope
1350
TDC
Average
1200
curve
P2 Actual P2
1134 psig
1050
PRESSURE (PSI)
900
750
Envelope
Actual P1
610 psig
Envelope
600
P1
Average curve
Average curve
450
ES 4102
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Clearance Volume
(including pockets)
Discharge Volume
Discharge
—Discharge valve valve opens
Pd —closes
—Minimum
Indicated Pd cylinder
predicts —volume
excessive
valve loss
Compression
Re-expansion
PRESSURE
—Suction valve
Suction closes
valve —Maximum cylinder
opens — volume
Ps
VOLUME
ES 4102
Figure 3.6. P-V Diagram indicating a pressure transducer with a range too low for the pressures measured
Pd
—Discharge valve Discharge
—closes valve
—Minimum cylinder opens
—volume
PRESSURE
Compression
Re-expansion
VOLUME
ES 4102
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Figure 3.7. P-V Diagram indicating a pressure transducer with a range too high for the
pressures measured
Pd
—Discharge valve Discharge
—closes valve
—Minimum cylinder opens
—volume
PRESSURE
Compression
Re-expansion
VOLUME
ES 4102
ES 5011
Hydrostatic and Helium Test of Com-
pressor Cylinders, Cylinder Heads, and
Valve Covers
1.0 Scope
This procedure outlines the necessary operations required for hydrostatic
and helium testing compressor cylinders and other related pressure retaining
components which, when secured to the cylinder, can be considered as part
of the cylinder or part of an unfired pressure vessel.
2.0 Requirements
Compressor cylinders and pressure retaining auxiliary parts, which are
secured to the cylinder, shall be hydrostatically tested with water and a
water soluble rust-preventative (Chem-Lub X-058, DuBois 915, or equal) in
accordance with the following standards:
Part Test Pressure
Cylinder (gas wetted surfaces) (MAWP) 1.5 times maximum allowable
working pressure
Cylinder Heads (gas wetted surfaces) 1.5 times maximum allowable
(MAWP) working pressure
Valve Covers (gas wetted surfaces) 1.5 times maximum allowable
(MAWP) working pressure
Bonnets and/or clearance pockets 1.5 times maximum allowable
i For bonnets/
unloaders, blueprints
(MAWP) (gas wetted surfaces)
(See Note)
working pressure
will designate if
specific areas are to be Cylinder (Water Jackets) 115 PSIG minimum -
hydro tested and any
specific pressure
150 PSIG maximum
requirements for
these areas.
Superior Cylinder (Water Jackets) 115 PSIG minimum -
150 PSIG maximum
Ajax Cylinder (Water Jackets) 100 PSIG minimum -
115 PSIG maximum
The part number drawing denotes the required test pressure for each
cylinder or component and should be reviewed before each test. Compressor
Performance Data Sheet (Form 1041-4) can be consulted for maximum
allowable working pressure (MAWP) and required hydrostatic test pressures
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to reach all gas wetted surfaces. Compressor heads and all other
pressure retaining components are to be stamped “TESTED” to
identify acceptance of hydrostatic testing. They should not be
stamped if they leak.
3.10 Parts (other than cylinder bodies) machined from steel plate, bar,
tubing, or forgings are exempt from hydrotesting, except those
fabricated by welding, where a defective weld joint might leak
directly to the atmosphere, or for those heavily machined parts
that may have potential problems as deemed by Engineering.
All cylinder bodies are to be hydrotested!
3.11 For hydrotesting and air or helium testing, electronic digital
pressure sensing instruments (accuracy and capacity to
15,000 psi) are to be used, regardless of the test pressure up
to the maximum capacity.
3.12 All pressure gages shall be certified per established frequency.
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helium only.
7.0 Documentation
7.1 The hydro test of each cylinder is recorded on a test log and filed
by the supervisor. Each cylinder is recorded by the foundry code
number, date of test, part number, and test results.
7.2 All cylinders (rejected and accepted) are recorded in the log.
7.3 A hydrostatic test data sheet (Form S.I. 411 - Rev. 4) must be
completed (see attached) on each cylinder and filed with the register
number in the Inspection office. Copies of these can then be provided
to Marketing when requested by the Sales Release.
7.4 When a helium test is performed, the appropriate section of the test
sheets is to be filled out.
7.5 If a unit is considered scrap, a scrap transaction is recorded and the
part identified as scrap. If a unit is considered salvageable or meets
the impregnation criteria (ES 5026), a Hold transaction is recorded,
the part identified as held for salvage.
8.4 Retest results are to be recorded in the log and on the test data sheet.
Water Jacket
Serial Number Test Pressure
Inspected By Tested By
Date Date
2. Hydrostatic Retest
Inspected By Tested By
Date Date
3. Helium Test
Inspected By Tested By
Date Date
* Helium Test Pressure is maximum allowable working pressure as stated on blueprint (unless
otherwise agreed to by customer and Quality Assurance Manager, and stated on the Quality Plan).
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RAM COMPRESSORS
Chapter 1 General:
Service Data
RAM Compressors Technical Data Book: RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
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SUPERIOR® COMPRESSORS
*These parts are for standard stock cylinders. Sold cylinders may have different parts.
Note: Cylinders 405CC/406CC are obsolete - included for reference purposes only.
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*These parts are for standard stock cylinders. Sold cylinders may have different parts.
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*These parts are for standard stock cylinders. Sold cylinders may have different parts.
Note: Cylinders 407CC/408CC are obsolete - included for reference purposes only.
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*These parts are for standard stock cylinders. Sold cylinders may have different parts.
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*These parts are for standard stock cylinders. Sold cylinders may have different parts.
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*These parts are for standard stock cylinders. Sold cylinders may have different parts.
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*These parts are for standard stock cylinders. Sold cylinders may have different parts.
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*These parts are for standard stock cylinders. Sold cylinders may have different parts.
1-214 RAM-DB-05-01-2002
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*These parts are for standard stock cylinders. Sold cylinders may have different parts.
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*These parts are for standard stock cylinders. Sold cylinders may have different parts.
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Parts Interchangeability
Frame Parts Interchangeability
The following list provides a summary of parts that are interchangeable
between the RAM-52 and the RAM-54. Most major components are
interchangeable between the two compressor frames facilitating quick
and accurate inventory control. This is especially helpful at those sites
which may operate both two and four throw RAM compressors. Although
quantities may vary, all tubing, piping and hardware will generally be the
same between RAM compressor models. Some parts will be labeled “See
Table” indicating that a choice can be made. This table of options is the
same for both RAM-52 and RAM-54 models; therefore, the parts listed may
all be the same.
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List A
Description Part No.
VVP Stem 902-045-001
VVP Packing O-Ring 900-838-029
VVP Backup Ring 926-404-001
VVP Handwheel 912-151
Wiper Packing Case Assembly 600-313
List B (Continued)
Cylinder Cylinder Valve Valve
Number Diameter Diameter Assembly No.
Suctn. YB 600 394
404 6.000" 4.000" Disch. YB 600 395
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List B (Continued)
Cylinder Cylinder Valve Valve
Number Diameter Diameter Assembly No.
Suctn. YB 600 287
411 10.500" 5.250" Disch. YB 600 288
List B (Continued)
Cylinder Cylinder Valve Valve
Number Diameter Diameter Assembly No.
Suctn. YB 600 183
417 15.500" 7.000" Disch. YB 600 184
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List B (Continued)
Cylinder Cylinder Valve Valve
Number Diameter Diameter Assembly No.
Suctn. YB 600 352
424 6.500" 4.875" Disch. YB 600 353
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VVP Head
Cylinder Range Number
4.5" - 5.0" 600-257-001
5.5" 600-243-001
6.0" 600-243-003
6.5" 600-233-001
7.0" 600-233-003
7.75"/407CC 600-075-001
7.75"/427CC 600-399-001
8.25"/408CC 600-075-002
8.25"/428CC 600-399-002
9.0" 600-206-001
9.5" 600-206-003
10.5" -11.0" 600-116-002
12.0" 600-196-001
12.5" 600-196-003
13.5" 600- 171-001
14.0" 600-171-003
15.5" - 16.0" 600- 101-001
17.5"- 20.0" 600-159-001
VVP Piston
Cylinder Range Number
4.5"- 5.0" 600-261-001
5.5"- 6.0" 600-076-003
6.5"- 7.0" 600-076-008
7.75"- 8.25" 600-076-001
9.0"- 9.5" 600-076-007
10.5"-11.0" 600-076-002
15.5"- 16.0" 600-076-002
12.0"- 12.5" 600-076-006
13.5"- 14.0" 600-076-005
17.5"- 20.0" 600-076-004
Valve Gasket
Cylinder No. Cylinder Range Part Number
401/402 4.5"- 5.0" 909-981-191
403/404 5.5"- 6 0" 909-981-192
423/424 6.5"- 7.0" 909-981-212
407/408/427/428 7.75"- 8.25" 909-981-199
409/410 9.0"- 9.5" 909-981-200
411/412 10.5"- 11.0" 909-981-197
413/414 12.0"- 12.5" 909-981-197
425/426 13.5"- 14.0" 909-981-211
417/418 13.5"- 16.0" 909-981-201
419/420 17.5"- 18.0" 909-981-125
421/422 19.5"- 20.0" 909-981-125
405/406 6.5"-7.0" 909-981-193
415/416 13.5"- 14.0" 909-981-199
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1 3
4 To come
2 6
5
7 8
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RAM COMPRESSORS
Chapter 1 General:
API 11P and 618 Comments and Exceptions
RAM Compressors Technical Data Book: RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
Summary
• API 618 is not specifically applicable to compression equipment in
the natural gas production industry—API 11P is.
• Superior compressors are tailored primarily to the natural gas
production and transmission industries, and thus conform more
closely to the specifications of API 11P rather than API 618.
• CES strives to comply with API 618 to the extent that it does
not compromise our objectives of short delivery lead times and
low cost as compared to fully compliant API 618 equipment.
The following comments and exceptions define those areas where
Superior equipment or documentation deviates from API 618.
General
CES' primary scope of supply is the compressor, gas engine driver (if
applicable), and information directly related to this equipment. Other
equipment, services, and information is typically provided through a third
party which contracts directly with the purchaser or CES. This company
can be a distributor, packager, or engineering company. API specification
applying to services not provided CES must be reviewed and confirmed by
the contractor.
Technically, Superior compressors are not API 618 compressors, but there
is some flexibility in the scope of supply that often allows the equipment
to meet many of the customer’s API 618 goals. That flexibility falls into
four categories:
• Standard options which may be added to the basic equipment at an
established price;
• Special options which are designed and manufactured for a specific
application. Due to their limited applicability, lead times will be
extended and pricing will be substantially higher than the base
equipment or standard options;
• Standard documentation is information that can be readily provided
upon request;
• Special documentation must be created specifically for the order.
Pricing will be established as required.
Although CES attempts to meet as many of the purchaser’s special
requirements as possible, any request outside of the standard equipment
or information offering adds to the time and cost involved in the project.
Accordingly, special requests should be limited to those items that are
absolutely necessary.
Standard documentation for CES equipment is not as extensive as outlined
in API 618, Appendix A or F, etc. It is typically limited to the Sales Release
(which includes equipment identification, customer specifications, and
performance), separate frame and cylinder outline drawings, performance
curves, Technical Data Manuals, and Instruction Manuals/Parts Lists.
Since CES does not routinely provide information in the API 618 format,
the customer should discuss specific documentation needs with their CES
representative.
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All comments and exceptions apply to the MH, WH, W7, and RAM
compressor models unless noted otherwise.
Section 1 - General
1.4.27 Superior rated power is from cylinder suction to the cylinder
discharge flange.
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2.6.3.1.4 All RAM cylinders are air cooled, as are a few MH/WH/W7
ductile iron cylinders in the 5.75 – 8.0 inch bore range. Forged
steel cylinders are air cooled, but water cooling is available as a
standard option.
2.6.3.2 Air cooled cylinders may be the only type available in selected
bore sizes. CES can provide a list of cylinders and types of
cooling upon request.
2.6.4.1 Gas flanges are not studded at the factory. Piping flanges are
typically bolted to the cylinders by the packager. Bolts, as
opposed to studs, greatly simplify installation.
Ring type joints are used as standard for gas connections on
forged steel cylinder bodies rated above 3000 psi.
2.6.4.2 See 2.6.4.1. The customer shall specify when studs are required.
2.6.4.3 Some cylinder gas flanges require special rectangular or oval
connections. Drawings of face and bolt patterns are available
upon request. Transition pieces are fabricated by the packager or
other subvendor.
2.6.4.4 Cylinder flange faces are not serrated.
2.6.4.5 Connections are NPTF rather than NPS.
2.6.4.6 Indicator taps are NPTF rather than NPS. Taps on cylinders rated
over 5000 psi are special.
2.7.2 Finger-type suction valve unloaders do not provide visual
indication of position, others do.
2.7.9 CES does not provide valve dynamic studies. These services can
be contracted through subvendors.
2.7.12 In addition to unloading by the specified methods, capacity can
also be controlled by manually adjusted variable volume heads
on low to moderately high pressure cylinders.
2.7.13 In finger-type valve unloaders, actuating air and process gas
that leak past their respective seals may mix in the intermediate
compartment that separates the working parts of the actuator
from the valve cap. This is a vented compartment. In the event
that both the air and gas seals fail and the vent line is restricted,
it would be possible for the two gases to mix in the actuator or
compressor cylinder. This is highly unlikely, but is theoretically
possible.
2.8.1 Piston and crosshead nuts are not positively locked.
Not all nuts are torqued to 1.5 times the threads root stress at
maximum rod load. All through bolts are torqued to at least 1.5
times, as are both the piston and crosshead nuts on the RAM.
2.8.2 Standard pistons do not have a drilled vent. Hollow pistons are
made of two or three pieces, which will allow pressure to escape
once external pressure is removed.
2.8.3 Standard cylinders may have loads higher than 5 psi on rings for
non-lubricated service.
2.8.4 Coated piston rods are available options. Rods for most standard
services are induction hardened.
2.8.4.2 Piston rods are within .001 inch in roundness and .002 inch in
diametrical variation.
2.8.5 Thread relief area is not polished but is 16 microinches. Material
information is available upon request.
2.8.6 See 2.6.2.1 and 2.8.4.
2.9.5 The RAM connecting rod is nodular cast iron, A536 Grade
80-55-06 [forged rod will be available in late 1998]. All others
are forged steel.
Cap on the crank pin end is removable; crosshead pin end is
solid.
Changes in section have ground rather than polished radii.
Crank pin bushings are press fit rather than locked in place.
Only the MH/WH model connecting rod bolts are wired; others
use nylon insert locking nuts, which have proven to be very
dependable for those models.
2.9.6 Crossheads are nodular iron rather than steel. Shoes are
replaceable, but not shim-adjustable.
2.9.7 MH/WH/W7 four- and six-throw frames come standard with
crankcase over-pressure relief valves. Valves are available options
for two-throw compressors and all RAMs.
Valves are mounted on the top of the frames due to space
constraints.
2.10.1 For clarity of definition, a long distance piece will permit the use
of an oil slinger, but a short distance piece will not. Since this is
a function of stroke and space inside the distance piece, the same
distance piece can be long for one cylinder but short for another,
depending on the frame and packing case.
2.10.1.1 Type A - The distance pieces for all forged steel cylinders and the
RAM are short. A slinger is not recommended for MH cylinder
nos. 630-636, 668-670.
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2.11.2 Cast iron packing case flanges are often used for lower pressure
service.
2.11.4.2.1 In cases where water cooling is applied at pressures below 2000
psi, o-rings do encircle the piston rod. Some vendors’ packing
cases do not require o-rings.
2.11.4.3 Although water cooling is always used in non-lubricated service,
it is normally only supplied with lubricated service at pressures
greater than 2000 psi. Steel plugs in packings are not a standard
option.
2.11.4.4 When required, an inline water filter for the packing is normally
provided by the packager.
2.11.5 Packing cooling information is available upon request. Cooling
should be separate from cylinder jacket cooling systems. Pressure
drop may exceed 25 psi at higher flow rates.
2.11.9 Rod installation sleeves are slightly larger than piston rod
diameters.
2.12.1 Crankcase lubrication is a pressurized system with an oil
temperature of about 180° F.
2.12.3.1 Some parts of the frame oil supply, such as the relief valve and
strainer housings, are cast iron.
2.12.3.2 A manual pre-lube pump mounted on the frame is an available
option. Auxiliary oil pumps are normally available through the
packager.
2.12.3.3 External relief valves are cast iron. The relief valve on the RAM is
integral to the oil pump.
2.12.3.4 Frame lubrication systems are rated at 120 psi rather than 150 psi.
2.12.3.5 CES does not supply a lube oil console.
2.12.4 Oil supply temperature can range from 140 – 175° F.
Tube bundles are not removable. Tube O.D. is 3/8" rather than 5/8".
Tubes can be copper.
Tube sheets can be aluminum (MH/WH), brass or steel (RAM/W7).
Cooler end caps are cast iron.
MH/WH coolers do not have drain plugs on the oil side.
2.12.5 Oil temperature control valve is provided by the packager if
specified.
2.12.6 Frame oil filters have 20 micron filter elements. The RAM has a 10
micron element option available.
Oil heaters are available options.
Filters cannot be replaced during operation.
Filter housings are not equipped with thermal relief valves.
2.13.1.1 CES recommends against single plunger-per-point systems, and
uses divider block systems almost exclusively.
2.13.1.4 The cylinder lubricant supply does not come from the lubricator
box. In cases where oil is drawn from the compressor frame,
a frame oil heater is available when required. External supplies
with heaters are in the packager’s or engineering contractor’s scope
of supply.
2.13.1.8 Cast-in oil passages through cylinder walls are carbon steel rather
than stainless.
Tubing is not match-tagged, but tubing is run to connection points
on both the frame and cylinders.
2.13.1.9 Superior cylinders are primed to prevent rust and are frequently
stocked for a variety of applications. Some synthetic oils may not
be compatible with the paint, which will necessitate stripping of
the paint from the cylinder. This procedure adds time and expense
to the process.
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2.14.6.1 CES has two classes of repairs. The first are those for
common defects which have repair procedures pre-approved by
engineering. The second class of repairs are those which are
reviewed on a case by case basis.
Repairs are not submitted to the purchaser for review unless
specified in the order.
Repair records are maintained by CES but are available to the
purchaser.
2.14.6.2 Impregnation is used for cylinder body repair when appropriate.
2.15.2 Rotation arrows on the MH/WH are high temperature plastic.
2.15.3 Standard nameplates do not have a location for purchaser item
or tag number.
2.15.4 Standard cylinder nameplates do not have locations for maximum
allowable temperature or cold clearance.
2.15.5 Although torque curves are provided to the motor manufacturer
and are available to the purchaser, an auxiliary nameplate
is normally not provided with the motor unless specifically
requested.
2.15.6 U.S. Customary units are used on nameplates.
Section 3 – Accessories
3.1.1.1 Although CES provides the information necessary for sizing
electric motor drivers, the motor selection and procurement is not
within CES’ scope of supply.
3.1.2.8 Shaft extensions for motor are not used. Most motors used to
drive Superior compressors have internal bearings supporting
both ends of the shaft. In rare cases where the drive end of the
motor shaft does not have a bearing, it is rigidly connected to
the compressor shaft by a hub. The compressor crankshaft does
not use a key, but rather a taper and pull-down bolt to press the
hub on.
3.2.2.1 Guards are provided by the packager.
3.5 Mounting plates, skids, and foundations are outside CES’ scope
of supply. CES does provide alignment requirements, weights
and unbalanced forces to the packager and foundation contractor.
3.6 Controls, instrument panels, and most machine instrumentation
are normally provided by the packager.
3.6.1.5 Standard compressor instrumentation specifications are available
upon request.
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4.3.2.6 Due to their relative simplicity, valve caps are tested for 15 rather
than 30 minutes.
4.3.2.7 See 4.3.2.1 (c).
4.3.3.2 Full equipment run tests can in some cases be contracted at the
packager facility.
4.3.4.1 A frame bar-over test is performed in the factory without
cylinders. Since the frame is shipped without the cylinders
attached, piston end clearance and rod runout are best done at the
customer’s facility after final assembly.
4.4.3.6 Suction and discharge flange openings on the cylinder are
covered with plywood.
4.4.3.7 Some threaded openings are plugged with plastic plugs.
4.4.3.9 Equipment lifting points and center of gravity are not identified.
4.4.3.9.1 Handling instructions and special lifting equipment are not
provided with compressor.
4.4.3.9.2 Metal tags are not used to identify separately shipped equipment.
4.4.7 Installation information is included in the Instruction Manual,
which is shipped separately from the equipment.
1-250 RAM-DB-05-01-2002
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SERVICE
ITEM NUMBER
STAGE
CYLINDER BORE - INCHES 4.5" - 20.0"
COOLED/NON-COOLED CYLINDER "Air-Cooled" Cylinder
MATERIALS
CYLINDER Ductile Iron
CYLINDER LINER (IF FURNISHED) No Liner Furnished
PISTON CI (4-5" 8.25" Cylinders)
Teflon Coated AL with (9.00" - 20.0" Cylinders)
Steel Ring Carriers
PISTON RINGS (RIDER-COMPRESSION) Carbon Filled Teflon®
WEAR BANDS Carbon Filled Teflon®
PISTON ROD 4140 Heat Treated Steel
PISTON ROD HARDNESS (BASE) - Rc 50-56 Rc Hardness
PISTON ROD COATING (Optional) Sour Gas - Tungsten Carbide
PISTON ROD COATING HARDNESS - Re (Optional) Sour Gas
VALVE SEATS 416 Stainless Steel (Hoerbiger - standard)
VALVE GUARDS (STOPS) 416 Stainless Steel (Hoerbiger - standard)
VALVE PLATES Peek (Polyetheretheketone) or Nylon or MT
VALVE SPRINGS Nimomic 90l
ROD PACKING CASE Cast Iron, or Steel
ROD PRESSURE PACKING RINGS Carbon Filled Teflon®
ROD WIPER PACKING RINGS Tinnized Cast Iron
CRANKSHAFT SAE 5046 Forged Steel/Counter Weighted
CRANKSHAFT MAIN JOURNAL BEARINGS Trimetal Copper, Lead, Tin
®
REGISTERED TRADEMARK OF E.I. DUPONT
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RAM COMPRESSORS
RAM 52
As the model number 52 indicates, this is a five inch stroke, two-throw
machine. The RAM 52 is capable of handling power requirements of up to
1,188 horsepower @ 1500 RPM.
RAM 54
This design also has a five inch stroke, four-throw frame capable of handling
power requirements of up to 2,375 horsepower @ 1500 RPM.
Cost Effective
The RAM compressor incorporates the latest design technology so that its
compact, heavy duty construction delivers the horsepower needed to fulfill
the requirements of almost any job. The low initial investment is a direct
result of the many years of engineering consideration given to the RAM’s
design and development.
Crankshaft
Heavy-duty, one-piece design made from hardened SAE 5046 forged steel
with integral counterweights for exceptional balancing. Precision ground
and polished for long life and durability. Both rod and main journals share
the same 4.9" (124mm) diameter. The replacement bearings incorporate the
same design and construction. The drive end extension is tapered* and the
auxiliary end is drilled and tapped for direct mounting of the lubricator/lube
oil pump drive shaft and gear. A coupling hub designed to fit a Thomas 550
or 600 CMR coupling can be supplied as required.
*Units produced in 1993 and before have keyway crankshafts.
Crosshead
A heat-treated cast iron crosshead is precision machined to accept
provisional balancing weights and two replaceable, tin-plated, aluminum
crosshead shoes. The crosshead shoes are precision machined and no
shims are required for their adjustment. This prevents costly downtime due
to damaged crossheads and crosshead guides. Two different designs are
available for greater balancing flexibility. (Refer to the balancing detail in
Section 1 for more information.) The crosshead pin is full floating and
retained by two snap rings. The crosshead area can be easily serviced
through a large O-ring sealed access door. This seal prohibits oil leakage
during long periods of operation.
2-4 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
Connecting Rod
Connecting rods are constructed of forged steel and are precision machined.
Each rod is shot-peened to enhance fatigue life. Two precision bushings are
press-fitted into the outboard eye of the rod. A .375" diameter, rifle-drilled
hole allows full-pressure lubrication to travel to the pin bushings and to the
crosshead shoes. Standard rod bolts are constructed of SAE 4140 steel with
rolled threads.
Gear Drive
The RAM incorporates a gear-driven, lube oil pump and pressure force-feed
lubricator system designed to eliminate the use of chains. All gears are
induction-hardened, 4145 heat-treated steel to ensure long, trouble-free
operation.
Frame Lubrication
The gear-driven, Viking model lubricating oil pump is flange mounted to the
frame with a pressure relief valve included for cold-start protection. A shell
and tube oil cooler, shipped separately for remote mounting, is provided.
The cooler is constructed of copper or admiralty tubing with threaded oil
and water connections. Other features include a non-shielded oil-pressure
gauge, low oil pressure shutdown switch, and an oil level sight glass. All the
necessary piping is supplied and mounted. Please note that while the hand-
operated pre-lube pump is no longer offered as a standard item, a pre-lube
pump of some sort is still required for proper operation.
Filtration
Filtration is accomplished by a frame-mounted, 10 micron, full-flow lube
oil filter. The filter has replaceable cartridge, seals, and a sight indicator
mounted with necessary piping. A lube oil strainer with screen, bushing, and
magnetic plug is also mounted with necessary piping.
Oil Cooler
A cooler is separately shipped for remote mounting. The cooler is complete
with copper or admiralty tubing and threaded water and oil-line connections.
2-6 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
Description Weight
Lbs (kg)
RAM 54
Description Weight
Lbs (kg)
2-8 RAM-DB-05-01-2002
BILL OF MATERIAL
6 WASHERS SUPPLIED WITH
WASHERS SUPPLIED WITH ADAPTOR PLATE MUST BE ITEM QUAN DESCRIPTION PART NUMBER
6
ADAPTOR PLATE MUST BE INSTALLED BETWEEN THE
INSTALLED BETWEEN THE ADAPTOR PLATE AND THE 1 1 HUB B-600-400
ADAPTOR PLATE AND THE COUPLING DISC PACK.
COUPLING DISC PACK. 2 1 NUT-COUPLING B-600-401
4 5
3 2 SETSCREW 09SS1008PF
7
4 5 4 1 ADAPTOR SEE TABLE
7
5 8 CAPSCREWS 03CS1620PC
6 4 WASHERS SUPPLIED WITH ADAPTOR
"D"
1 2 3
ON HUB
5.71
FIRST BOLT
FACE OF HOLE COMPRESSOR
COUPLING CL FIRST BOLT FACE OF
COUPLINGG
L BOLT HOLE
"B"
ENGINE
"AA" "CC"
CL BOLT HOLE
"C" "B"
1706G2 RAM 52 B-600-413 YB-903-866 X .14 ------ 17.40 17.54 ------ 22.500/22.497
1706G2 RAM 54 B-600-413 YB-903-866 X .14 ------ 17.40 17.54 ------ 22.500/22.497
1712G RAM 52 B-600-413 YB-903-865 X .83 ------ 17.40 18.23 ------ 26.500/26.497 ALT. DESCRIPTION DATE
1712G RAM 52 B-600-413 YB-903-865 X ------ 4.37 17.40 ------ 13.03 26.500/26.497
1712G RAM 54 B-600-413 YB-903-865 X .83 ------ 18.23 ------ 26.500/26.497 REVISED DIM'S A & C,
1712G RAM 54 B-600-413 YB-903-865 X ------ 4.37 17.40 ------ 13.03 26.500/26.497 A 7/21/95
ADDED DIM'S AA, CC, & D
COOPER
AJAX-SUPERIOR
1716G RAM 54 B-600-413 YB-903-865 X .83 ------ 17.40 18.23 ------ 26.500/26.497 THE ENCLOSED DRAWINGS CONTAIN CONFIDENTIAL AND TRADE SECRET INDUSTRIES PO BOX 540, SPRINGFIELD, OHIO 45501
INFORMATION WHICH IS THE PROPERTY OF COOPER INDUSTRIES SUPERIOR
1716G RAM 54 B-600-413 YB-903-865 X ------ 17.40 ------ 13.03 26.500/26.497 AND RECEIPT OR POSSESSION DOES NOT CONVEY ANY RIGHTS TO LOAN, OUTLINE DRAWING
SELL, OR OTHERWISE DISCLOSE SAID INFORMATION. REPRODUCTION OR
2406G RAM 54 B-600-413 YB-903-865 X 15.55 ------ 17.40 32.95 ------ 26.500/26.497 USE OF SAID INFORMATION FOR ANY PURPOSE OTHER THAN THAT IN SHT OF ALT. NO.
CONNECTION WITH WHICH SAID INFORMATION WAS SUPPLIED MAY NOT BE
A
2408G RAM 54 B-600-412 YC-903-749 X 15.55 ------ 18.40 33.95 ------ 26.500/26.497 MADE WITHOUT EXPRESSED WRITTEN PERMISSION OF COOPER INDUSTRIES
DRAWING NO.
SUPERIOR. THIS DOCUMENT IS TO BE RETURNED TO COOPER INDUSTRIES COUPLING
SUPERIOR UPON REQUEST AND IN ALL EVENTS UPON COMPLETION OF THE
PURPOSE FOR WHICH IT IS LOANED. ARRANGEMENTS SK-7500 -302
2-9
Chapter 2: General Frame Data
2-10 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
Lubrication
General
The complete lubrication system of the compressor may be conveniently
divided into two parts of equal importance:
– The system that provides lubrication to the frame running parts.
(See Figure 2-1)
– The system that provide lubrication for the cylinders. (See Figure 3-3)
Refer to Engineering Standards 1001 and 1002 in Section 1 for lube oil
specifications. This section deals with frame lubrication. Refer to Section 3
(General Cylinder Data) for information about cylinder lubrication.
2-12 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
1 1/4" pipe
Optional
Pressure pre-lube
Lube oil capacity relief valve oil
RAM 52 -14 internal line with (Optional)
RAM 54 - 20 check valve Pre-lube
3/4" check valve 3/4" tubing hand pump
100 complete
Oil pump strokes for
initial priming
1 1/4" pipe on cold start
1 1/4"
check
valve 3/4" tubing
Keckley Off mounted
lube oil Optional pre-lube
strainer pump (to be supplied
by customer).
Sump
i
Represents typical engine jacket water temperatures.
All specifications based on 1200 RPM. The RAM frame lubri-
Typical differential pressure or temperature. cation logic diagram
Piping to be supplied by customer. is subject to change
Represents direction of fluid flow. without notice.
13.00
THROW #2
CLT
PLAN VIEW
COMPR.
CRANK
CL
11.50
RAM-DB-05-01-2002
SUPERIOR UPON REQUEST AND IN ALL EVENTS UPON COMPLETION OF THE
PURPOSE FOR WHICH IT IS LOANED.
LEVEL CONTROL
Chapter 2: General Frame Data
SK-7500-301
SUPERIOR® COMPRESSORS
RAM COMPRESSORS
Frame Specifications
RAM 52 Standard Frame Specifications
Power Rated *
1,500 RPM BHP (kW) 1,188 (866)
1,200 RPM BHP (kW) 950 (709)
Maximum Horsepower
Per Any One Throw BHP (kW) 600 (447)
Number of Throws 2
Stroke in (mm) 5 (127)
* Frames with keyway shafts have power ratings of 800 BHP (597 kW) at
1,200 RPM and 1,000 BHP (746 kW) at 1,500 RPM.
Oil Cooler (shipped separately ........................ Shell and tube heat exhanger
for remote mounting)
2-18 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
Crankshaft
Weight Lbs (kg) 276 (125)
Length in (mm) 31.13 (790.6)
Extension Length (tapered)* in (mm) 4.88 (123.83)
Extension Diameter in (mm) 5.13 (130.18)
Journal Diameter in (mm) 4.9 (124)
Bearings
Main and Rod Bearings, Split Shell
Inside Diameter in (mm) 4.9 (124)
Width in (mm) 2.8 (71.1)
Thickness in (mm) 0.350 (9.0)
Quantity, per unit No. 8
Thrust Bearings
Inside Diameter in (mm) 5.3 (134.6)
Width in (mm) 1.3 (33.6)
Thickness in (mm) 0.313 (7.9)
Quantity, per unit No. 2
Connecting Rod
Weight Lbs (kg) 60 (27)
Length, ctr. -ctr. in (mm) 12 (304.8)
Bolt Quantity and Arrangement Two - 1" bolts per rod
Crosshead
Weight
Light Lbs (kg) 55-57 (25.4)
Heavy Lbs (kg) 95-97 (44.0)
Diameter
Light in (mm) 9.5 (241.3)
Heavy in (mm) 9.2 (233.7)
Width
Light in (mm) 7.1 (180.3)
Heavy in (mm) 7.75 (196.8)
Recommended Oil
Operating Temp. °F (°C) 160 (70.4)
Heat Rejection
1,500 RPM BTU/hr (Watt) 21,500 (6,300)
1,200 RPM BTU/hr (Watt) 16,000 (4,690)
H2O Temperature To
Cooler (typical) °F (°C) 155 (67.65)
2-20 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
Connecting Rod Pin Bushing .... SAE 792 steel backed bronze
(Crosshead Pin Bushing)
2-22 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
400
300
200
Suction Pressure = Discharge Pressure = Atmospheric
(Bypass Open)
100 Breakaway Torque = 50 Ft. - Lbs.
0
0 200 400 600 800 1,000 1,200 1,400 1,600
Speed-RPM
2-24 RAM-DB-05-01-2002
LEGEND
CONN. DE SCRIPTI
ON CONN. SIZE
A LUBE O ILOU TLETTO COO LER 1-1/4" NPT
B LUBE O IL INLETOFR
M COO LER 1-1/4" NPT
Z C LUBE O IL FILL
CONNECTION 1-1/4" NPT
D LUBE O IL DRAINCONNECTION 3/4" NPT
W W
DRIVE END
21.00 21.00
6.19
C
X
CL THROW #1
6.19
2.00 25.31
23.50 THROW #2
6.16 CL
26.00
2.06
10.72
B
B FOUNDATION PLAN
ROT.
28.17
X
24.42
14.17
15.14 ALT. DESCRIPTION DATE
11.19 (360 MM)
C ADDED SOLE PLATE HLS. PCN55169 12/10/99 MW
5.68 B ADDED SHT3 W/SHIPPED LOOSE ITEMS 9/29/95 DP3
2.92 A ADDED ROTATION ARROW 7/31/95 DP3
COO PER
AJAX-SUPERIOR
THE EN CLOSED DRAWIN GS CONTAINCONFIDENTIAL AND TRADESECRET IND USTRIES PO BOX 540 , SPRINGFIELD
, OHIO 4550 1
INFORMATION WH ICH IS THE PROPERTY OF COOPER IND USTRIES SUPERIO R
1.50 LUBE OIL LEVEL AND RECEIPT OR POSSESSION DOES NOT CONVEY ANY RIGHTS TO LOAN, OUTLINE DRAWING
2" NPT FOR OPTIONAL SELL,OR OTHERWISE DISCLOSE SAID INFORMATION. REPRODUCTIONOR
D SIGHT GUAGE
LUBE OIL HEATER USE OF SAID INFORMATION FOR ANY PURPOSE OTHER THAN THAT IN SH T 1 OF 3 ALT.NO. C
CONNECTIO N WITH WH ICH SAID INFORMATION WA S SUPPLIED MAYNOT BE
MADE WITH OUT EXPRESSED WRITTEN PERMISSION OF COOPER IND USTRIES
AUX END VIEW DRAWING NO .
SUPERIO R. TH IS D OCUMENT IS TO BE RETURNED TO COOPER IND USTRIES MODE L
SUPERIOR UPON REQUEST AND IN ALL EVENTS UPON COMPLETION OFE TH
PURPOSE FOR WH ICH IT IS LOANED . RAM 52 SK-7500-104
2-25
2-26
LEGEND
W
25.63 25.63
CL COMPRESSOR
16.00 DIA B.C.
THROW #1 THROW #2 Z
CL
X
5.68
118.00
8.00
8.00 DDIA
IA
IA
Y
4.81 1-1/2" NPT FOR LUBE
OIL LEVEL CONTROLLER ID I W
1 DIA.
( W2 8
(WHEN REQUIRED)
5.71 A CD A W
COOPER
AJAX-SUPERIOR
THE ENCLOSED DRAWINGS CONTAIN CONFIDENTIAL AND TRADE SECRET INDUSTRIES PO BOX 540, SPRINGFIELD, OHIO 45501
INFORMATION WHICH IS THE PROPERTY OF COOPER INDUSTRIES SUPERIOR
AND RECEIPT OR POSSESSION DOES NOT CONVEY ANY RIGHTS TO LOAN,
SELL, OR OTHERWISE DISCLOSE SAID INFORMATION. REPRODUCTION OR
USE OF SAID INFORMATION FOR ANY PURPOSE OTHER THAN THAT IN SHT 2 OF 3 ALT. NO. C
CONNECTION WITH WHICH SAID INFORMATION WAS SUPPLIED MAY NOT BE
MADE WITHOUT EXPRESSED WRITTEN PERMISSION OF COOPER INDUSTRIES DRAWING NO.
SUPERIOR. THIS DOCUMENT IS TO BE RETURNED TO COOPER INDUSTRIES MODEL
RAM-DB-05-01-2002
SUPERIOR UPON REQUEST AND IN ALL EVENTS UPON COMPLETION OF THE
PURPOSE FOR WHICH IT IS LOANED.
Chapter 2: RAM 52
RAM52 SK-7500-104
SUPERIOR® COMPRESSORS
2-28 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
RAM COMPRESSORS
Frame Specifications
RAM 54 Standard Frame Specifications
Power Rated *
1,500 RPM BHP (kW) 2,375 (1,772)
1,200 RPM BHP (kW) 1,900 (1,418)
Maximum Horsepower
Per Any One Throw BHP (kW) 600 (447)
Number of Throws 4
Stroke in (mm) 5 (127)
* Frames with keyway shafts have power ratings of 1,600 BHP (1,193kW)
at 1,200 RPM and 2,000 BHP (1,491kW) at 1,500 RPM.
Oil Cooler (shipped separately ........................ Shell and tube heat exchanger
for remote mounting)
2-32 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
Crankshaft
Weight Lbs (kg) 552 (250.38)
Length in (mm) 67.13 (1,705)
Extension Length (tapered)* in (mm) 4.88 (123.83)
Extension Diameter in (mm) 5.13 (130.18)
Journal Diameter in (mm) 4.9 (124)
Bearings
Main and Rod Bearings, Split Shell
Inside Diameter in (mm) 4.9 (124)
Width in (mm) 2.8 (71.1)
Thickness in (mm) 0.350 (9.0)
Quantity, per unit No. 16
Thrust Bearings
Inside Diameter in (mm) 5.3 (134.6)
Width in (mm) 1.3 (33.6)
Thickness in (mm) 0.313 (7.9)
Quantity, per unit No. 2
Connecting Rod
Weight Lbs (kg) 60 (27)
Length, ctr. -ctr. in (mm) 12 (304.8)
Bolt Quantity and Arrangement Two - 1" bolts per rod
Crosshead
Weight
Light Lbs (kg) 55-57 (25.4)
Heavy Lbs (kg) 95-97 (44.0)
Diameter
Light in (mm) 9.5 (241.3)
Heavy in (mm) 9.2 (233.7)
Width
Light in (mm) 7.1 (180.3)
Heavy in (mm) 7.75 (196.8)
Recommended Oil
Operating Temp. °F (°C) 160 (70.4)
Heat Rejection
1,500 RPM BTU/hr (Watt) 43,000 (12,600)
1,200 RPM BTU/hr (Watt) 32,000 (9,378)
H2O Temperature To
Cooler (typical) °F (°C) 155 (67.65)
2-34 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
Connecting Rod Pin Bushing .... SAE 792 steel backed bronze
(Crosshead Pin Bushing)
2-36 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
2-38 RAM-DB-05-01-2002
MEGEO D
UFFPQ VF1 )7, 405.21 WCSSGF JROGV CPOO . CDQBPGNR
GML CPOO . TI E
H R U OGYGOLQIVEUGZ V
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B BEEFE TQVBVJQP BTTQY 7/31/95 ER3
F RFD DLBIMQDC CP9UGL Q BMLR9GLBMLEGCDLRG9I 9LC RP9CD QDBPDR
GLEMPJ9R GML UFGBF GQ RFD NPMNDPRWME BMMNDP GL CSQRPGDQ QSNDPGMP
9LC PDBDGNR MP NMQQDQQGML CMDQ LMR BMLTDW 9LW PG FRQ RM IM9L
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D QSNDPGMP SNML PD OSDQR 9LC GL 9II DTDLRQ SNML BMJNIDRGML MEDRF
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RAM-DB-05-01-2002
Chapter 2: RAM 54
2-42 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
RAM COMPRESSORS
Flexibility
A broad range of cylinders provide great flexibility for changing field
conditions. Special spacers and a standard variable volume pocket unloader
allow for maximum capacity control. Minimum clearance heads are also
available if specified by the customer. Prime movers can be selected from
Superior’s extensive line of high performance diesel, duel fuel, and natural
gas engines.
State-of-the-art Design
The standard line-up of RAM cylinders are all non-cooled and precision
machined from cast ductile iron or forged steel. This increases their strength
under high pressure conditions. Each cylinder is pressure tested to one
and one-half times its maximum allowable working pressure (MAWP) to
guarantee the RAM’s safe and efficient operation.
Valves
As with all Superior compressors, a wide selection of compressor valves is
available to accommodate any application. The typical compressor valve
has been efficiently designed and engineered for high-speed, low-clearance
applications and precision manufactured using the latest in machining
technology. Hoerbiger Corporation of America was chosen as the
compressor valve supplier because of their flexibility and capability to
respond to any application quickly and efficiently.
Hoerbiger high-speed “CT Series” compressor valves are standard
equipment on RAM compressors. Hoerbiger valves, with stainless steel
bodies and PEEK or MT dependent on valve size plates, are specifically
designed for the RAM’s low-clearance cylinder line-up.
Suction valve unloaders are available. Please note, however, that these are
not standard stock items. Additional engineering time is required to properly
size cylinders and evaluate appropriate operating conditions. Suction valve
unloaders are restricted to use on cylinders with 4-7/8” valve diameters and
larger. Consult Cooper Energy Services Engineering for availability and
information.
3-4 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
Valve Spacers
Valve spacers for additional clearance flexibility are standard on 6.5”
cylinders and larger. The spacers are located on top of the valve cage.
Piston
The piston is available in a one- or a three-piece integral piston-rod design.
Depending on the cylinder class, it is constructed of cast iron with two cast
aluminum end pieces sandwiching a cast iron ring carrier.
Cooper Energy Services designed the small-bore, high-pressure cylinders
to operate typically with a one-piece, “lubrited” cast iron piston and rider-
compression rings. The rider compression ring creates a tight seal against
the running bore of the cylinder, and supports the piston. Piston and
cylinder bore scuffing will not occur. The larger bore cylinders have a three-
piece piston configuration, consisting of two aluminum piston end pieces
sandwiching a cast iron ring carrier. Standard rider bands and piston rings
are used. See Piston Rings in this section.
Piston Rod
Forged steel cylinders are an integral piston-rod assembly. The piston rod is
constructed of AISI E 4140 heat-treated, induction-hardened steel with class
2A 2”-8 rolled threads. Special optional construction is available for sour
gas applications. See Sour Gas Cylinder Specifications in the Additional
Information section. A single nut secures the piston to the end of the rod,
allowing for easy field servicing of the assembly.
Piston Rings
Two-piece, rider-compression rings are standard on all cylinders up to 9.5”
in bore. A combination of two-piece compression rings and rider band
is standard on all other cylinders, ranging from the 10.5” to 20” series.
The “rider-compression” ring concept provides the same protection as the
standard rider band, enhancing the service life of the high-stage RAM
cylinder lineup. Carbon-filled Teflon is used as a standard material for
construction; however, other materials may be substituted as dictated by the
application and/or by customer preferences.
Packing
Full-floating, vented, and non-cooled packing consists of carbon-filled
Teflon pressure rings and tinnized cast iron oil rings. The packing assembly
is typically lubricated on the small-bore (high stage) cylinders. Forged steel
cylinder packings are water-cooled and lubricated.
3-6 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
RAM COMPRESSORS
3-10 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
3-12 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
4.50 C15A 401CC 1 2.744 69.03 55.39 124.42 7245 5814 6529
5.00 C15A 402CC 1 2.744 85.22 71.59 156.81 8945 7513 8229
5.50 C15B 403CC 1 3.193 103.12 89.48 192.60 8478 7357 7917
6.00 C15B 404CC 1 3.193 122.72 109.08 231.80 10089 8968 9529
* 6.50 C15C 405CC 1 3.193 Not Recommended for 1500 RPM operation *
7.00 C15C 406CC 1 3.193 Not Recommended for 1500 RPM operation
6.50 C15C 423CC 1 5.689 144.02 130.39 274.41 7291 6601 6946
7.00 C15C 424CC 1 5.689 167.03 153.40 320.43 8456 7766 8111
* 7.75 C15D 407CC 1 8.029 204.74 191.11 395.85 7344 6855 7100
* 8.25 C15D 408CC 1 8.029 232.01 218.38 450.39 8322 7833 8078
7.75 C15D 427CC 1 8.029 204.74 191.11 395.85 7344 6855 7100
8.25 C15D 428CC 1 8.029 232.01 218.38 450.39 8322 7833 8078
9.00 C15E 409CC 1 8.029 276.12 262.48 538.60 9904 9415 9660
9.50 C15E 410CC 1 8.029 307.65 294.01 601.66 11035 10546 10791
9.50 C15FC 434DC
10.50 C15F 411CC 2 7.006 375.82 362.19 738.01 7725 7444 7585
11.00 C15F 412CC 2 7.006 412.47 398.83 811.360 8478 8198 8338
11.00 C15FC 433CC
12.00 C15G 413CC 2 7.006 490.87 477.24 968.11 10089 9809 9949
12.50 C15G 414CC 2 7.006 532.63 519.00 1051.63 10948 10667 10808
* 13.50 C15H 415CC 2 8.029 621.26 607.63 1228.89 11142 10898 11020
* 14.00 C15H 416CC 2 8.029 668.14 654.50 1322.64 11983 11738 11861
13.50 C15H 425CC 2 11.530 621.26 607.63 1228.89 7759 7589 7674
14.00 C15H 426CC 2 11.530 668.13 654.50 1322.63 8344 8174 8259
15.50 C15I 417CC 2 13.380 818.97 805.34 1624.31 8814 8667 8741
16.00 C15I 418CC 2 13.380 872.66 859.03 1731.69 9392 9245 9319
17.50 C15J 419CC 2 18.060 1043.96 1030.32 2074.28 8324 8215 8270
18.00 C15J 420CC 2 18.060 1104.47 1090.83 2195.30 8806 8698 8752
19.50 C15K 421CC 2 18.060 1296.21 1282.58 2578.79 10335 10227 10281
20.00 C15K 422CC 2 18.060 1363.54 1349.90 2713.40 10872 10763 10818
3-14 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
RAM COMPRESSORS
3-18 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
3-20 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
3-22 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
Valve Materials
Valve Seat 416 Stainless Steel
Valve Guard 416 Stainless Steel
Guide Ring 416 Stainless Steel
Springs 17-7 PH Stainless
Steel
Valve Plate Non-Metallic -
PEEK or MT
Piston
Material:
Lubrited CI 4.5" - 8.25"
Hardness HB 183 - 285
Cast Aluminum ends 9.00" - 20.00"
Hardness HB 70
Cast Iron Carrier HB 183 - 285
Number of Pieces:
Solid (one-piece) 4.5" - 8.25"
Split (three-piece) 9.00" - 20.00"
Piston Rod
Diameter In (mm) 2 (50.8)
Material 4140 Steel, heat
treated
Hardness Induction hardened
HB (Rc) 269 - 321 (50 - 56)
Tensile Strength Psi (MPa) 130,000 (634)
3-24 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
5.50 1600 C15B 403CC 4.00" -4 20.48 20.48 8.10 24.35 None None
6.00 1600 C15B 404CC 4.00" -4 18.58 18.58 6.81 20.40 None None
* 6.50 1250 C15C 405CC 4.00" -4 15.21 15.21 9.59 17.47 7.44 8.22
* 7.00 1250 C15C 406CC 4.00" -4 14.23 14.23 8.26 15.33 6.41 7.01
6.50 1500 C15C 423CC 4.88" -4 19.37 19.37 9.59 22.70 11.32 12.51
7.00 1350 C15C 424CC 4.88" -4 17.69 17.69 8.26 19.60 9.76 10.63
* 7.75 900 C15D 407CC 5.75" -4 17.95 17.95 10.07 19.98 10.95 11.73
* 8.25 900 C15D 408CC 5.75" -4 18.20 18.20 8.89 18.10 9.66 10.27
7.75 1250 C15D 427CC 5.75" -4 17.95 17.95 10.07 19.98 10.95 11.73
8.25 1200 C15D 428CC 5.75" -4 18.20 17.28 8.89 18.10 9.66 10.27
9.00 850 C15E 409CC 5.75" -4 14.29 14.29 12.10 15.53 8.12 8.54
9.50 850 C15E 410CC 5.75" -4 13.85 13.85 10.86 14.07 7.29 7.62
9.50 600 C15FC 434DC 5.25" -8
10.50 600 C15F 411CC 5.25" -8 14.27 14.27 11.61 15.72 4.89 5.07
*11.00 600 C15F 412CC 5.25" -8 16.04 16.04 10.58 16.20 4.57 4.60
11.00 600 C15FC 433CC 5.25" -8
12.00 500 C15G 413CC 5.25" -8 12.15 12.15 13.89 13.19 3.74 3.85
12.50 500 C15G 414CC 5.25" -8 12.28 12.28 12.80 12.38 3.45 3.54
*13.50 280 C15H 415CC 5.75" -8 11.78 11.78 13.28 12.77 3.61 3.69
*14.00 280 C15H 416CC 5.75" -8 12.14 12.14 12.35 11.94 3.36 3.43
13.50 450 C15H 425CC 6.50" -8 14.56 14.56 13.28 16.17 4.37 4.47
14.00 450 C15H 426CC 6.50" -8 15.20 15.20 12.35 15.14 4.37 4.47
15.50 325 C15I 417CC 7.00" -8 11.94 11.94 5.33 12.15 5.02 5.10
16.00 300 C15I 418CC 7.00" -8 11.65 11.65 5.00 11.84 4.71 4.78
17.50 200 C15J 419CC 8.00" -8 12.51 12.51 5.29 12.69 6.18 6.26
18.00 200 C15J 420CC 8.00" -8 11.89 11.89 5.00 12.05 5.84 5.91
19.50 185 C15K 421CC 8.00" -8 10.23 10.23 4.26 10.32 4.97 5.03
20.00 175 C15K 422CC 8.00" -8 9.69 9.69 4.05 9.80 4.73 4.78
MWP = Maximum Working Pressure. Psi. HCS = Head End Clearance Added per Valve Spacer
HC = Minimum Head End Clearance with CCS = Crank End Clearance Added per Valve Spacer
Minimum Clearance Head Variable Volume Pocket Travel = 5.0 inches
HCO = Minimum Head End Clearance with
Variable Volume Clearance Pocket
HC1 = % Clearance Added per Inch of Pocket Travel
Maximum Rod Load = 30,000 lbs.
i RAM Cylinder
Maximum Working Pres-
CC = Crank End Clearance sures were
uprated midyear 1993.
(Clearances are expressed as a percentage of total cylinder volume.)
*Obsolete and not available for production. For reference only.
5.50 1600 C15B 403CC 23.76 20.62 82.49 71.59 154.08 103.12 89.48 192.60
6.00 1600 C15B 404CC 28.27 25.13 98.17 87.27 185.44 122.72 109.08 231.80
* 6.50 1250 C15C 405CC 33.18 30.04 115.22 104.31 219.53 144.05 130.39 274.41
* 7.00 1250 C15C 406CC 38.48 35.34 133.63 122.72 256.34 167.036 153.40 320.43
6.50 1500 C15C 423CC 33.18 30.04 155.22 104.31 219.53 144.02 130.39 274.41
7.00 1350 C15C 424CC 38.48 35.34 133.63 122.72 256.34 167.03 153.40 320.43
* 7.75 900 C15D 407CC 47.17 44.03 163.79 152.89 316.68 204.74 191.11 395.85
* 8.25 900 C15D 408CC 53.46 50.31 185.61 174.70 360.31 232.01 218.38 450.39
7.75 1250 C15D 427CC 47.17 44.03 163.79 152.89 316.68 204.74 191.11 395.85
8.25 1200 C15D 428CC 53.46 50.31 185.61 174.70 360.31 232.01 218.38 450.39
9.00 850 C15E 409CC 63.62 60.48 220.89 209.98 430.88 276.12 262.48 538.60
9.50 850 C15E 410CC 70.88 67.74 246.12 235.21 481.33 307.65 294.01 601.66
12.00 500 C15G 413CC 113.10 109.96 392.70 381.79 774.49 490.87 477.24 968.11
12.50 500 C15G 414CC 122.72 119.58 426.10 415.20 841.30 532.63 519.00 1051.63
* 13.50 280 C15H 415CC 143.14 140.00 497.01 486.10 983.11 621.26 607.63 1228.89
* 14.00 280 C15H 416CC 153.94 150.80 534.51 523.60 1058.10 668.13 654.50 1322.63
13.50 450 C15H 425CC 143.15 140.00 497.01 486.10 983.11 621.26 607.63 1228.89
14.00 450 C15H 426CC 153.94 150.80 534.51 523.60 1058.10 668.13 654.50 1322.63
15.50 325 C15I 417CC 188.69 185.55 655.18 644.27 1299.45 818.97 805.34 1624.31
16.00 300 C15I 418CC 201.06 197.92 698.13 687.22 1385.35 872.66 859.03 1731.69
17.50 200 C15J 419CC 240.53 237.39 835.16 824.26 1659.42 1043.96 1030.32 2074.28
18.00 200 C15J 420CC 254.47 251.33 883.57 872.66 1756.23 1104.47 1090.83 2195.30
19.50 185 C15K 421CC 298.68 295.51 1036.97 1026.06 2063.03 1296.21 1282.58 2578.79
20.00 175 C15K 422CC 314.16 311.02 1090.83 1079.92 2170.75 1363.54 1349.90 2713.40
i RAM Cylinder
Maximum Working Pres-
sures were
uprated midyear 1993.
3-26 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
Cylinder Bore CylinderCyl + Bottles 1000 RPM Design 900 RPM Design
Class Range Weight Est Weight Full Support Pipe Support Full Support Pipe Support
C15A 4.5/5.0 1825 2920 Recommended -- Recommended --
C15B 5.5/6.0 2510 4015 Recommended -- Recommended --
C15C 6.5/7.0 2430 3885 Recommended -- Recommended --
C15D 7.75/8.25 1975 3160 Recommended -- Recommended --
C15E 9.0/9.5 2050 3280 Recommended -- Recommended --
C15F 10.5/11.0 2640 4225 Recommended -- Recommended --
C15FC
C15G 12.0/12.5 2950 4720 Required -- Recommended --
C15H 13.5/14.0 3360 5375 Required -- Required --
C15I 15.5/16.0 3515 5625 Required -- Required --
C15J 17.5/18.0 3720 5950 Required -- Required --
C15K 19.5/20.0 4220 6750 Required -- Required --
Bottle weights (sum for both suction and discharge bottles) are estimated to be 60% of the cylinder weight. Weights are in Lbs.
For some cylinder/design speed combinations, the cylinder may be installed on the package with one of several support setups.
The best of the choices is listed as recommended.
*Wedge-type discharge bottle supports are to be used only when no head end supports are used.
3-28 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
Cylinder Flange
Lf Df
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3-30 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
RAM COMPRESSORS
3-34 RAM-DB-05-01-2002
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SUPERIOR® COMPRESSORS
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3-39
Chapter 3: Cylinder Specifications
3-40 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
Cylinder Number
Bore in
405CC
6.5
406CC
7.0
i Cylinders
405CC/406CC are
obsolete and not
(mm) (165.1) (177.8) available for production.
This page is for reference pur-
Crank End Displacement (CD) poses only.
1,500 RPM (Cu. ft/min) 130.39 153.40
1,200 RPM (Cu. ft/min) 104.31 122.72
Head End Displacement (HD)
1,500RPM (Cu. ft/min) 144.02 167.03
1,200 RPM (Cu. ft/min) 115.22 133.63
Clearance
% Crank end (CC) 17.47 15.33
% Head end (HC) 15.21 14.23
% HC 0 - minimum VVP 15.21 14.23
% HC 1 - per inch VVP 9.59 8.26
% Head end Clearance per spacer (HCS) 7.44 6.41
% Crank end Clearance per spacer (CCS) 8.22 7.01
% Minimum Head Clearance 15.21 14.23
VVP Bore Diameter in 4.5 4.5
(mm) (114.3) (114.3)
3-42 RAM-DB-05-01-2002
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Chapter 3: Cylinder Specifications
3-44 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
Cylinder Number
Bore in
407CC
7.75
408CC
8.25
i Cylinders
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obsolete and not
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This page is for reference pur-
Crank End Displacement (CD) poses only.
1,500 RPM (Cu. ft/min) 191.11 218.38
1,200 RPM (Cu. ft/min) 152.89 174.70
Head End Displacement (HD)
1,500 RPM (Cu. ft/min) 204.74 232.01
1,200 RPM (Cu. ft/min) 163.79 185.61
Clearance
% Crank end (CC) 19.98 18.10
% Head end (HC) 17.95 18.20
% HC 0 - minimum VVP 17.95 18.20
% HC 1 - per inch VVP 10.07 8.89
% Head end Clearance per spacer (HCS) 10.95 9.66
% Crank end Clearance per spacer (CCS) 11.73 10.27
% Minimum Head Clearance 17.95 18.20
VVP Bore Diameter in 5.5 5.5
(mm) (139.7) (139.7)
3-46 RAM-DB-05-01-2002
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Chapter 3: Cylinder Specifications
3-64 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
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3-69
Chapter 3: Cylinder Specifications
Lubrication
General
The complete lubrication system of the compressor may be conveniently
divided into two parts of equal importance:
– The system that provides lubrication to the frame running parts.
(See Figure 2-1).
– The system that provides lubrication for the cylinders.
(See Figure 3-3)
Refer to Engineering Standards 1001 and 1002 in Section 1 for lube oil
specifications. This section deals with cylinder lubrication. Refer to Section
2 (Frame Specifications) for information about frame lubrication.
3-70 RAM-DB-05-01-2002
SUPERIOR® COMPRESSORS
3-72 RAM-DB-05-01-2002