RECOMMENDED MAINTENANCE INTERVALS FOR

INTERMITTENT DUTY- RECIPROCATING COMPRESSORS

Like all equipment, Ariel compressors do require maintenance. The frequency of
maintenance is dictated by the environment in which the compressor is placed, the loads the
user imposes on the compressor and the cleanliness of the gas.
First and foremost on the preventative maintenance list is the completion and compliance
with the Ariel Corporation Packagers Standard and Compressor Start Up Check List. All items
must be adhered to, both before and after start up.
The following is a guide only and, as stated above, may vary due to operating conditions. The
time intervals start from the start up date of the unit. If your oil supplier's recommended oil
service changes are more frequent than the Ariel recommendations, the suppliers intervals
should be followed. Regular oil analysis is recommended. If problems develop the oil should
be changed immediately and the cause of the problem determined and corrected.
A log book should be kept with each unit. Every maintenance item can be entered with
exacting detail in order that records will be available for tracking maintenance costs per unit
and for trouble-shooting.
Operator logs should be reviewed by qualified personnel to determine trends in compressor
performance and/or maintenance.
CAUTION! BE SURE THAT THE COMPRESSOR IS COMPLETELY VENTED TO
RELIEVE ALL GAS PRESSURE, AND THE DRIVER WILL NOT EXERT
TORQUE ON THE COMPRESSOR CRANKSHAFT THAT COULD RESULT IN
INJURY, PRIOR TO TAKING COUPLING READINGS, RE-CHECKING
BOLTING TORQUES ON PRESSURE CONTAINING COMPONENTS OR
REMOVING ACCESS COVERS FOR PERFORMING INTERNAL
INSPECTION OR MAINTENANCE ON THE COMPRESSOR. IN THE CASE
OF A DIRECT DRIVE MOTOR, THE BREAKER IS LOCKED OUT. FAILURE
TO FOLLOW THESE STEPS CAN RESULT IN SERIOUS PERSONAL
INJURY OR DEATH.

Daily
After running a new compressor (or after a re-location, re-configuring or major overhaul) for
the first 24 hours, shutdown, vent gas system and perform a hot alignment check at coupling
within 30 minutes, while barring driver shaft to packagers recommendations. Realign if
necessary to hold coupling hub face and rim hot alignment within 0.005 inch (0.13 mm) TIR,
except for hub O.D. >17 in. (>43 cm) angular hub-face limit is increased to 0 1 (0.0167).
Also check fastener torque on gas nozzle flange, valve cap, cylinder head, compressor rod
packing flange and, if applicable, crosshead guide to frame bolting. Reference Ariel Technical
Manual, Fastener Torque Tightening Values or Toolbox Torque Chart, ER-63. After 150 hours,
repeat this fastener torque check.

Page 2, #9: Changed shutdown pressure to 45 psig (3.1 barg).

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RECOMMENDED MAINTENANCE INTERVALS FOR

INTERMITTENT DUTY- RECIPROCATING COMPRESSORS
If bearing temperatures increase or a visual inspection of the crankcase indicates bearing
wear, check main, connecting rod and crankshaft-thrust bearing clearances. Replace
affected bearings if clearances are out of tolerances. See the Ariel Technical Manual for
instructions and clearance tolerances.
1.

2.

3.

4.
5.
6.
7.

8.
9.
10.

11.
12.
13.

Check frame oil pressure. It should be 50 to 60 psig (3.5 to 4.2 barg) when at
operating temperature. Compressor inlet oil temperature is 190F
(88C) maximum.
Check frame oil level. It should be visible in the sight glass and approximately
mid-level when running, if not, determine and correct cause. Do not overfill. Check
oil makeup tank for sufficient oil supply.
Check lubricator block cycle time. Refer to information plate on top of lubricator
box for correct cycle time. Very dirty or wet gas may require a more frequent cycle
time than normal.
Check primary and secondary packing vents for blowing. If blowing, determine
cause and, if necessary, replace packing internal parts.
Check and correct any gas leaks.
Check and correct any oil leaks.
Check operating pressure and temperatures. If not normal, determine cause of
abnormality and correct. It is recommended that a daily log of operating
temperatures and pressure be kept for reference.
Check shutdown set points.
Low oil pressure shutdown 45 psig (3.1 barg) minimum.
High discharge gas temperature shutdowns are to be set within 10% or as close
as practical above the normal operating discharge temperatures, but not to
exceed the Maximum Discharge Temperature Shutdown Setting for the service
in which the compressor is operating.
High and low pressure shutdowns are to be set as close as practical.
Consideration should be given to the rod load capacity of the machine.
Check lubricator box oil level.
Check for unusual noises or vibrations.

Every 400 Hours (in addition to Daily Requirements)

After running a new compressor (or after a re-location, re-configuring or major overhaul) for
400 hours, shutdown, vent gas system and check fastener torque on gas nozzle flanges,
valve caps, cylinder heads and compressor rod packing flanges. Reference Ariel Technical
Manual, Fastener Torque Tightening Values or Toolbox Torque Chart, ER-63. Fasteners that
turn at the first month check, should be re-checked after 800 hours. If loosening persists,
consult your packager or Ariel to help determine the cause and recommend the correction.
1.

Check and confirm safety shutdown functions.

Every 2000 Hours (plus Daily & 400 Hours)

1.

Drain and replace lubricator box oil.

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RECOMMENDED MAINTENANCE INTERVALS FOR

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2.

3.

4.
5.
6.
7.

Change oil filter or when oil filter differential pressure exceeds the filter change
value, see filter information plate on the top cover or Ariel Technical Manual, Lube
Section for value.
Change oil. A more frequent oil change interval may be required if operating in an
extremely dirty environment or if the oil supplier recommends it or if an oil analysis
dictates it.
Clean sintered element in the small oil filter supplied on the force feed lubrication
system or every time main oil filter is changed.
Clean strainer when oil is changed.
Open frame when oil is changed and visually inspect for foreign material.
Disassembly is not recommended unless a reason for it is found.
Check cylinders for the proper lubrication rates. Reference Ariel Technical
Manual, Lube Section for a practical indication using the paper test method.

4000 Hours (plus Daily/400 & 2000 Hours)

1.

Check crosshead guide clearance with feelers and if outside the limits listed in the
Ariel Technical Manual, Clearances Table, replace the affected parts.
2. Inspect valves for broken plates and loose center bolts, replace broken parts and
tighten center bolts. Reference Ariel Technical Manual, Fastener Torque
Tightening Values or Toolbox Torque Chart, ER-63.
3. Inspect cylinder bores for damage or wear. If the cylinder bore surface is
blemished or gouged, efficiency can be affected and/or rapid ring wear can result,
or is more than 0.001 inch per inch of cylinder bore diameter (0.001 mm/mm) out
of round or tapered, the cylinder body should be replaced or the bore restored.
Contact Ariel for re-boring and bore restoration guidelines.
4. Inspect piston ring end gap. Replace rings that are outside the maximum limit
listed in the Ariel Technical Manual, Clearance Tables.
5. Re-tighten hold down stud-nuts to proper torque values. Inspect for frame twist or
bending to be sure the main bearing bores are in alignment. Check frame top
cover mounting surface flatness tolerance and/or soft foot (reference Ariel
document ER-82 or Technical Manual Section 2). For soft foot check, more than
0.002 inch (0.05 mm) pull down requires re-shimming.
6. Realign if necessary to hold coupling hub face and rim hot alignment within 0.005
inch (0.13 mm) TIR, except for hub O.D. >17 in. (>43 cm) angular face limit is
increased to 0 1 (0.0167).
7. Inspect piston rods for damage and excessive wear. If gouged or scratched,
replace the rod. If the rod is more than 0.005 inch (0.13 mm) under size, out of
round more than 0.001 inch (0.03 mm), or tapered more than 0.002 inch (0.05
mm) replace the rod.
8. Rebuild cylinder packing cases.
9. Rebuild oil wiper cases.
10. Check and re-calibrate all temperature and pressure gauges.
11. Check and record compressor rod run out.
12. Grease VVCP stem threads at grease fitting, with 2 to 3 pumps of multi-purpose
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RECOMMENDED MAINTENANCE INTERVALS FOR

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13.
14.
15.
16.

17.

grease using a standard hand pump grease gun.

Clean crankcase breather filter.
Adjust drive chains.
Pressure test distribution blocks.
Check gas nozzle flange, valve cap, cylinder heads, compressor rod packing,
crosshead pin through bolt, crosshead guide to frame, crosshead guide to
cylinder, cylinder mounting flange to forged steel cylinder, distance piece to
cylinder, distance piece to crosshead guide and tandem cylinder to cylinder
fastener torque.
If the compressor is equipped with crankcase over-pressure relief valves, inspect
and exercise valves to the manufacturers recommendations.

8,000 Hours (plus Daily/400/2000 & 4000 Hours)

1.

2.

Check main, connecting rod, and crankshaft-thrust bearing clearances with a pry
bar and dial indicator. See the Ariel Technical Manual for instructions and
clearance tolerances. Any time bearing clearances are outside the limits, replace
the affected bearings. Disassembly to check clearances is not recommended.
Disassembly should be performed if the pry bar check indicates excessive
clearance.
Check auxiliary end chain drive for sprocket teeth undercutting and chain for
excessive stretching.

16,000 Hours (plus Daily/400/2000/4000 & 8000 Hours)

1.
2.
3.

Check crosshead pin to crosshead pin bore and connecting rod bushing bore by
removing crosshead pins.
Check for excessive wear in the auxiliary end drive chain tightener.
Check for excessive ring groove wear in pistons.

32,000 hours (plus Daily/400/2000/4000/8000 & 16,000 Hours)

1.
2.

Replace lubricator distribution blocks.

Replace crosshead bushings.

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