V-02260-1510-K-151-0053 Iom

RAPID PROJECT PACKAGE 3
EQUIPMENT:
1510‐K‐151
TR PROJECT NO. 02260

PURCHASE ORDER NUMBER : 0226005040
REVIEW RESPONSE BY PURCHASER:
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contractual terms and conditions:
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VOID DATE:
DOCUMENT DATA VENDOR IDENTIFICATION: BURCKHARDT COMPRESSION AG
DOCUMENT TITLE: Installation, Operation and Maintenance Manual
VENDOR DOCUMENT NO.: IM200322_2001754 REV: 0 CODE: MAN‐0001
PURCHASER DOCUMENT NO.: V‐02260‐1510‐K‐151‐0XXX
V-02260-1510-K-151-0053 REV: A CLASS: O
RAPID-P0003-3004-MEC-MAN-1510-0481
OWNER DOCUMENT NO.: RAPID‐P0003‐3004‐MEC‐MAN‐1510‐0XXX REV: A
V-02260-1510-K-151-0053-A
DOCUMENT NUMBER V‐02260‐1510‐K‐151‐0XXX ‐A Rev Page
Project Package Originator Discipline Doc. Type Unit nº Serial nº
3004 MEC MAN 1510 0XXX A 638
RAPID P0003 0481
PETRONAS RAPID PROJECT

(PACKAGE 3)

Installation, Operation and Maintenance
Manual
1510‐K‐151

OWNER approval:
Name:
Date

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Document Class: O X

Pages modified under this revision:

A 18‐MAY‐16 IFA ‐ Issued for REVIEW kalajdzisa_a MUELLER_A FEUSI_M
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Burckhardt Compression AG
Im Link 5
P.O. Box 65
CH-8404 Winterthur
Switzerland
Tel. +41 (0) 52 262 55 00
Fax +41 (0) 52 262 00 53
www.burckhardtcompression.com
Instruction Manual Compressor Type

2B1XC2.64_1
IM 200322en
Serial No.
200322
for Process Gas
Process Gas Nitrogene (N2)
Compressor Project No.

2001754
Key Word
PRPC PENGERANG-09
Purchaser
Técnicas Reunidas S.A.,
MADRID,
SPAIN
Order No.
0226005040
Operating Company
PRPC Refinery and Cracker Sdn. Bhd.,
PENGERANG,
MALAYSIA
Item No.
1510-K-151
Original instructions
Table of Contents
Table of Contents
1 Definitions for this Document
2 Elementary Safety Advice
3 Plant Configuration and Function
4 General Design and Function of

Compressors
5 Transport, Installation and Pre-Commis-

sioning
6 Operation
7 Trouble Shooting
8 Preventive Maintenance
9 Dismantle and Assemble Compressor Com-

ponents
10 Clean and Degrease Plant and Compressor

Components
11 Decommissioning or Dispose Plant
12 Spare Parts
13 Appendix
14 Index
17.05.2016 Rev. 001/kalajdzisa_a 2B1XC2.64_1 IM 200322en

Table of Contents
IM 200322en 2B1XC2.64_1 Rev. 001/kalajdzisa_a 17.05.2016

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

1.2 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3 Legal Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4 Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.4.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.4.2 Target Groups and Assumed Knowledge . . . . . . . 1-4
1.5 Compressor Designation . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.6 Contact Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.7 Structure and Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.7.1 Document Structure . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.7.2 Visual Elements . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.8 Term Cross Reference to API Standard . . . . . . . . . . . . . . . 1-6
1.9 Warnings and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.9.1 Level of Hazard Seriousness . . . . . . . . . . . . . . . . 1-7
1.9.2 Useful Information . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.9.3 Warning Symbols Used in this Instruction Manual 1-8
1.10 Registered Trademarks and Brands . . . . . . . . . . . . . . . . . . 1 - 10
18.05.2016 Rev. 001/kalajdzisa_a 2B1XC2.64_1 IM 200322en 1–1

1–2 IM 200322en 2B1XC2.64_1 Rev. 001/kalajdzisa_a 18.05.2016

Revisions
1.1 Revisions
Book Chapter Page Technical Date Description

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

tion Manual will only be adapted to these or corrected upon request.
Please integrate incoming revision sheets in the Instruction Manual imme-
diately.
We greatly appreciate new ideas and recommendations for this Instruction
Manual.
1.2 Copyright
The copyright for this Instruction Manual remains with Burckhardt Com-
pression. Instructions and drawings may be neither
• partly or completely copied
nor
• duplicated, used or passed on to third parties
without our authorization.

Any violation of these terms will be prosecuted.
1.3 Legal Disclaimer

Burckhardt Compression warrants that its products are free of defects in
design, workmanship and material upon delivery. Excluded from such war-
ranty or any other guarantee and/or liability for defects are all deficiencies
which cannot be proven to have their origin in bad material, faulty design
or poor workmanship such as, but not limited to, deficiencies resulting from
normal wear and tear (e.g. for compressor valve parts, packing rings, oil
scraper rings, bearings and mechanical shaft seal rings, gaskets, etc.), or
deficiencies resulting from improper maintenance, failure to observe the
operating instructions or other reasons beyond Burckhardt Compression's
control. Explicitly excluded is any warranty for wrong conservation and pro-
tection. Burckhardt Compression will not take over any liability for defects
arising out of third parties' modifications or repairs.

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

Burckhardt Compression does not accept liability for damages and oper-
ating troubles resulting from neglecting the instructions here.
1.4.2 Target Groups and Assumed Knowledge

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

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

Compressor Designation
1.5 Compressor Designation

Name Plate Name plates are tagged to the crankgear and to each cylinder. The serial
number is located on the name plates.
The IM number in the footer of the Instruction Manual corresponds with the
serial number of the compressor. If an order includes several compressors,
the IM number will comply with the lowest serial number.
PA_XX_0001b_01
1 2 3 4 5 6 7 8
Fig. 1-1 Example for compressor designation
1 Number of cranks 5 Cylinder lubrication:

2 Compressor type: – = lubricated
B = horizontal C = non-lubricated
C = vertical 6 Number of cylinders of 1st stage
3 Number of stages 7 Cylinder diameter of 1st stage [cm]
4 Piston stroke [mm:] 8 Revision index
Q = 125
Y = 160
S = 200
X = 250, 280, 320
A = 250, 280, 320
C = 280, 315, 350
E = 315, 360, 400
1.6 Contact Address

Please contact your local Burckhardt Compression Office or Burckhardt
Compression Agent.
For details visit our website www.burckhardtcompression.com.
In case of an incident, contact our 24-hour emergency service:
Tel. +41 52 262 53 53
Contact in Switzerland: Burckhardt Compression AG

Burckhardt Compression Services
Sulzer-Allee 25
8404 Winterthur
Switzerland
Tel. +41 52 262 54 77 Fax +41 52 262 00 53
www.burckhardtcompression.com
info@burckhardtcompression.com

Structure and Layout
1.7 Structure and Layout
1.7.1 Document Structure

The first four chapters are designed to familiarize you with the compressor
plant. The following chapters describe compressor installation, operation
and service. For your convenience, each page provides the chapter and
section title in its header to make browsing the document easier.
1.7.2 Visual Elements

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

The designation of the compressor components of Burckhardt Compres-
sion can differ to the designation of the API standard. The following table
contains the comparison of the different designations.
Depending on the type of the compressor, some terms listed in the table
below may not be used in this manual.
Designation according to API Designation according to

Anchor bolts Foundation bolts
Auxiliary pump Prelubrication pump
Baseplate Skid
Crankcase Crankgear
Crankpin bearing Connecting rod bearing
Crankpin bushing Crosshead pin bearing
Crankpin journal Crankshaft journal
Crankshaft-driven lube-oil pump Gear oil pump
Cylinder head Valve head
Cylinder pressure packing Piston rod packing
Motor end Drive end
Multi-piece piston 2-piece piston
3-piece piston
Oil pump end Non drive end
Oil-wiper packing Oil scraper
Outboard bearing External bearing
Outboard cylinder head Cylinder cover
Pulsation suppressor Pulsation damper
Shaft key Sunk key

Warnings and Symbols
Designation according to API Designation according to

Single-piece piston Solid piston
Slinger Oil shield
Slugging wrench Flogging spanner
Valve cage, valve hold down Lantern
Wear band, rider ring Guide ring (rider ring)
Wiper packing rings Wiper elements
1.9 Warnings and Symbols
1.9.1 Level of Hazard Seriousness

The following signal words are used in this Instruction Manual. Please pay
careful attention to these.
DANGER
Your life or physical wellbeing are in serious danger if such warnings are
ignored.
 Follow the prevention instructions carefully.
WARNING
Severe injuries or damage to the equipment can occur if such warnings are
ignored.
CAUTION
Damage to the equipment or your tools can be the consequence if such
warnings are ignored.
1.9.2 Useful Information
Useful information and tips make your life easier. Follow these notes for
your convenience.

1.9.3 Warning Symbols Used in this Instruction Manual

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

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

to more specifically. The symbols used in this Instruction Manual have the
following significance:
Automatic start-up possible
Electrical danger or hazard
Machine under maintenance or overhaul
Flammable material or risk of fire
Oxidizing materials
Potentially explosive atmosphere
Hot surface, don’t touch!
Pressurized vessel or pipe – depressurize plant before

you start working!
Suspended loads
Slip hazard – watch your step!

Corrosion hazard, avoid contact with caustic substances!
Toxic hazard
Risk of frost or low temperature
Drawing-in and crush hazard – keep hands clear!
Read instruction for operation and maintenance
Wear hearing protection
Do not remove Instruction Manual from compressor site

Registered Trademarks and Brands
1.10 Registered Trademarks and Brands

Burckhardt Plate Valve™ is a trademark of Burckhardt Compression AG,
Im Link 5, 8404 Winterthur, Switzerland.
Chockfast® is a trademark of ITW Philadelphia Resins, 130 Commerce
Drive, Montgomeryville, PA 18936, USA.
ERMETO® is a trademark of SENIOR AEROSPACE ERMETO, F-41330
Fosse, 8, rue du Clos Thomas, Cedex, France.
Keyphasor® is a trademark of Bently Nevada, Llc, 1631 Bently Parkway
South, Minden, NV 89423, USA
LOCTITE® is a trademark of Henkel Corporation, Henkel Loctite Deutsch-
land GmbH, Arabellastr. 17, D-81925 München, Germany.
MASTERFLOW® is a trademark of BASF, The Chemical Company.
MOLYKOTE® is a trademark of Dow Corning Corporation, Corporate
Center, P.O. Box 994, MIDLAND MI 48686-0994, USA.
NORD-LOCK® is a trademark of Nord-Lock International AB. Nord-Lock®
products are supplied by Nord-Lock GmbH, In der Waage 10, D-73463
Westhausen, Germany.
PEEK™ is a trademark of Victrex plc, Hillhouse International, Thornton
Cleveleys, Lancashire FY5 4QD, United Kingdom.
Redura® is a trademark of Burckhardt Compression AG, Im Link 5, 8404
Winterthur, Switzerland.
RUD® is a trademark of RUD Ketten, Rieger & Dietz GmbH und Co. KG,
Friedensinsel, D-73432 Aalen, Germany.
SERTO® is a trademark of SERTO AG, CH-8355, Aadorf, Switzerland.
SUPERBOLT® is a trademark of Nord-Lock International AB. The SUPER-
BOLT® tensioner is supplied by Nord-Lock AG, Rietwiesstrasse 2, 8735
St.Gallenkappel, Switzerland.
SWAGELOK® is a trademark of Swagelok Company, Solon Ohio, 44139,
USA.
Tectyl® is a trademark of Ashland Consumer Markets (Valvoline) in the Eu-
rope, Middle East and African (EMEA) region. Ashland Nederland BV, Pe-
setastraat 5, 2991 XT, Barendrecht, the Nederlands
TURCITE® and STEPSEAL® are trademarks of Trelleborg AB (publ), P.O.
Box 153, SE-231 22 Trelleborg, Sweden.
1 – 10 IM 200322en 2B1XC2.64_1 Rev. 001/kalajdzisa_a 18.05.2016

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

2.2 Legal Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Obligations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.4 Safety Measures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.4.1 Warning Signs at Compressor Site . . . . . . . . . . . 2-5
2.4.2 Preventive Measures . . . . . . . . . . . . . . . . . . . . . . 2-5
2.4.3 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.4.4 Mechanical Hazard. . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.4.5 Thermal Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.4.6 Electrical Hazard . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.4.7 Protection against Loud Noise . . . . . . . . . . . . . . . 2-7
2.4.8 Handling Lubricants . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.4.9 Handling Chemicals . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.5 Explosion Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 11
2.5.1 Explosion Risk . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 11
2.5.2 Protection Principles. . . . . . . . . . . . . . . . . . . . . . . 2 - 11
2.6 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 11
2.7 Compressor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 12
2.8 Safe Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . 2 - 12
2.8.1 Cleaning of Compressor Plant . . . . . . . . . . . . . . . 2 - 12
2.8.2 Compressor Maintenance . . . . . . . . . . . . . . . . . . 2 - 13
2.8.3 Commissioning after Maintenance . . . . . . . . . . . . 2 - 13
2.9 Process Gas and Purge Gas . . . . . . . . . . . . . . . . . . . . . . . 2 - 14
2.9.1 Gas Specification . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 14
2.9.2 Hazard Identification Diamond . . . . . . . . . . . . . . . 2 - 14
2.9.3 N2 Nitrogen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 16


Avoiding Dangers
2.1 Avoiding Dangers

Safety means recognizing and avoiding dangers as well as knowing and
controlling the process.
The compressor is designed and built in accordance with the present state-
of-the-art technology and the recognized technical safety regulations. Nev-
ertheless, risks to users, property, and environment can arise when the
compressor is operated carelessly or improperly.
The compressor may only be operated if the following criteria are taken into
consideration:
• the compressor’s intended use,
• the compressor’s faultless operation, with special regard to safety re-
quirements.
2.2 Legal Regulations

CE Conformity Please refer to Quality Documentation for the applicable declaration of con-
formity issued for this project:
• EC Machinery Directive 2006/42/EC
• Pressure Equipment Directive 97/23/EC
• Atmospheric Explosion Protection 94/9/EC
2.3 Obligations
The safety of personnel can only be ensured if these safety instructions
and the safety notices in this manual are strictly observed and followed.
Therefore, the Instruction Manual must always be available to all people
performing the tasks described.
Additionally, general national rules of accident prevention and occupational
medicine must be observed.
Superior Authority’s It is the superior authority’s responsibility to

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

Obligations
Trainees may only operate the compressor under supervision of an expe-

rienced person.
The compressor must be operated and maintained in such a way that the
safety of the operator, maintenance personnel or third party is guaranteed
at all times.
Personnel’s Obligations Personnel charged with duties on the compressor plant

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

faults which could impair safety immediately by professionals according to
chapter 7 Trouble Shooting.

Safety Measures
2.4 Safety Measures
2.4.1 Warning Signs at Compressor Site

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

fore you start working!
Hot surface, don’t touch!
Corrosion hazard, avoid contact with caustic sub-

stances!
2.4.2 Preventive Measures

• Provide approved fire-extinguishing equipment.
• Provide marked escape routes furnished with emergency stop devices.

Safety Measures
2.4.3 Safety Devices

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

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

Safety Measures
2.4.7 Protection against Loud Noise

Personnel must be equipped with hearing protection if the continuous
sound pressure level meets 85 to 87 dB(A) per day or week. For sound
pressure level figures see section “Technical Data” in chapter 13 Appendix.
2.4.8 Handling Lubricants
For more detailed information see Material Safety Data Sheet (MSDS) from
supplier.
Hazards Under normal condition of use, lubricants are not considered hazardous
according to regulatory guidelines. Nevertheless, the superior authority is
obliged to inform the personnel handling lubricants about possible dangers
to humans and the environment which are imposed by the particular mate-
rial.
Hazard classification can be made according to:
• flash point,
• toxicity,
• MAC-value (Maximum Allowable Concentration for working area).
DANGER
Health hazard!
Excessive exposure can irritate the eyes, skin or respiratory system.
Slip hazard.
 Wear oil-resistant gloves and/or other protective clothing when hand-
ling lubricants.
 If eye contact is likely, wear protective goggles.
 If mists are generated, and/or when ventilation is not adequate, wear
approved respirator mask.
 Do not eat, drink or smoke.
DANGER
Fire and explosion hazard!
 No open fire.
 No smoking.
Storage, Labeling • Do not store in open or unlabeled containers.

• Do not store near heat, sparks, flame or strong oxidants and combus-
tible materials.
• Storage areas must be marked with clearly visible warning signs.
• In storage rooms, good ventilation must be ensured.

Safety Measures
Disposal • Oils must be recycled, return them to the supplier.

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

Hazards The superior authority is obliged to inform the personnel handling chemi-
cals about possible dangers to humans and the environment.
• flash point,
• toxicity,
DANGER
Health hazard and fire hazard!
Chemicals can be toxic, caustic, flammable and explosive.
 Do not eat, drink or smoke in the proximity of chemicals!
 Before handling any chemicals,
• pay attention to the warning symbols, peril indications and safety
advice on the label of the storage container,
• familiarize yourself with procedures in the event of contamination,
poisoning, corrosion, spilling, leakage of unknown substance.
 Always wear adequate protective clothing when handling chemicals.
Storage, Labeling • Do not store chemicals in open containers.

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

Safety Measures
Handling • Don’t spill chemicals.

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

tional regulations.
• It is strictly forbidden to dispose of chemicals in toilets, cleaning rooms,
water drains, into the ground or waste containers etc.
Acids and Lyes
DANGER
Health hazard!
If water is added to concentrated acids or lyes, it can boil and spit
dangerously.
Inhalation of vapors or aerosols may lead to severe lung damage.
Skin or eye contact leads to chemical burn (danger of blindness).
 Avoid any contact with eyes and skin.
 Use face shield or heavy protective goggles, suitable protective gloves
and apron.
 If vapors form, wear approved respirator mask.
 If large amounts of vapors occur, leave danger zone immediately.
 Dilution: always pour concentrated acids or lyes/caustic soda into
water while stirring, never contrariwise.
DANGER
Fire hazard!
Flammable acids or lyes: danger of fire, vapors form explosive mix-
tures with air.
 No open fire.
 No smoking.
Leak Response
• Adsorb any spillage with appropriate material (e.g. diatomaceous
earth, mountain flour).
• Subsequently clean thoroughly with water.
Fire-Fighting Measures
• If possible, quench small fires by means of a fire blanket.
• Extinguish fire with carbon dioxide or dry chemical. Do not use water.

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

Explosion Protection
First Aid
• Should eyes have been affected, rinse immediately for 15 minutes with
• Remove wet clothing at once.
• Rinse affected skin immediately with large quantity of water.
• Give artificial respiration if victim is not breathing.
• Get medical attention – take Material Safety Data Sheet (MSDS) to
physician with victim.
2.5 Explosion Protection
2.5.1 Explosion Risk

An explosive atmosphere normally requires oxygen and flammable sub-
stances in a certain ratio to each other. For an explosion to occur, also a
corresponding ignition source is required such as open flames, hot sur-
faces, electrical or mechanical sparks, electrostatic discharge (e.g. even
tiny quantities of ignition energy from the clothing worn by workers), short
circuits, ultrasonics, electromagnetic radiation, shock waves and adiabatic
compression.
2.5.2 Protection Principles

• Rule out the risk of creating an explosive atmosphere right from the
very start. For example, purge the compressor plant with nitrogen to
avoid generating explosive mixtures.
• Avoid the ignition of an explosive atmosphere by using corresponding
machines, parts and materials, as well as complying with corre-
sponding instructions and procedures for working in such areas.
• The last measure is limiting the effects of an explosion to a harmless
level (e.g. by means of corresponding constructional measures, or cau-
tious selection of the erection site).
2.6 Intended Use

Correct Application This compressor type is exclusively designated for the compression of gas
as specified for this application (see section 2.9.1 Gas Specification). Any
other use is considered improper and is strictly forbidden.
Appropriate utilization includes adherence to instructions for installation,
dismantling, assembly, commissioning, operation and maintenance speci-
fied by the manufacturer.
Incorrect Application Any utilization beyond this specific designation is considered as not to con-
form to designation. Burckhardt Compression will not be liable for damages
resulting from incorrect application. The risk of such non-permissible appli-
cations must be borne solely and entirely by the operating company.
18.05.2016 Rev. 001/kalajdzisa_a 2B1XC2.64_1 IM 200322en 2 – 11

Compressor Operation
If you want to extend the contractual range of application, please consult

Burckhardt Compression Services in Switzerland.
Address see section 1.6 Contact Address.
Design Changes of Modifications to the compressor plant are only permitted with the written
Compressor approval of Burckhardt Compression. We will decline any claim resulting
from unauthorized modifications.
Software Changes Do not change the code of software programs under any circumstances!
2.7 Compressor Operation

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

Keep the compressor and surrounding area clean and tidy. Use appro-
priate cleansing agents and materials. For safe use of cleansing agents
see section 2.4.9 Handling Chemicals.
Please take care of the environment!
DANGER
Fire hazard!
Dust accumulation on large, hot surfaces (e.g. compressor or main
motor) might cause an ignition source within an explosive atmo-
sphere.
In this case operator is obliged to specify a regular cleaning procedure.
 Special attention must be assured, to avoid dust accumulation on com-
pressor surface and related auxiliaries.
 Follow cleaning instructions given in chapter 10 Clean and Degrease
Plant and Compressor Components.

Safe Maintenance Practices
2.8.2 Compressor Maintenance

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

the operational safety of the compressor cannot be assured.
WARNING
Limited operational safety!
The specially designed characteristics of the compressor or related plant
components and/or their operational safety may be influenced negatively
(= increased risk) by improper actions.
 Do not modify parts or spare parts.
 Use genuine spare parts only.
 Do not use unsuitable material.
 Do not modify clearances on compressor.
 Eliminate troubles immediately.
 Replace worn parts.
CAUTION
Increased risk!
Damage to the equipment or risk of injury can occur.
 Only use original (OEM recommended) tools.
 Only use special tools delivered with compressor.
 Clean tools after use and store them in a closed and corrosion-resistant
cabinet nearby the compressor.
2.8.3 Commissioning after Maintenance

Before commissioning,
• check working order of compressor and motor by turning the flywheel
min. 1 rotation in running direction,
• fit flywheel guard and assure working order.

Process Gas and Purge Gas
2.9 Process Gas and Purge Gas
2.9.1 Gas Specification
Process gas composition Normal case [mol%]

N2 Nitrogen 100.00%
Purge gas Normal case

N2 Nitrogen 100.00%
Buffer gas Normal case

N2 Nitrogen 100.00%
Summary information about above mentioned gases or foreign matters in

process gas (if applicable) see later in section 2.9.
For in-depth safety information, please consult the respective Material

Safety Data Sheets, e.g. on the Internet.
2.9.2 Hazard Identification Diamond

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

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

occur.
3 Material can be ignited under almost all ambient

temperature conditions.
4 Highly flammable at all temperatures.

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

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

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

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

Don’t use water as an extinguishing agent!
XA_XX_0038b_02
OX Material possesses oxidizing properties.
Fig. 2-1 Hazard identification diamond

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

2.9.2 Hazard Identification Diamond.
0 Health = 0
0 0 Fire = 0
Reactivity = 0
For in-depth safety information, please consult the respective Material

Safety Data Sheets, e.g. on the Internet.
DANGER
Health hazard!
Risk of suffocation! Nitrogen gas is an asphyxiant and presents a
health hazard by displacing the oxygen in the atmosphere. At high
concentrations, unconsciousness or death may occur.
 Depressurize the installation before you open the compressor.
 When working on the compressor, make sure there is sufficient circu-
lation of fresh air.
 Be aware of any signs of dizziness or fatigue. Exposures to fatal con-
centrations of nitrogen could occur without any significant warning
symptoms.
 During an emergency situation, before entering the area, check for ox-
ygen-deficient atmospheres.
Fire-Fighting Measures Nitrogen does not burn – however, containers, when involved in fire, may
rupture or burst in the heat of the fire.
Leak Response • Wear self-contained breathing apparatus to rescue people and to seal
leak.
• Evacuate the affected area.
• Seal leak, when possible without risk.
First Aid • Remove victims to fresh air, as quickly as possible.

• Give artificial respiration if necessary.
• Get immediate medical attention – take Material Safety Data Sheet
(MSDS) to physician with victim.

Plant Configuration and Function
3 Plant Configuration and Function
3.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.2 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2.1 Pneumatic Barring Device . . . . . . . . . . . . . . . . . . 3-4
3.3 Gas System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.2 Purge System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.3 Buffer Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3.4 Pulsation Damper . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.4 Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.4.1 Avoiding Deposits. . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.5 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.5.1 Oil Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.5.2 Oil Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10
3.5.3 Oil Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10
3.5.4 Oil Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10
3.5.5 Oil Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10
3.6 Control and Operating Elements . . . . . . . . . . . . . . . . . . . . 3 - 10
3.6.1 Local Instrument Board (LIB) . . . . . . . . . . . . . . . . 3 - 11
3.6.2 Local Operator Panel (LOP) . . . . . . . . . . . . . . . . . 3 - 11
3.7 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11
3.7.1 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 12
3.7.2 Temperature Monitoring . . . . . . . . . . . . . . . . . . . . 3 - 12
3.7.3 Pressure Monitoring . . . . . . . . . . . . . . . . . . . . . . . 3 - 13
3.7.4 Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13
3.7.5 Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13
3.7.6 Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13
3.7.7 Non-Return Valve . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13
3.7.8 Vibration Monitoring . . . . . . . . . . . . . . . . . . . . . . . 3 - 13
3.7.9 Piston Rod Monitoring . . . . . . . . . . . . . . . . . . . . . 3 - 14
3.7.10 Level Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 14
3.7.11 Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 14
3.7.12 Flywheel Guard . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 14
3.7.13 Proximity Probe for Barring Device . . . . . . . . . . . 3 - 14


Overview
3.1 Overview
The term “safe location”, as used in this Instruction Manual, may refer to
any location to which the process gas, purge or buffer gas can be taken
safely, e.g. flare, atmosphere or any other location. For details about the
applied safe location, please refer to section “P & I Diagram” in chapter 13
Appendix.
The process gas is compressed to the required pressure by a process gas

compressor with appropriate number of stages.
The compression act generates heat, therefore certain compressor compo-
nents and in most cases the compressed gas must be cooled.
The lubricating system assures that bearing and crosshead are sufficiently
lubricated.
3.2 Drive System
Fig. 3-1 Process gas compressor with flexible coupling
The compressor is driven by a direct coupled electric motor. For better il-
lustration, Fig. 3-1 shows a typical view without flywheel guard.

Drive System
DANGER
Rotating components, drawing-in and crush hazard!
 Do not operate the compressor with flywheel guard removed!
For the description of the electric motor refer to the documentation of the
motor manufacturer.
3.2.1 Pneumatic Barring Device
PB_L1_0049b_01
Fig. 3-2 Pneumatic barring device
1 Flywheel
2 Pawl
3 Proximity probe
4 Barring device
For maintenance purposes a pneumatically operated barring device is

fitted. An engaged barring device turns on the flywheel compressor and
motor. A proximity probe prevents compressor start-up with engaged bar-
ring device. For description of barring device, refer to manufacturer’s doc-
umentation.
For detailed description of the pneumatic driven barring device refer to the
manufacturer’s documentation (see Customer Documentation or Technical
Documentation).

Gas System
3.3 Gas System

For information about the gas system see section “P & I Diagram” in
chapter 13 Appendix.
3.3.1 Suction Strainer

To prevent foreign matter from entering the compressor from the suction
side, fit a suction strainer of sufficient strength and appropriate mesh size
in the suction line to the first stage. Install according to client’s and manu-
facturer’s instructions.
If you have any doubts or questions concerning the appropriate strength or
mesh size of the suction strainer, please contact Burckhardt Compression
Services, address see section 1.7 Contact Address.
CAUTION
Heavily contaminated gas or very hard foreign particles can damage the
suction strainer.
 Observe the specifications concerning the gas composition.
3.3.2 Purge System

Dependent on the chemical properties of the process gas, a purge system
is required to protect personnel and equipment.
Components of Purge For layout of the purge system see section “P & I Diagram” in chapter 13
System Appendix.
Purging during Normal During normal operation of the compressor, the distance piece is continu-
Operation ously purged with nitrogen. This procedure avoids process gas entering the
crankgear which may otherwise alter the viscosity of the lubricating oil or
could result in a corrosive or explosive atmosphere in the distance piece or
crankgear.

Gas System
3 5
4
B
PB_XX_0006c_01
C
Fig. 3-3 Purge system (typical view)
A) Cylinder 3) Purge gas to distance piece

B) Distance piece 4) Buffer gas to distance piece
C) Crankgear packing
1) Leak gas from piston rod packing 5) To flare
2) Buffer gas to piston rod packing 6) Via breather to atmosphere
Purging prior to After operation of the compressor with a toxic, explosive or flammable pro-
Maintenance or Normal cess gas (if applicable), the compressor plant must be purged with dry inert
Operation gas like nitrogen prior to performing any maintenance work. The same ap-
plies after maintenance, prior to normal operation with an explosive or flam-
mable process gas or if contamination of process gas with air must be
prevented.
3.3.3 Buffer Gas

Depending on the chemical properties of the process gas, buffer gas is re-
quired to protect personnel and equipment. During normal operation of the
compressor, the piston rod packing and the distance piece packing is sup-
plied with buffer gas. The excessive buffer gas is led to a process gas de-
pendent safe location (see section “P & I Diagram” in chapter 13
Appendix).
This procedure avoids process gas entering the crankgear which may oth-
erwise alter the viscosity of the lubricating oil or could result in a corrosive
or explosive atmosphere in the distance piece or crankgear.

Cooling System
3.3.4 Pulsation Damper

Up- and downstream of the process gas line pulsation dampers are fitted
to reduce gas pulsations in the piping. For further reduction of pulsations,
orifice plates are fitted on the pulsation damper.
XA_P3_0001b_01
Fig. 3-4 Pulsation damper (typical view)
1 Orifice plate (detail see section “Technical Data” in chapter 13 Appendix)
3.4 Cooling System

For information about the cooling system see section “P & I Diagram” in
The compression of the process gas generates heat which is almost com-
pletely dissipated by the coolant. A clean, non-corrosive coolant with a suf-
ficient low freezing point must be used. Via a supply manifold, the coolant
is led to the individual elements.
At commissioning, the various control valves must be adjusted: the coolant
flow rates at minimum allowable coolant pressure must still be sufficient –
even during the summer months – to prevent the outlet flow temperature of
the coolant rising above the max. admitted value.
Manually operated control valves are installed in the individual coolant lines
allowing to optimize the outlet temperature of the coolant.
The drain valves in the cooling system can be used for blowing in air or
flushing suspended matters/deposits while the plant is in operation.

Lubricating System
CAUTION
Risk of frost!
If the ambient temperature and/or gas temperatures drop below 0 °C and
if cooling water without or inappropriate antifreeze solution is used, the
cooling water may freeze.
 Use always appropriate antifreeze solution.
3.4.1 Avoiding Deposits

A minimal flow of coolant must always be maintained.
CAUTION
Deposits in piping!
 Avoid stationary coolant.
3.5 Lubricating System

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

nance instructions of accessories: see Technical Documentation.
The lubricating system guarantees that bearing and crosshead are lubri-
cated. The lubricating oil circulates in a closed system.
Prelubrication Pump The prelubrication pump provides lubricating oil to bearing and crosshead
before the compressor is started. Therefore, the prelubrication pump must
be started a short time before the compressor is started. The prelubrication
pump must also be started at a compressor shutdown or if the compressor
has been stopped by one of the safety devices except of low lubricating oil
pressure and emergency stop.
Gear Oil Pump During compressor operation, lubrication is ensured by the gear oil pump,
which is driven by the crankshaft.
The temperature control valve maintains the defined oil temperature. The
temperature control valve makes the lubricating oil bypass the oil cooler if
the oil temperature is below the preset value.
3.5.1 Oil Skid

This is a general function description. As built illustration see section “Gen-
eral Arrangement” in chapter 13 Appendix.

Lubricating System
11
10
PA_XX_0067b_01
5
Fig. 3-5 Oil skid (typical view)
1 Oil cooler 7 Non-return valve

2 Temperature indicator 8 Pressure gauge or transmitter
3 Temperature control valve 9 Lubrication pump
4 Pressure control valve 10 Oil tank
5 Shut-off valve 11 Sight glass
6 Duplex oil filter
During normal operation, the lubrication pump sucks oil from the oil tank
through the oil strainer, forcing it through the oil cooler (1) and the duplex
oil filter (6) to the compressor bearing and crosshead.
The lubrication pump (9) provides lubricating oil to bearing and crosshead
before the compressor is started.
The non-return valve in the lubricating system prevents the standby oil
pump from turning backwards and lubricating oil from leaking back to the
oil tank due to the operating pressure of the lubricating oil.
The shut-off valves (5) up- and downstream of the lubrication pump remain
normally open. They are closed for maintenance work on the lubrication
pump.

Control and Operating Elements
Duplex Oil Filter The duplex oil filter consists of two filter housings and is equipped with a
differential pressure indicator or switch. During normal operation, the oil
flows through one of the two filter elements. If the degree of contamination
exceeds the tolerance threshold (differential pressure between filter inlet
and outlet) the operator must switch to the other filter element. The contam-
inated filter element can be cleaned/replaced whilst the plant continues op-
erating.
3.5.2 Oil Drain

The oil drain is installed on the oil tank.
3.5.3 Oil Strainer

For each oil pump an oil strainer is installed in the suction line of the oil tank
to prevent solid contaminants in the lubricating system.
3.5.4 Oil Level Transmitter

A level transmitter is installed in the oil tank to protect the compressor from
low lubricating oil level.
3.5.5 Oil Sight Glass

A sight glass on the oil tank allows local observation of lubricating oil level.
When the compressor is running, 1/2 of the oil sight glass should be cov-
ered.
3.6 Control and Operating Elements
DANGER
Electrical danger or hazard.
 Before any inspection or repair on the compressor or any related elec-
trical item, turn high and/or low-voltage main switch off at the switch
box and padlock the switch in the off-position.
 Always keep control panel and/or local operator panel locked. Only au-
thorized personnel may have access.
 Do not allow work on or near exposed live parts of equipment unless it
is absolutely unavoidable. Suitable precautions must be taken to pre-
vent injury, both to workers and to anyone else who may be in the area.

Safety Devices
DANGER
Automatic start-up possible!
Severe injuries caused by unexpected start-up of compressor.
 Before any inspection or repair on the compressor turn high and/or low-
voltage main switch off at the switch box and padlock the switch in the
off-position.
 If this is not possible, make sure there is no way of starting the com-
pressor (disconnect control panel, PLC etc.).
3.6.1 Local Instrument Board (LIB)
For detailed description of the local instrument board refer to the documen-
tation of the manufacturer (see Technical Documentation).
Various instruments are installed on the local instrument board. For more
information about these instruments see section “Instrumentation” in
3.6.2 Local Operator Panel (LOP)
For detailed description of the local operator panel refer to the documenta-
tion of the manufacturer (see Technical Documentation).
On the local operator panel (LOP) the main motor of the compressor as
well as auxiliary equipment can be started and stopped.
The local operator panel is either installed on the local instrument board
(LIB) or is a stand-alone panel. In any case, the LOP must be installed right
beside the compressor unit. For applicable installation see Technical Doc-
umentation.
3.7 Safety Devices
For detailed description of safety devices refer to the documentation of the

manufacturer (see Technical Documentation).
The installation points of safety devices are given on the corresponding

“P&I Diagram” in chapter 13 Appendix.
For set values of safety devices see section “Instrumentation” in chapter 13
Appendix.

Safety Devices
The final settings of the safety devices are determined during pre-commis-
sioning of the compressor plant by our specialists – according to the actual
operation values.
DANGER
Inoperable safety devices!
Risk of severe injuries.
 To ensure correct operation, the safety devices (setpoints, switching
points etc.) must be tested and calibrated periodically.
 Safety devices must only be attended to by authorized personnel.
Safety devices must not be isolated, bypassed or have their settings
changed without authorization.
 Defective safety devices must be replaced immediately.
3.7.1 Emergency Stop

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

Temperature safety devices protect the compressor against excessively
high or low temperatures.
Thermostats which protect the compressor against high temperatures must
be adjusted to a value of about 10–15 °C above the maximum operating
temperature (considering bypass operation, if applicable).
Various temperature indicators allow local observation and remote moni-
toring of temperature values.
Temperature Monitoring of The temperatures of the piston rod packings are monitored. The thermo-
Piston Rod Packing couples are installed in the packing flange. Elevated temperatures are a re-
sult of increased gas leakage from the packing rings. If the temperature of
a piston rod packing is above the critical value, an alarm is triggered.
Temperature Monitoring of The temperatures of suction and discharge valves are monitored. The ther-
Suction and Discharge mocouples are installed in the valve cover. Elevated temperatures are a re-
Valves sult of defective or contaminated valves etc. If the temperature of a valve is
above the critical value, an alarm is triggered.
Temperature Monitoring of The temperatures of main bearings are monitored. The thermocouples are
Main Bearings installed in the bearing cover.
Temperature Monitoring of The temperature of oil is monitored. The thermocouples are installed on the
Oil oil skid.

Safety Devices
3.7.3 Pressure Monitoring

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

Mechanical safety valves protect the compressor and its auxiliary equip-
ment against excessive pressures. Safety valves are the ultimate protec-
tion devices for compressor, vessels and pipes. They must be inspected
periodically with regard to plant operating conditions.
Each stage is safeguarded by a mechanical safety valve which opens at
excessive pressure and exhausts to a process gas dependent safe location
as indicated on the corresponding “P&I Diagram” in chapter 13 Appendix.
Under operating conditions, due to gas pulsations, the safety valves can
blow off at pressures slightly below the set values.
Design and installation of safety relief valves is plant owner responsibility.
3.7.5 Relief Valve

The lubricating system and the cooling system are equipped with spring
loaded relief valves.
3.7.6 Breather
The breather are installed on the frame cover to prevent pressure fluctua-
tion (due to pump effect of crosshead) in the crankgear.
3.7.7 Non-Return Valve

A non-return valve (in client’s scope) is installed in the discharge line to pre-
vent process gas from flowing back to the compressor system.
The non-return valve in the lubricating system prevents the prelubrication
pump from turning backwards and lubricating oil from leaking back to the
crankgear due to the operating pressure of the lubricating oil.
3.7.8 Vibration Monitoring

Vibration monitoring of the piston rod is done by the proximity probe(s) in-
stalled in the packing flange.

Safety Devices
A vibration sensor protects the compressor from destructive shocks due to

excessive vibrations caused by loosening of bolted connections, damaged
piston, valves and bearings. If the recorded values exceed a defined limit,
the compressor will be shut down.
3.7.9 Piston Rod Monitoring

Proximity probes are installed on piston rod packing flanges to monitor the
piston rod. The system protects the compressor from excessive rod vibra-
tion. The guide ring (rider ring) wear is also evaluated based on the signal
of this sensor.
3.7.10 Level Monitoring

Lubricating System A level transmitter is installed in the oil tank to protect the compressor from
low lubricating oil level.
3.7.11 Level Indicator

Lubricating System A sight glass on the oil tank allows local observation of lubricating oil level.
3.7.12 Flywheel Guard

A proximity switch is installed on the flywheel guard to prevent the com-
pressor from starting with engaged bar or barring device.
3.7.13 Proximity Probe for Barring Device

A proximity probe is installed on the pneumatic barring device (see
Fig. 3-2) to prevent the compressor from starting with engaged barring de-
vice.

General Design and Function of Compressors
4 General Design and Function of

Compressors
4.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.2 Crankgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.2.1 Drive End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.2.2 Non-Drive End . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 11
4.2.3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 13
4.2.4 Connecting Rod and Crosshead . . . . . . . . . . . . . 4 - 15
4.3 Distance Piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 17
4.3.1 Oil Scraper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 19
4.3.2 Distance Piece Packing . . . . . . . . . . . . . . . . . . . . 4 - 20
4.4 Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 21
4.4.1 Piston Rod Packing . . . . . . . . . . . . . . . . . . . . . . . 4 - 23
4.4.2 Piston Rod and Piston . . . . . . . . . . . . . . . . . . . . . 4 - 26
4.4.3 Piston Rod Runout . . . . . . . . . . . . . . . . . . . . . . . . 4 - 29
4.4.5 Suction Valves and Discharge Valves . . . . . . . . . 4 - 31
4.4.6 Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 35


Overview
4.1 Overview
This chapter describes the general design and function of a compressor of
type BA or BX.
In this description the function and design of the compressor is simplified.

The illustrations may differ from your installation.
The exact design with its technical details and technical data is shown in
chapter 9 Dismantle and Assemble Compressor Components and chapter
13 Appendix.
Process gas compressors are designed according to API 618. All types of
process gas compressors have an non-gastight crankgear. Breathers are
fitted to the crankgear to prevent rise of gas pressure inside the crankgear.
The linear movement of piston rod and piston is ensured by the crosshead
and the guide rings (rider rings) at the pistons.
The three main parts of a process gas compressor are crankgear, distance
piece and cylinder.
Depending on the application, a single-compartment or a two-compartment
distance piece is installed.
All process gas compressors can be provided with either lubricated or non-
lubricated cylinders.

Overview
1 2 3 4 5 6 7 8 9
18 17
PB_XX_0039b_01
16 15 14 13 12 11 10
Fig. 4-1 Process gas compressor type BA/BX
1 Crankgear 11 Two-compartment distance piece

2 Non-drive end 12 Distance piece packing
3 Crankshaft 13 Oil scraper
4 Connecting rod 14 Drive end
5 Crosshead 15 Single-compartment distance
6 Piston rod piece
7 Piston rod packing 16 Tail rod
8 Piston 17 Step piston
9 Valves 18 Valve head
10 Cylinder
Crankgear The crankgear (1) consists of the crankcase and its components. Main
components are crankshaft (3), connecting rod (4) and crosshead (5).
The crankgear is of non-gastight design. It is equipped with breathers and
an oil-tight crankshaft seal. Optionally it can be equipped with an explosion
relief valve.
During operation, the crankgear is normally filled with air. The crankgear
pressure is maximal 0.05 bar g/0.005 MPa g higher than atmosphere pres-
sure. If the pressure unit is kg/cm2, the same values as for bar g apply. For
special applications, the crankgear can be purged with nitrogen.
The oil reservoir usually is in an external oil tank. For special applications
the oil reservoir can also be in the crankgear.
Drive End At the drive end (14) of the crankgear, normally a flywheel is fitted to the
crankshaft. The flywheel compensates uneven load from the compressor
to the motor.
If only small irregular torques occur, a flywheel is not necessary and the
compressor can be directly coupled to the motor.
In this case a small flywheel is used as a barring wheel for the barring de-
vice. It can be mounted either on the drive end or the non-drive end of the
motor.

Overview
Where the crankshaft protrudes from the crankcase at the drive end, the
crankshaft seal prevents oil leakage to the environment and contaminants
from entering the compressor.
Non-Drive End The non-drive end (2) is closed by a cover, sealed with a flat gasket.
Crankshaft The crankshaft (3) normally is coupled via the flywheel to the electric motor
on the drive end. In special cases, i.e. if the compressor is driven by a
single bearing motor, the crankshaft is coupled directly to the motor shaft.
Depending on the number of cranks, the crankshaft is supported by two or
more bearings which consist of two bearing shells.The bearing shells are
held together by bearing covers. An axial bearing on the drive end limits the
axial movement of the crankshaft.
Connecting Rod and The rotation of the crankshaft is transformed via the connecting rod (4) into
Crosshead a reciprocating movement of the crosshead (5). The exact guided cross-
head moves the piston rod.
During compressor operation the connecting rod bearing, the crosshead
pin bearing and the crosshead itself are usually lubricated by an external
oil pump.
Distance Piece Depending on the gas properties, a two-compartment distance piece (11)
or a single-compartment distance piece (15) is used.
The two-compartment distance piece (11) is designed to contain flam-
mable, hazardous, or toxic gases.
For all other gases a single-compartment distance piece can be used.
Oil Scraping The wiper elements are installed in a housing/plate which is located on the
crankgear side of the distance piece.
Distance Piece Packing The distance piece packing (12) is only used in a two-compartment dis-
tance piece. It is installed in the intermediate partition of the distance piece.
The distance piece packing provides a distinct separation of the outer and
the inner compartment of the distance piece.
Cylinder In the cylinder (10), the process gas is compressed to the required pres-
sure by a piston with piston rings. Depending on the application, the cyl-
inder is lubricated or non-lubricated. The number of stages depends on the
pressure ratio between suction and final discharge pressure.
Each cylinder is equipped with a replaceable cylinder liner.
Piston Rod Packing The piston rod packing (7) seals off the gas compression area. The packing
rings are in forced contact with the piston rod. As a standard, the packing
is provided with a leakage line which is led to a safe location or the flare.
Piston Rod and Piston The piston rod (6) is connected to the crosshead by either a SUPERBOLT®
nut or a hydraulic nut.
The piston is equipped with piston rings and guide rings (rider rings). The
piston rings are used for sealing. The guide rings (rider rings) ensure the
linear movement of the piston rod together with the crosshead.
Piston Rod Runout and In order to monitor the rod vibration a proximity sensor is installed in vertical
Piston Rod Monitoring direction on the piston rod packing flange. The same sensor is used to
monitor the guide ring (rider ring) wear to prevent any contact between
piston and cylinder liner.

Overview
In order to have a reference of the position of the piston, a trigger sensor/

Keyphasor® is installed on the drive end side. The trigger sensor/Key-
phasor® is used to detect the rotation angle of the crankshaft via a moni-
toring system.
Valves The suction and discharge valves (9) ensure the gas delivery to the indi-
vidual stages.
Burckhardt Compression has its own valves: Burckhardt Plate Valve™,
Burckhardt Poppet Valve™, and, licensed by Burckhardt Compression,
Manley® valves.
Capacity Control There are different possibilities of capacity control, e.g. by suction valve ac-
tuators, clearance pockets, rotation speed control, and bypass over 1st
stage or bypass overall.

Crankgear
4.2 Crankgear
2 3 4 5
1 8
PB_M0_0022b_01
Fig. 4-2 Crankgear (typical view)
1 Non-drive end 5 Crosshead

2 Crankcase 6 Main bearing
3 Center bearing 7 Crankshaft
4 Connecting rod 8 Drive end
Crankgear The crankgear consists of the crankcase (2) and its compressor compo-
nents. Main components are crankshaft (7), main bearings (6), connecting
rod (4), crosshead (5) and crankshaft seal at the drive end (8). The crank-
gear is neither of gastight nor pressure-tight design.
In the crankgear the rotating movement of the crankshaft is converted to a
reciprocating movement of the crossheads by the connecting rods.
During operation, the crankgear is normally filled with air. The crankgear is
provided with breathers and, optionally, with explosion relief valves to pro-
tect the crankgear against rapid pressure rise.
Depending on the number of cranks, one ore more breathers are installed.
Crankcase
Burckhardt crankcases are designed for atmospheric pressure. All ports
are closed by frame covers and sealed with flat gaskets.
The crankcase is cast in one piece, the standard material is EN-GJL-250.

Crankgear
Components of Lubrication
Lubricating System
The oil reservoir is in an external oil tank.
During compressor operation, the lubrication of bearings and crossheads
is ensured by an oil pump which is located on the oil skid. In special cases
– instead of 2 external oil pumps – there is a crankshaft driven gear oil
pump and a prelubrication pump.

Crankgear
4.2.1 Drive End
12
11
2
10
3
6
PB_M1_0031b_03
Fig. 4-3 Drive end (typical view)
1 Crankcase 7 Oil pipe

2 Oil trap 8 Crankshaft
3 Main bearing, drive end 9 Connecting rod bearing
4 Seal rings 10 Connecting rod
5 Crankshaft flange 11 Cylindrical pin
6 Axial bearing 12 Trigger sensor/Keyphasor®

Crankgear
The drive end is of oil tight design. The flywheel which is fitted to the crank-
shaft flange (5) compensates irregular torque from the compressor to the
motor.
If only small irregular torques occur, a flywheel is not necessary and the
compressor can be directly coupled to the motor.
In this case a small flywheel is used as a barring wheel for the barring de-
vice. It can be mounted either on the drive end or the non-drive end of the
motor.
Crankshaft Seal
The crankshaft is sealed at the drive end by two lip-seal rings. They are lo-
cated in the oil trap (2) on the drive end side. The outer lip-seal prevents
contaminants from entering the compressor; the inner lip-seal prevents oil
loss.
Since the diameter of the crankshaft flange is bigger than the diameter of
the lip-seals, the two lip-seal rings are sliced to enable an easy replace-
ment if necessary.
Trigger Sensor/Keyphasor®
The trigger sensor/Keyphasor® (12) reports the top dead center to the
monitoring system. In combination with other vibration sensors this allows
crank angle referenced vibration analysis.
Main Bearing
For design and function of the main bearing (3) see section 4.2.3 Crank-
shaft.

Crankgear
4.2.2 Non-Drive End
2
6
PB_M1_0032b_02
Fig. 4-4 Non-drive end (typical view)
1 Crankcase 4 Connecting rod

2 Crankshaft 5 Oil pipe
3 Connecting rod bearing 6 Main bearing, non-drive end
As a standard, the non-drive end is closed by a cover sealed with a flat

gasket. In special cases a crankshaft driven gear oil pump can be fitted to
the non-drive end of the compressor.
External Oil Pump

During compressor operation, lubrication of bearings and crossheads is
ensured by an oil pump on the oil skid. The supply pipe from the oil skid is
connected to the oil collector at the non-drive end of the compressor.
Gear Oil Pump

During compressor operation, lubrication of bearings and crossheads is
ensured by the gear oil pump.
Lubrication of Bearings and Crosshead

An oil collector distributes the oil to the main bearings.

Crankgear
The connecting rod bearings and the crossheads are lubricated via the
bores in the crankshaft and in the connecting rod.
Main Bearing
For design and function of the main bearing (6) see section 4.2.3 Crank-
shaft.

Crankgear
4.2.3 Crankshaft
1 2 3
PB_M1_0038b_03
6 5 4
Fig. 4-5 Crankshaft (typical view)
1 Main bearing non-drive end 4 Axial bearing

2 Center bearing 5 Crankshaft
3 Main bearing drive end 6 Lubricating oil bore
The rotation of the crankshaft (5) is transformed into a reciprocating move-

ment of the crosshead via the connecting rod.
Depending on the number of cranks, the crankshaft is supported by two or
more bearings (1, 2, 3). All main bearings are identical. The lubricating oil
from the main bearing to the connecting rod passes through bores in the
crankshaft.

Crankgear
Crankshafts of Burckhardt Compression are always forged. Independent of

the number of cranks, no counterweights are used.
On the drive end, the crankshaft is coupled to the electric motor. The cou-
pling can be flexible or rigid. Compressors with shaft power < 250 kW may
be V-belt driven.
Main Bearing and Axial Bearing

The compressor is provided with precision shell bearings.
The lower bearing shell is supported by the crankcase. The upper bearing
shell is fixed by a bearing cover which is fitted on the crankcase. The
bearing shells are marked and must not be interchanged.
At the drive end there are two axial bearing halves (4) on either side of the
main bearing. They take up the axial clearance of the crankshaft.
Center Bearing
For crankshafts with four or more cranks center bearings are used, the de-
sign of the center bearings (2) is identical to the main bearing.

Crankgear
4.2.4 Connecting Rod and Crosshead
1
2
10
PA_M3_0017b_02
11
Fig. 4-6 Connecting rod and crosshead (typical view)
1 Piston rod 7 Connecting rod

2 Adjusting ring 8 Connecting rod bearing half
3 Piston rod nut 9 Crankshaft
4 Crosshead 10 Connecting rod bolt
5 Crosshead pin 11 Connecting rod cover
6 Crosshead pin bearing
Connecting Rod The connecting rod (7) is the link between crankshaft (9) and crosshead
(4). It converts the rotation of the crankshaft into a reciprocating movement
of the crosshead.
The forged connecting rod and connecting rod cover (11) have been ma-
chined together and match-marked as pairs. The connecting rod bearing
halves and the connecting rod bolts (10) are also marked.
The nuts for the connecting rod bolts are tightened either by a SUPER-
BOLT® nut or hydraulically.

Crankgear
The connecting rod bolts have rolled threads and are not positive locked
(i.e. they need no mechanical locking) due to their high pretension and high
elasticity.
Connecting Rod Bearing

The connecting rod has two bearings. At the big end is the connecting rod
bearing (8). It consists of two halves which are identical. They have no
shims. Therefore, the bearing clearance cannot be readjusted.
The design of the connecting rod bearing is of trimetallic type with a gal-
vanic running layer as a standard.
Crosshead Pin Bearing

The crosshead pin bearing (6) is at the small end of the connecting rod. It
is a part of the connecting rod and designed as a bush. It is typically of a
galvanic running layer type. The crosshead pin bearing is lubricated via the
bore in the connecting rod.
Crosshead Crossheads can be built as 1-piece crosshead or as 3-piece crosshead.

The crossheads are made of cast steel with a white metal layer in the area
of sliding.
The standard crosshead is a 1-piece crosshead. Optionally, 3-piece cross-
heads with replaceable crosshead shoes are available.
The crosshead is moved back and forth in the crosshead guide by the con-
necting rod. The crosshead guide is part of the crankcase.
The lubrication of the crosshead takes place from the crankshaft bearing
via the bore in the connecting rod along the crosshead pin to the crosshead
body.
Connection between The piston rod is connected to the crosshead with a SUPERBOLT® nut or
Crosshead and Piston Rod optionally with a hydraulically tightened nut.
The cylinder clearance is adjusted by inserting a washer between the ad-
justing ring (2) and the crosshead (4).

Distance Piece
4.3 Distance Piece
1 2 3 8 4 5
PB_M6_0024b_03
12 11 10 9 8 7 6
Fig. 4-7 Sectional view of distance piece (typical view)
1 Crankgear end 7 Distance piece packing

2 Breather 8 Various connections
3 Buffer or purge gas to the distance 9 Inner compartment
piece packing 10 Oil drain
4 Distance piece cover 11 Oil scraping
5 Cylinder end 12 Distance piece
6 Outer compartment
Distance Piece The distance piece is the area between piston rod packing and the oil-
scraping. It separates the crankgear from the gas cylinder.
Depending on the gas properties a two-compartment distance piece or a
single-compartment distance piece is used.
All ports of the distance piece are closed by distance piece covers (4),
sealed with flat gaskets.
The distance piece is attached to the crankgear either by SUPERBOLT®
connections or by hydraulically tightened nuts.
Single-Compartment Distance Piece Type B

The Burckhardt Compression single-compartment distance piece is always
of type B (long version of distance piece). This allows to fit an oil shield on
the piston rod. In combination with the oil scraping (11), the oil shield pre-
vents oil creepage along the piston rod.

Distance Piece
Depending on the gas properties the single-compartment distance piece is

purged with nitrogen or equipped with a breather (2).
The single-compartment distance piece is provided with an oil drain.
Two-Compartment Distance Piece Type C

The Burckhardt Compression two-compartment distance pieces are al-
ways of type C (type long/long). This allows to fit an oil shield on the piston
rod. In combination with the oil scraper, the oil shield prevents oil creepage
along the piston rod.
It consists of a inner compartment (9) and a outer compartment (6). The
outer compartment is designed for an overpressure of
• 4 bar g, or
• 0.4 MPa g, or
• 4 kg/cm2 g.
The two-compartment distance piece is provided with a distance piece

packing (7).
The distance piece packing can be fed with buffer gas or purge gas to pre-
vent process gas entering the inner compartment. Additionally the outer
compartment can be purged to remove process gas.
The inner compartment is provided with an oil drain (10) and with a
breather (2).

Distance Piece
4.3.1 Oil Scraper
4
8
7 5
PB_M5_0009b_03
6
Fig. 4-8 Oil scraping (typical view)
1 Oil scraper plate 5 Wiper element

2 Cover 6 Spring plate
3 Piston rod 7 Pre oil scraper cover
4 Oil shield 8 Prewiper element
The oil scraping consists of the oil scraper plate (1), the prewiper element
(8) and the wiper elements (5). The oil scraper plate is installed in the dis-
tance piece at the crankgear side.
The prewiper element removes the largest quantity of oil from the piston
rod.
The wiper element (5) remove the remaining oil from the piston rod.
The wiper elements are kept in place by a spring plate (6) which is fixed to
the cover (2). The standard wiper elements are 3-piece plastic wiper ele-
ments. As an option, 1-piece metal wiper elements can be implemented.
The two types of oil wiper elements can be interchanged.
Scraped off oil runs back into the crankgear.
In combination with the wiper elements an oil shield (4), installed above the
wiper elements prevents oil creepage along the piston rod (3).

Distance Piece
4.3.2 Distance Piece Packing
PB_M6_0025b_01
4
Fig. 4-9 Distance piece packing (typical view)
1 Housing 3 Seal element

2 Cover 4 Side-loaded pressure ring
The distance piece packing is installed in the intermediate partition of a

two-compartment distance piece. It clearly separates the inner compart-
ment from the outer compartment.
The distance piece packing is equipped with two sets of seal rings.
These sets ensure a sealing effect in both directions. A set consists of a
seal element (3) and a side-loaded pressure ring (4). They are fixed against
each other by a positioning pin.
The distance piece packing rings are of the same type as the rings in piston
rod packing flange.
Depending on the application buffer gas or purge gas can be supplied to
this packing to prevent process gas from entering the inner compartment,
respectively the crankgear itself.

Cylinder
4.4 Cylinder
1 2 3 4 5 6 7
PB_C0_0056b_01
Fig. 4-10 Sectional view of cylinder (typical view)
1 Piston rod 5 Piston

2 Piston rod packing 6 Valve
3 Cylinder bottom 7 Cylinder cover
4 Cylinder
Cylinder In the cylinder (4), the process gas is compressed to the required pressure
by the piston (5). The number of stages depends on the total pressure ratio
between suction and final discharge pressure or the specified discharge
temperature.
Cast cylinders are mainly assembled of three parts, the cylinder bottom, the
cylinder and the cylinder cover. Depending on the necessary pressure, the
material are grey-, nodular cast iron or cast steel.
Cylinders with only two suction and discharge valves are normally made of
forged steel. In this configuration the cylinder bottom (3) is integrated in the
cylinder and no single part.
The cylinder is bolted to the distance piece.
Normally pistons are double acting i.e. in the cylinder the gas is com-
pressed on both sides of the piston.
Each cylinder is equipped with a cylinder liner which can be replaced in
case of wear. Depending on the application, the cylinder liner is made of
grey cast iron or nitrited steel. For NACE applications Ni-Resist or nitrited
steel is used, depending on the pressure and lubricated/non-lubricated cyl-
inders. For easy replacement, Burckhardt Compression does not shrink in
any cylinder liner.
Each horizontally arranged cylinder is supported by a cylinder support and
accurately aligned. The cylinder, and if necessary the cylinder cover (7), is
water cooled.

Cylinder
Spacer Ring
The spacer ring is installed between cylinder cover and cylinder. It in-
creases the top cylinder clearance and thereby reduces the volumetric ef-
ficiency. Spacer rings are mainly used to adapt capacity to the specified
volume flow.
Step Piston Cylinder The step piston cylinder is used to compress the gas in two stages which
are arranged in one line (on one crank). Each piston is single acting.
Instead of a cylinder cover there is a valve head where the suction and the
discharge valves for the upper piston are located.
Burckhardt Compression does not use tandem cylinders.
Cylinder with Tail Rod To ensure rod reversal for small pistons (and therefore lubrication of the
crosshead pin bearing) a tail rod can be installed.

Cylinder
4.4.1 Piston Rod Packing
1 2 3 4
7 6 5
PB_C5_0047b_01
Fig. 4-11 Piston rod packing with longflow cooling (typical view)
1 Packing flange 5 Pressure breaker

2 Seal element (zone C) 6 Seal elements (zone B)
3 Packing cup 7 Cooling water inlet
4 Basic bush

Cylinder
The piston rod packing is fitted to the bottom side of the cylinder and seals
the compression space. The packing is designed as a cartridge for easy
maintenance. The packing is configured by Burckhardt Compression for
every application, whether high-pressure, lubricated or non-lubricated cyl-
inders, or other special process conditions.
Longflow Cooling
To suit the various applications the piston rod packings can be built in the
following designs:
• purged or sealed (buffered)
• lubricated or unlubricated
• cooled or uncooled
PB_C5_0048b_02
Fig. 4-12 Lubricating oil flow (typical view)
1 Lubrication
1
PB_C5_0049b_03
Fig. 4-13 Leak gas and buffer gas (typical view)
1 Buffer gas
2 Leak gas

Cylinder
Piston Rod Packing Configuration

The configuration of the packing rings depends on the application of the
compressor.
The engineering is done with software Redura® sealing system.
In general, a piston rod packing is equipped with a set of seal elements
(zone C), a pressure breaker and a variable amount of seal elements (zone
B). A seal element consists of a support ring and 1 or 2 of the following ring
types:
• pressure breaker,
• seal element with radial cut,
• seal element with step bridge cut,
• seal element with tangential cut,

Cylinder
4.4.2 Piston Rod and Piston
5 6
10 11 9
PB_C1_0108b_01
8 7
Fig. 4-14 Piston details
1 – 7 Guide ring (rider ring)

2 Piston nut SUPERBOLT® 8 Piston ring
3 Hardened washer 9 Center ring
4 – 10 Piston rod
5 Upper and lower piston crown 11 Groove for oil shield
6 Piston skirt
Piston Rod The piston rod (10) is indirectly connected to the crosshead by the cross-
head coupling.
The piston rod (10) is connected to the crosshead by either a SUPER-
BOLT® nut or a hydraulic nut.
Where the piston is attached to the piston rod there is a rolled thread at its
end. The piston and piston rod guidance is provided by the forced-fed lu-
bricated crosshead, the cylinder liner and the guide rings (rider rings).

Cylinder
The piston rod is divided in two sections by a groove (11). In this groove an
oil shield is installed which prevents oil creepage further up along the piston
rod.
The standard piston rod is made of nitrided steel with a nitrided surface. In
accordance with the application, other materials are used.
Piston The standard piston is double acting i.e. it compresses the process gas as
well on its upper as on its lower piston side.
The pistons are equipped with sealing and guiding elements. The number
and type of sealing elements depends on the application.
The guide rings (rider rings) ensure the linear movement of the piston rod
together with the crosshead.
Cylinder Clearance
The cylinder clearance is the gap between piston and cylinder cover in the
Top Dead Center (TDC) respectively between piston and cylinder bottom
in the Bottom Dead Center (BDC).
The cylinder clearance is adjusted by inserting a washer between the ad-
justing ring and the crosshead.
Piston Design According to the application, different piston design types are used for pro-
cess gas compressors:
3-Piece Piston
The 3-piece piston consists of a upper and a lower piston crown (5) and a
piston skirt (6).
2-Piece Piston
The 2-piece piston consists of a upper and a lower piston half. It is fixed to
the piston rod either by means of a piston nut SUPERBOLT® or a hydraulic
piston nut.
Solid Piston
The solid piston is a one-piece piston. It is fixed to the piston rod either by
means of a piston nut SUPERBOLT® or a hydraulic piston nut.
Solid Piston with Integrated Piston Rod

The solid piston with piston rod consists of one part, that means the piston
is not screwed onto the piston rod. This kind of piston is used for small cyl-
inder diameters.
Step Piston
The step piston is a single acting piston. There are always two pistons in-
stalled in one line (on one crank). In this way the step piston is effectively
double acting and ensures the rod reversal (and therefore lubrication of the
crosshead pin bearing).

Cylinder
Step pistons can either be built as a one-piece piston, or the higher stage
piston can be fixed to the lower stage piston.
Piston Rings
The piston rings are used for sealing. Number, types and design of piston
rings are individually configured depending on the application. The engi-
neering is done with software Redura® sealing system. Combinations of
lap joint piston rings which are overlapping at the end and/or scarf joint
piston rings with bevel cut are used.
Connection between Piston Nuts

Piston Rod and Piston
The piston is fastened to the piston rod with a piston nut. There are two dif-
ferent types of piston nuts:
• piston nut SUPERBOLT®
• hydraulically tightened piston nut
Piston Nut SUPERBOLT®

This tensioning system is based on the principle of breaking down the force
for a single large screw connection into several manageable torques, using
the pressure screws threaded through the body of the piston nut. The hard-
ened washer underneath the nut provides a flat surface for the pressure
screws to push against.
In order to avoid contamination/corrosion of pressure screws in connection
with certain gases, the piston nut SUPERBOLT® has a groove to accom-
modate an O-ring.
Hydraulically Tightened Piston Nut

A piston nut for hydraulic tightening can be used.

Cylinder
4.4.3 Piston Rod Runout

Piston rod runout is always an inspection requirement during the shop as-
sembly of a new compressor to verify alignment.
On installation of the compressor in the field, the piston rod runout must
also be checked.
It is also a requirement of the normal compressor maintenance, especially
after overhaul and reassembly of the cylinders.
Runout must be checked in both horizontal and vertical directions. Check
runout at crosshead and cylinder to verify a perfect running of crosshead
and piston.
Adjustment of Piston Rod Runout

The runout can be adjusted by use of the adjusting ring at the crosshead.

Cylinder
1 2 3 4 5
PB_C1_0109b_01
Fig. 4-15 Location of piston rod and trigger sensor/Keyphasor® (schematic view)
1 Trigger sensor/Keyphasor® 4 Piston rod proximity probe

2 Crankshaft 5 Piston
3 Piston rod
Piston Rod Proximity Probe

The rod is monitored with one vertical proximity probe (4) on each piston
rod. The proximity probe detects excessive rod vibration. The guide ring
(rider ring) wear is also evaluated.
An alarm is set if the piston rod vibration exceeds a set limit. Additionally
the guide ring (rider ring) wear is evaluated based on this sensor signal. An
alarm is set to prevent damage due to contact of cylinder liner and piston.
Trigger Sensor/Keyphasor®
For detailed illustration see section 4.2.1 Drive End.
A trigger sensor /Keyphasor®(1) – installed at the drive end – reports the
top dead center to the monitoring system. In combination with other vibra-
tion sensors this allows crank angle referenced vibration analysis.

Cylinder
4.4.5 Suction Valves and Discharge Valves

The suction valves and discharge valves ensure the gas delivery from the
suction side to the discharge side of each compressor cylinder. Both valves
are self-acting and work as non-return valves.
Location and Fixation of Valves
6 5
PB_CX_0002b_01
1
Fig. 4-16 Location and fixation of valves
1 Cylinder 4 Valve cover bolt

2 Valve 5 Pressure screw
3 Lantern 6 Valve cover
The valves are fixed in the cylinder cavities by means of lanterns (3), valve
covers (6) and pressure screws (5). However, pressure screws are not
used if valves are very small or not according to API 618.
The lanterns on the suction side are shorter than those on the discharge
side.
Valve Types Burckhardt Compression has its own valves: Burckhardt Plate Valve™,
Burckhardt Poppet Valve™, and, licensed by Burckhardt Compression,
Manley® valves. The most suitable valve type will be selected in accor-
dance with process requirements and the handled gas.
The center bolt is screwed into the valve seat of the discharge valves or into
the valve guard of the suction valves. This design prevents the center bolt
from falling into the cylinder if it becomes loose.

Cylinder
The diameter of the suction valve is larger than the diameter of the dis-
charge valve. This prevents suction valves from being installed in place of
discharge valves and vice versa.
Both of these design features meet the API 618 requirements.
Burckhardt Plate Valve™
1 2 3 4
XA_CX_0076b_01
10 9 8 7 6 5
Fig. 4-17 Sectional view of Burckhardt Plate Valve™ (typical view of a suction
valve)
1 Valve seat 6 Damper plate

2 Nut 7 Valve guard
3 Center bolt 8 Lift washer
4 NORD-LOCK® washer pair 9 Cylindrical pin
5 Valve plate 10 Valve spring
The Burckhardt Plate Valve™ is of proven design. The sealing element, the
valve plate (5), has concentric rings that are joined together by radial con-
nections. The valve plate is loaded by springs (9). The lift of valve plate is
adjusted by lift washers (8).
The dynamic valve behavior can be influenced by the springs and the lift of
valve plate. However, it will be simulated for each valve and process con-
dition to yield optimal behavior and best reliability. The damper plate (6)
supports the dynamic valve behavior.
The valve plate and the damper plate are made of stainless steel. For spe-
cial applications there are non-metallic valve plates. If a non-metallic valve
plate is used, no damper plate is necessary.

Cylinder
Burckhardt Poppet Valve™
1 2 3 4
XA_CX_0078b_01
10 9 8 7 6 5
Fig. 4-18 Sectional view of a Burckhardt Poppet Valve™ (typical view of a suction
valve)
1 Valve seat 6 Spring support

2 Nut 7 Poppet
3 Center bolt 8 Spring
4 NORD-LOCK® washer pair 9 Seat plate
5 Cylindrical pin 10 Valve guard
The Burckhardt Poppet Valve™ is equipped with many individual poppets

(7) that work independently of each other. The poppets are pressed against
the seat plate (9) by springs (8) and the differential pressure to reach tight-
ness. To protect the bottom of the spring bore, the spring is supported by a
plastic spring support (6).
The Burckhardt Poppet Valve™ is designed with a separate replaceable
seat plate. However, the seat plate needs no re-machining in case of
damage to its sealing face. It can be easily replaced.
The rounded form of the poppets and the optimized flow area result in less
pressure drop and increase efficiency. They perform excellent in de-
manding applications with gases containing oil and particles. The poppets
are always made of plastic.

Cylinder
Manley® Valve, licensed by Burckhardt Compression
1 2 3 4
XA_CX_0077b_01
8 7 6 5
Fig. 4-19 Sectional view of Manley® Valve (typical view of a suction valve)
1 Valve seat 5 Valve disc

2 Nut 6 Valve guard
3 Center bolt 7 Spring button
4 NORD-LOCK® washer pair 8 Spring
The Manley® Valve is equipped with single non-metallic valve discs (5).
They work individually. Each ring is pressed against the sealing face by the
springs (8), (i.e. the spring forces) and the differential pressure. The
springs press on the valve disc via a spring button (7) made of plastic.
The valve disc design results in lower pressure drop and therefore in less
power consumption of the compressor. It also provides maximum avail-
ability for gases that contain impurities.

Cylinder
4.4.6 Capacity Control
9 1
4
7
5
PB_C3_0010b_01
Fig. 4-20 Suction valve actuator and controlled suction valve, actuator piston in full
load position by control medium pressure (typical view)
1 Spring 6 Controlled suction valve

2 Actuator piston 7 Mixture of leaking process gas
3 Pressure pin and control medium
4 Nipple 8 Control medium
5 Intermediate piece (only for smaller 9 Control medium return pipe
valves)
There are different possibilities of capacity control, e.g. by suction valve ac-
tuators, clearance pockets, rotation speed control, and bypass over 1st
stage or bypass overall.

Cylinder
If capacity is not controlled by controlled suction valves, please proceed di-

rectly to paragraphs “Rotation Speed Control” and/or “Bypass Control”.
Suction Valve Actuator and The easiest way to adjust capacity is by means of controlled suction
Controlled Suction Valves valves (6). The valves are equipped with actuators and finger unloaders to
operate the compressor at steps of 0 %, 50 % or 100 % load. Depending
on the number of 1st stage pistons, smaller steps are possible.
This type of capacity control can be applied to all three valve types.
The actuators are either operated by spring (1) or medium. Common con-
trol mediums are nitrogen, air, process gas or oil.
A spring operated actuator keeps the suction valve open at no-load when
control medium pressure is off.
The medium operated actuator, however, only keeps the suction valve
open at no-load if the actuator is pressurized.
The flow of the medium for the actuators is controlled by the control unit
which has the function of a 3-way valve. The control unit is either hand op-
erated, pneumatically operated or electrically activated.
Actuator Options
Actuators can be equipped with a visual position indicator. It is located on
top of the actuator. The indicator shows the state of the actuator and of the
valve (open or closed).
To protect actuators from getting clogged by impurities, the actuator is
equipped with a scraper ring. It is located in the nipple (4) at the lower end
of the actuator.
If process gas and control medium of the actuator have to be hermetically
separated, the pressure pin is surrounded by a diaphragm sealing.
Clearance Pocket Control Clearance pocket control is used in connection with controlled suction
valves. It is only applied in the cylinder cover and therefore only on the
upper piston side. It is used to achieve smaller steps in reducing the ca-
pacity of a compressor. The achieved steps depend on the number of 1st
stage pistons as well as on the additional clearance.
If clearance pocket control is used, capacity can be reduced by opening the
clearance pocket in the cylinder cover. Due to the larger cylinder clearance,
the volumetric efficiency is reduced.
Rotation Speed Control Capacity can also be adjusted by speed control of the main motor. This is
achieved by a frequency converter that gets its input signal from the moni-
toring of the suction or discharge pressure.
The frequency converter then gives a control signal to the main motor
which adjusts its speed accordingly.
Bypass Control A common way of reducing the capacity is either a bypass over the 1st
stage or a bypass overall.

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

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

5.1.1 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.1.2 Importance of Cleanliness . . . . . . . . . . . . . . . . . . 5-3
5.1.3 Mandatory Tightening Torques . . . . . . . . . . . . . . . 5-3
5.2 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.2.1 Safety of Transport . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.2.2 Shipping Package. . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.2.3 Shipping Condition . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.2.4 Unload Compressor . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.2.5 Check Scope of Supply . . . . . . . . . . . . . . . . . . . . 5-8
5.2.6 Store Components prior to Installation . . . . . . . . . 5-8
5.3 Dimensions, Weights, Space Requirement. . . . . . . . . . . . . 5 - 10
5.4 Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 12
5.5 Grouting Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 13
5.6 Prepare Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 15
5.7 Lifting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 18
5.7.1 Tightening Torques for Attachment Gear . . . . . . . 5 - 18
5.7.2 Lift Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 19
5.7.3 Lift Crankgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 20
5.7.4 Lift Crankgear with Distance Pieces. . . . . . . . . . . 5 - 21
5.7.5 Lift Cylinder with Distance Piece . . . . . . . . . . . . . 5 - 22
5.7.6 Lift Distance Piece . . . . . . . . . . . . . . . . . . . . . . . . 5 - 23
5.7.7 Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 24
5.7.8 Lift Plant Components . . . . . . . . . . . . . . . . . . . . . 5 - 25
5.8 Install Compressor on Foundation . . . . . . . . . . . . . . . . . . . 5 - 28
5.8.1 Place and Level Compressor . . . . . . . . . . . . . . . . 5 - 28
5.8.2 Grout Foundation Bolts. . . . . . . . . . . . . . . . . . . . . 5 - 30
5.8.3 Grout Supporting Surface of Sole Plates . . . . . . . 5 - 32
5.8.4 Tighten the Foundation Bolts . . . . . . . . . . . . . . . . 5 - 33
5.9 Check Crankshaft Deflection . . . . . . . . . . . . . . . . . . . . . . . 5 - 35
5.10 Assemble Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 36
5.10.1 Prepare Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5 - 36
5.10.2 Cylinder Support. . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 36
5.10.3 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 40
5.10.4 Install Pneumatic Barring Device . . . . . . . . . . . . . 5 - 43
5.10.5 Turn Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 43
5.10.6 Cylinder Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 44
5.11 Install Electric Motor and Coupling . . . . . . . . . . . . . . . . . . . 5 - 45
5.11.1 Place Electric Motor . . . . . . . . . . . . . . . . . . . . . . . 5 - 45
5.11.2 Align Electric Motor. . . . . . . . . . . . . . . . . . . . . . . . 5 - 47
5.11.3 Grout Foundation Bolts. . . . . . . . . . . . . . . . . . . . . 5 - 49
5.11.4 Check Crankshaft Deflection . . . . . . . . . . . . . . . . 5 - 50

5.11.5 Grout Sole Plates . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 51

5.12 Install Plant Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 52
5.12.1 Prepare Installation . . . . . . . . . . . . . . . . . . . . . . . . 5 - 52
5.12.2 Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 52
5.12.3 Oil Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 56
5.12.4 Local Instrument Board LIB . . . . . . . . . . . . . . . . . . 5 - 56
5.13 Install Pipe Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 58
5.13.1 Prepare Fabrication . . . . . . . . . . . . . . . . . . . . . . . . 5 - 58
5.13.2 Fabricate Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 59
5.13.3 Check Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 62
5.13.4 Pickle and Passivate Piping . . . . . . . . . . . . . . . . . 5 - 64
5.13.5 Sandblast Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 68
5.13.6 Recommendation for Pipe Support . . . . . . . . . . . . 5 - 68
5.13.7 Recommendation for Tube Fittings . . . . . . . . . . . . 5 - 71
5.13.8 Final Assembly of Piping . . . . . . . . . . . . . . . . . . . . 5 - 83
5.13.9 Hydrostatic Pressure Test . . . . . . . . . . . . . . . . . . . 5 - 85
5.14 Non-Return Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 85
5.15 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 85
5.15.1 Fit Grounding Wire . . . . . . . . . . . . . . . . . . . . . . . . 5 - 85
5.16 Pre-Commissioning of Compressor Plant . . . . . . . . . . . . . . 5 - 88
5.16.1 Prerequisite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 88
5.16.2 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 88
5.16.3 Crankgear Lubricating System . . . . . . . . . . . . . . . 5 - 89
5.16.4 Check Cleanliness of Gas System . . . . . . . . . . . . 5 - 90
5.16.5 Turn Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 90
5.16.6 Mechanical Test Run . . . . . . . . . . . . . . . . . . . . . . . 5 - 91
5.16.7 Blowing out the Gas Piping System . . . . . . . . . . . 5 - 92
5.16.8 Nitrogen Test Run . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 94
5.16.9 Assess Vibrations . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 94
5.16.10 Frame Vibration Measurement . . . . . . . . . . . . . . . 5 - 97
5.16.11 Inspect Compressor Plant . . . . . . . . . . . . . . . . . . . 5 - 98
5.16.12 Preserve Compressor Plant after Installation . . . . 5 - 98
5.16.13 Maintain Plant during Decommissioning . . . . . . . . 5 - 100
5.16.14 Recommission Plant . . . . . . . . . . . . . . . . . . . . . . . 5 - 100

Important Notes
5.1 Important Notes
5.1.1 Technical Support

Service life and lifetime of the compressor greatly depend on the quality of
the installation works. An insufficient foundation layout and/or non-appro-
priate assembly can lead to increased vibrations (see section 5.16.9 As-
sess Vibrations) and, therefore, to problems and/or service interruptions.
Examples of possible consequences are: bursting of pipes, excessive wear
of piston rings and guide rings (rider rings).
We strongly recommend to install the compressor under the supervision of

a specialist from Burckhardt Compression. For damage caused by nonpro-
fessional installation, Burckhardt Compression will not assume any liability.
If you have any questions concerning transport, installation or pre-commis-

sioning procedures, please consult Burckhardt Compression Services (ad-
dress see section 1.6 Contact Address).
5.1.2 Importance of Cleanliness

Prior to dispatch, all assembled parts of the compressor as well as acces-
sories coming in contact with process gas have been cleaned either in our
works or by sub-suppliers. Parts from sub-suppliers have been checked for
cleanliness.
Care must be taken that all parts and surfaces of the plant components ex-
posed to process gas are compatible with the process gas and free from
contaminants.
If any cleaning of surfaces is necessary, refer to section 10.1 Cleaning
Specification and the cleaning instructions in chapter 10 Clean and
Degrease Plant and Compressor Components.
CAUTION
Contamination of process gas!
All components coming in contact with process gas must be checked for
cleanliness prior to their installation.
 When performing overhauls or exchanging spare parts, make sure that
all significant surfaces have been cleaned according to the cleaning
specification prior to assembly or installation.
 If in doubt about cleanliness, repeat cleaning procedure.
5.1.3 Mandatory Tightening Torques

Plant For mandatory tightening torques and tightening method of bolted connec-
tions see section 8.5.1 Tightening Torques and Method.

Important Notes
Compressor For tightening methods of bolted connections see section 8.7.7 Tightening
Methods.
For mandatory tightening torques, appropriate tightening methods and ap-

plicable lubricants: see section “Compressor” in chapter 13 Appendix.

Transport
5.2 Transport
5.2.1 Safety of Transport

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

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

Transport • Pay attention to center of gravity and attachment points.
• Use proper lifting and transport devices.
• Use appropriate attachment gear.
• Attach load securely.
• Give clear signals.
DANGER
Suspended loads!
Falling loads can cause serious injury or death.
 Protect carrying ropes/straps against sharp edges.
 Do not stand beneath suspended loads.
WARNING
Plant components like coolers, pulsation dampers, separators can fall!
 Store them securely.
 Keep them from falling.
5.2.2 Shipping Package

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

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

specification please refer to the contract):
• Land packing (truck, train or airfreight) is used for door-to-door delivery
– without intermediate storage.
• Seaworthy packing is applied to goods with oversea destinations and
several handling as well as for shipments in containers from seaport to
seaport. This type of packing guarantees a protection of the material for
a period of 6 months when stored in a covered and dry place.
• Long-term packing protects the goods during a longer storage period
(> 6 month) and is only applied when specifically requested by the cus-
tomer. Protection is only guaranteed when suppliers storage instruc-
tions are strictly followed.
All items are packed in wooden boxes which provide a long-lasting seal and
protect its content against climatic and chemical influences. The package
is suitable to withstand high dynamic and static forces.
Marking of Packages The wooden boxes are marked on the two longitudinal sides with water-
proof paint. Packages requiring special handling are additionally marked
with the international standardized handling instructions:
XA_XX_0087a_02
This side up Fragile Keep dry Protect Center of Use no Sling here
goods from heat gravity hooks
Fig. 5-1 Package handling instructions
Pay attention to the instructions on the package concerning transport, han-

dling and storage.
Guarantee claims are not accepted if the package is untimely opened or
damaged as a consequences of improper handling.
Preservation Depending on the nature of the goods, different kinds of corrosion protec-
tion will be applied to compressor, plant components and spare parts sus-
ceptible to corrosion due to atmospheric or climatic influences.
Compressor
To protect the internal parts against corrosion, cylinders are flushed with
dry nitrogen prior to dispatch. VCI (Volatile Corrosion Inhibitor) mats are in-
serted into cylinder and crankgear for protection.
Tectyl® is used to protect blank compressor parts. The wax-like coating can
be removed without difficulty with any hydrocarbon compound.

Transport
Damper, Gas Cooler

To protect the internal parts against corrosion, the vessel is filled with dry
nitrogen prior to dispatch. An adhesive label with corresponding warning
sign is affixed to the vessel.
Coolant Skid, Oil Skid

To protect the internal parts against corrosion, the skid is filled with dry ni-
trogen prior to dispatch. An adhesive label with corresponding warning sign
is affixed to the skid.
WARNING
Pressurized system part!
To protect the internal parts against corrosion, some components are filled
with dry nitrogen prior to dispatch.
 Take notice of the corresponding warning sign.
 Depressurize system part before you start installation work.
Components, Spare Parts

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

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

Please proceed according to sections 5.2.1 Safety of Transport and 5.7
Lifting Procedure.

Transport
5.2.5 Check Scope of Supply

The scope of supply is specified in the sales documents and packing list. If
installation takes place right away, check the delivery for completeness im-
mediately after receiving of the goods. Any transport damage and/or
missing parts must be reported immediately. For preservation reasons, do
not open long-term packages as long as you do not start installation work.
As soon as the wooden boxes are opened to check the individual items,
compressor components and plant components must be stored in a orderly
manner in a dry place, protected from environmental influences (store-
house).
CAUTION
Corrosion or contamination due to improper storage after opening
the consignment.
 Do not check delivery in long-term packages beforehand. Wait until the
material is used.
 For intermediate storage of opened consignment consult Burckhardt
Compression Services (address see section 1.6 Contact Address) con-
cerning protective measures to be taken.
5.2.6 Store Components prior to Installation

Storage Guarantee for Our storage guarantee for this contract is limited to a period of 6 months
Unopened Package after delivery (ex works), providing the necessary measures have been
taken to avoid the entry of moisture and water during transport and storage.
Upon expiration of this time limit:
• Open the wooden box and check preservation state of the complete
consignment.
• If necessary, clean or renew the preservation.
Opened or Damaged Guarantee claims for the preservation are not accepted if the package is
Package opened for custom purposes during transport or at construction site, or if it
is damaged due to improper handling. In this case, we are not liable for
damaged parts. This also applies to any damage that may occur during the
period of guarantee, as a result of such damaged parts.
We request customers to check opened and/or damaged consignments as
early as possible and to immediately report to us any damage observed.
This will enable us to make suggestions to the customer concerning further
procedure to be adopted.

Transport
Intermediate Storage If the compressor plant is not installed immediately after transport, all com-
ponents must be stored in a dry place, protected from environmental influ-
ences (storehouse).
If this is not possible, the packed

goods must be protected against
water, namely by means of storage
under a roof.
The wooden boxes must also be
protected against the entry of water
from below, i.e. by placing them on
wooden beams.
XA_XX_0008a_02
Fig. 5-2 Intermediate storage
Components must be stored safely. They must not tip over or topple down
when jolted by vehicles or hooked onto by hanging crane cables.
CAUTION
Corrosion due to improper preservation during long-term storage.
 For long-term storage consult Burckhardt Compression Services (ad-
dress see section 1.6 Contact Address) concerning protective mea-
sures to be taken.
After the guarantee period is expired, inspect the stored parts in regular in-
tervals and in accordance with section 5.2.2 Shipping Package. Replace
moisture absorbent agent if necessary.
with dry nitrogen prior to dispatch. If these plant components are stored for
a longer time, pressure must be controlled and nitrogen filled up if neces-
sary.
DANGER
Health hazard!
Risk of suffocation! Nitrogen can leak from plant components such
as coolers, dampers, etc. into the storage rooms and displace the ox-
ygen in the atmosphere. At high concentrations, unconsciousness or
death may occur.
 Before entering the area, check for oxygen-deficient atmospheres.
 Make sure there is sufficient circulation of fresh air.
symptoms.

Dimensions, Weights, Space Requirement
5.3 Dimensions, Weights, Space Requirement
Compressor Dimensions
Length 7942 mm
Width 1809 mm
Height 2040 mm
Electric Motor Dimensions
Length 5073 mm
Width 2912 mm
Height 3250 mm
Weights (Approximative)
Compressor complete (without flywheel) 20340 kg

Electric motor 25425 kg
Flywheel 3350 kg
Crankgear complete 5200 kg
Distance piece 1020 kg
st
Cylinder 1 stage (inclusive covers, valves and piston rod 6550 kg
packing)
Cylinder cover 1st stage 487 kg
st
Piston with piston rod 1 stage 460 kg
st
Piston rod packing 1 stage 97 kg
Crosshead 120 kg
Connecting rod 156 kg
Crankshaft 731 kg

Dimensions, Weights, Space Requirement
Space Requirements
1 2 3
1 4
PB_XX_0038b_02
F
Fig. 5-3 Space requirements
1 Crankgear
2 Cylinder
3 Piston
4 Flywheel
W For piston removal 9000 mm

F For flywheel removal 1120 mm
D Diameter of flywheel 2040 mm

Foundation
5.4 Foundation
The Basics about • The pouring of the foundation must be accomplished according to the
Foundation foundation plan of Burckhardt Compression.
• The foundation must be resistant to the lubricating oils, to coolant and
to process gases of the compressor.
• Prevent surfaces from infiltration by oil or coolant.
• The foundation must be reinforced and casted in one pouring.
• Compressor and electric motor are to be anchored to the foundation

with foundation bolts.
• The foundation layout must be evaluated and dimensions determined
by a civil engineer, who is also responsible for reinforcement. The foun-
dation must have adequate distance from buildings and other founda-
tions.
• Vibration-isolating procedures may only be carried out after notifying
Burckhardt Compression. Also contact us if bad ground conditions
exist. Acceptable vibration values are stated on the foundation plan,
see section “Foundation” in chapter 13 Appendix.
Foundation Block
1 3
XA_XX_0099b_02
30°
30°
Fig. 5-4 Distance from foundation block to building (recommended solution)
1 Detail, correct design

2 Joint, 20 mm
3 Detail, incorrect design
1. Separate the compressor foundation block from all parts of the building
by a joint. Seal joints with elastic material.
2. Do not arrange building parts close to the compressor foundation block
(see Fig. 5-4, detail 1 for correct design). Non-compliance may result in
transfer of vibrations onto the building. Pay attention to building’s nat-
ural frequencies. Consider compressor speed.
3. Do not arrange building supports or bases close-by or beneath the
compressor foundation block (Fig. 5-4, detail (3) shows the incorrect
design).

Grouting Material
Foundation Bolt Holes
We recommend to line foundation bolt holes for compressor and motor ex-
clusively with corrugated pipes as they ensure an optimal, pulling-proof
connection of the foundation bolt in the foundation (see Fig. 5-6, version A).
 Sufficiently fasten the corrugated pipes before pouring concrete in the
appropriate positions.
 Make sure that their positions do not change during pouring of con-
crete.
Prerequisite for • The valid reference points/center lines must be marked on the founda-
Installation tion by the construction supervision (customer side).
• Before installation, check the dimensional accuracy of the foundation
according to the foundation plan of Burckhardt Compression.
Grouting Surfaces
• The surface of the foundation as well as the foundation bolt grout
pockets must be roughened up with suitable tools for the best binding
effect with the concrete.
• The surface of the foundation as well as the grout pockets for the foun-
dation bolts must be clean and absolutely free of residual matter like oil,
wood, plastics, etc. Any material used for foundation bolt grout pockets
must be removed before the concrete has set.
5.5 Grouting Material

Requirements For grouting work, we recommend to use grouting material based on ce-
ment or epoxy.
The grouting material must fulfill the following requirements:
• Minimum resistance to pressure = 60 N/mm2.
• Flow properties: liquid and capable of flowing.
• Free of shrinkage and swelling.
• No ferritic additives.
• The coefficient of expansion must correspond to that one of the con-
crete and should be preferably low.
Product Recommendation The following table of various products represents a recommendation of

non-shrinking grouts used by Burckhardt Compression.
Manufacturer Product Compressor installation Epoxy Cement

based based
ITW Philadelphia Resins Chockfast® Red On concrete foundation 
ITW Philadelphia Resins Chockfast® Black Skid mounted 

Prepare Installation
Manufacturer Product Compressor installation Epoxy Cement

based based
ITW Philadelphia Resins Chockfast® Orange Marine applicationa 
BASF Construction MASTERFLOW 648 ® b
On concrete foundation 
Chemicals PCI Repaflow EP Plus
BASF Construction MASTERFLOW® 928 Foundation bolts and ac- 
Chemicals MASTERFLOW 870 ® cessories
PCI Repaflow
a.Chockfast® Orange is approved or accepted for its intended marine use by American Bureau of Shipping. Lloyd‘s
Register, Bureau Veritas, Det Norske Veritas, Germanischer Lloyd and most other major regulatory agencies worldwide.
b. MASTERFLOW products may in certain regions be on the market under different product names.
Tab. 5-1 Grouting material product information
For grouting of the compressor’s supporting surface, Burckhardt Compres-

sion recommends to use one of the in Tab. 5-1 listed epoxy grouting mate-
rials.
If another grouting material than listed in Tab. 5-1 will be used, please con-
sult your local civil engineer for support.
Handling of Grouting Consider following points:

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

ences and/or infiltration of oil, we recommend the application of an oil-re-
sistant coating.
5.6 Prepare Installation

Prepare Jackscrews With compressors of type horizontal it is not necessary to remove the jack-
screws after grouting.

1. To avoid clogging, lubricate the

threads of the jackscrews be-
fore setting them, using
MOLYKOTE® G-N Plus or ball-
bearing grease.
2. For each foundation bolt, use a
jackscrew and adjust to re-
quired height. Adjustment range
is 12 to 22 mm, depending on
jackscrew type.
3. For additional height adjust-
ment, add shims.
Fig. 5-5 Jackscrew
4. Level the jackscrews accurately. It must be ensured, that the jack-

screws are kept absolutely horizontal in all directions by using a preci-
sion spirit level.
5. Use mortar for temporary fixation of the jackscrews.
Prepare Sole Plates 6. Clean the bottom side of sole plates, getting into contact with the
(Compressor) grouting material. The supporting surface must be clean and absolutely
free of oil, rust, paint and grease. The epoxy grouting material shall
stick onto the sole plates.
7. Protect the surface of the crankgear and the sole plates which are not
getting in contact with the epoxy grouting material.
Prepare Sole Plates 8. Clean the bottom side of sole plates, getting into contact with the
(Motor) grouting material. The supporting surface must be clean and absolutely
free of oil, rust, paint and grease. The epoxy grouting material shall
stick onto the sole plates.
9. Protect the surface of the motor and the sole plates which are not get-
ting in contact with the epoxy grouting material.
Prepare Foundation Bolts 10. Insulate the foundation bolts at least for 1/3 length from the top with
thick tape or using an insulating tube of foam material (free expansion
length of foundation bolt).
11. Center the foundation bolts in the through holes of the compressor
using cardboard or sealing material. This procedure enables a later re-
adjustment of the compressor.

A B
1
1/3
1/3
3
2/3
2/3
6
XA_XX_0036b_03
Fig. 5-6 Prepare foundation bolts (typical view)
A Version with corrugated pipe (pre- 3 Grout pocket for foundation bolt
ferred) 4 Foundation bolt
B Standard version 5 Foundation
1 Cardboard or sealing material 6 Corrugated pipe
2 Insulation/tape
CAUTION
Insufficient alignment of foundation bolts
We urgently advise against casting-in foundation bolts before setting of
compressor!
 Nevertheless, if this procedure is still desired (necessary), make sure
that the foundation bolts are fixed by a jig in the correct position.
 When pouring the foundation, do not offset the foundation bolts.
Specify Encasing 12. Before placing the compressor on the foundation, specify how to en-
case the supporting surfaces to be poured. Jackscrews can be cast-in.
Specify the encasing accordingly.
Specify Encasing (Motor) 13. Before placing the motor on the foundation, specify how to encase the
supporting surfaces to be poured. Jackscrews can be cast-in.
CAUTION
Stress cracks in the epoxy grouting material due to thermal expan-
sion of the compressor.
 Provide expansion joints every 1.5 meter.
Prepare Foundation 14. Coat the foundation surface with oil protective coating (1).

1 2 3
PA_XX_0002b_01
Fig. 5-7 Protective coating (typical view)
1 Oil protective coating

2 Grout pocket for foundation bolt
3 Foundation

Lifting Procedure
5.7 Lifting Procedure
This section describes also the lifting procedure for cylinder and distance
piece – despite the fact that the compressor is transported completely as-
sembled – to use for a later dismantling of the compressor e.g. for mainte-
nance reason.
5.7.1 Tightening Torques for Attachment Gear

Lifting Rings
(RUD®: VLBG) Size of Carrying Tightening
thread capacity torque
M12 1.0 t 100 Nm
M16 1.5 t 150 Nm
M20 2.5 t 250 Nm
RUD VLBG
M24 4.0 t 400 Nm
XA_T9_0025c_01
RUD VLBG
M27 4.0 t 400 Nm
M30 5.0 t 500 Nm
M36 7.0 t 700 Nm
M42 15.0 t 1500 Nm
Tab. 5-2 Lifting rings
The lifting rings remain fitted; do not remove them after use. Please note
the transport and lifting specification in the following sections.

Lifting Procedure
5.7.2 Lift Compressor

Take care to avoid any damage; please refer also to section 5.2.1 Safety of
Transport.
DANGER
Suspended loads!
 Lift compressor only in the correct manner as described and illustrated
in this Instruction Manual.
 Check correct tightening torque for attachment gear.
 Make sure that the carrying capacity of the hoist corresponds at least
to the heaviest individual component weight.
°
45
n.
mi
Fig. 5-8 Transport and lifting of compressor on transport frame PB_T9_0173b_01
max. 90°
PB_T9_0051a_01
Fig. 5-9 Transport and lifting of compressor

Lifting Procedure
5.7.3 Lift Crankgear

Transport.
DANGER
Suspended loads!
 Lift crankgear only in the correct manner as described and illustrated in
this Instruction Manual.
PB_T9_0149a_01
Fig. 5-10 Transport and lifting of crankgear

Lifting Procedure
5.7.4 Lift Crankgear with Distance Pieces

Transport.
DANGER
Suspended loads!
 Lift crankgear with distance piece only in the correct manner as de-
scribed and illustrated in this Instruction Manual.
to the weight of the heaviest individual component.
min. 45°
PB_T9_0180b_02
Fig. 5-11 Transport and lifting of crankgear with distance pieces

Lifting Procedure
5.7.5 Lift Cylinder with Distance Piece

Transport.
DANGER
Suspended loads!
 Lift cylinder with distance piece only in the correct manner as described
and illustrated in this Instruction Manual.
PB_T9_0133a_03
Fig. 5-12 Transport and lifting of cylinder with distance piece

Lifting Procedure
5.7.6 Lift Distance Piece
This section describes also the lifting procedure for distance piece – de-
spite the fact that the compressor is transported completely assembled or
cylinder and distance piece are pre-assembled – to use for a later disman-
tling of the compressor e.g. for maintenance reasons.
Transport.
DANGER
Suspended loads!
 Lift distance piece only in the correct manner as described and illus-
trated in this Instruction Manual.
m
in.
45
°
PB_T9_0005a_01
Fig. 5-13 Transport and lifting of distance piece

Lifting Procedure
5.7.7 Lift Cylinder
This section describes also the lifting procedure for cylinder – despite the
fact that the compressor is transported completely assembled or cylinder
and distance piece are pre-assembled – to use for a later dismantling of the
compressor e.g. for maintenance reasons.
Transport.
DANGER
Suspended loads!
 Lift cylinder only in the correct manner as described and illustrated in
PB_T9_0154a_01
Fig. 5-14 Transport and lifting of cylinder

Lifting Procedure
5.7.8 Lift Plant Components

Transport.
DANGER
Suspended loads!
 Lift plant components only in the correct manner as described and illus-
trated in this Instruction Manual.
Following illustrations exemplify how to transport and lift plant components.

Consider them for applicable plant components.
Lift plant components and use carrying ropes according to the relevant di-
rective (angle must be > 45°).
Example for Damper

(Typical View)
Fig. 5-15 Transport and lifting of a damper (horizontal design)

Lifting Procedure
Example for Auxiliary Skid Chose suitable lifting method according to design, weight and dimension of
(Typical View) auxiliary skid (see Fig. 5-16 and Fig. 5-17).
Fig. 5-16 Transport and lifting of an auxiliary skid, using spreader frame

Lifting Procedure
Fig. 5-17 Transport and lifting of an auxiliary skid, using spreader beam

Install Compressor on Foundation
5.8 Install Compressor on Foundation
The final installation procedure of the compressor on to the foundation is

defined at site by our field service engineer according to site conditions.
The following general description of the installation of the compressor is
only a guide line.
5.8.1 Place and Level Compressor

Check Preparation 1. Check preparations according to section 5.6 Prepare Installation:
• Sufficient distance between jackscrews and foundation bolts.
• The supporting surface must be clean and absolutely free of oil,
rust, paint and grease. The epoxy grouting material shall stick onto
the sole plates.
1 2 3
PA_XX_0002c_01
Fig. 5-18 Place jackscrews (typical view)
1 Oil protective coating

2 Grout pocket for foundation bolt
3 Foundation
4 Jackscrew
Transport and Lifting of For transport and lifting of compressor, take care to avoid any damage;
Compressor please refer to section 5.2.1 Safety of Transport.
2. Attach carrying ropes to the compressor in the safe manner as illus-

trated in 5.7.2 Lift Compressor.

DANGER
Suspended loads!
 Lift compressor only in the correct manner as described and illustrated
in this Instruction Manual.
Place Compressor
2
3
4
PA_XX_0027c_01
11 10 9 8 7
Fig. 5-19 Placing compressor onto foundation
1 Crankgear 7 Foundation bolt

2 Protective cap 8 Oil protective coating
3 SUPERBOLT® tensioner 9 Grout pocket for foundation bolt
4 Washer 10 Fixation bolt (crankgear–sole
5 Sole plate plate)
6 Foundation 11 Jackscrew
3. Lift the compressor.

4. Fix the sole plates with the fixing screws to the compressor.
5. Fix the foundation bolts with temporary nuts to the compressor.
6. Place the compressor including its sole plates and foundation bolts on
the jackscrews, located between the grout pockets for the foundation
bolt.

7. Center the foundation bolts in the holes of the sole plates by using a
cardboard or sealing material.
 You are able to readjust the sole plates later.
Level Compressor 8. The compressor must be leveled out exactly in length, cross and diag-
onal direction using a precision spirit level. Place the spirit level on top
of a machined surface of the crankgear. Do not place the spirit level on
top of a cylinder.
The display accuracy (scale lines) of the spirit level must show at least
0.2 mm/m. The horizontal misalignment of the compressor must not ex-
ceed 0.1mm/m, that means a deflection of half distance between two
scale lines on spirit level.
9. Make sure that all jackscrews are evenly loaded. Check this on the
basis of the resistance on the spanner and with light hammering di-
rectly on the jackscrews.
10. Level the compressor lengthwise, crosswise and in diagonal direction

by turning the jackscrews using a spanner.
11. Carefully check the aligned crankgear and foundation bolts.
5.8.2 Grout Foundation Bolts
1. Before grouting the foundation bolts of the compressor, once again

check the center line of the electric motor with respect to the foundation
bolt grout pockets, to ensure proper motor setting.
2. Make sure that the foundation bolts are fixed in correct position. When
pouring, do not offset the foundation bolts.

A B
XA_XX_0036c_03
Fig. 5-20 Grout foundation bolts (typical view)
1 Non-shrinking grouting material

2 Foundation bolt
3 Foundation
Proceed with grouting of supporting surface only after the grouting material
of the foundation bolts has hardened. Please refer to manufacturer’s in-
structions.

5.8.3 Grout Supporting Surface of Sole Plates
For grouting of the compressor’s supporting surface, Burckhardt Compres-

sion recommends to use one of the in Tab. 5-1 listed epoxy grouting mate-
rials.
CAUTION
Inappropriate use of grouting material can lead to deformation of
crankgear!
 Strictly follow grout manufacturer’s instructions (e.g. layer thickness,
treatment temperature etc.).
 Grouting must be carried out or supervised by an authorized company.
8
1
7
PB_XX_0101b_01
6
4
5
Fig. 5-21 Grouting of sole plates (typical view)
1 Crankgear 5 Foundation
2 – 6 Foundation bolt
3 Open space 7 Epoxy grouting material
4 Non-shrinking or epoxy grouting ma- 8 Sole plate
terial
3. With respect to the grouting manufacturer’s instruction, grout the sup-

porting surface across the entire length.

CAUTION
Stress cracks in the epoxy grouting material due to thermal expan-
sion of the compressor.
 Provide expansion joints if the entire length exceeds 1.5 meter.
PB_XX_0018b_01
1
5 2
3
4
Fig. 5-22 Grouted supporting surface without expansion joint
1 Crankgear 4 Foundation
2 Sole plate 5 Open space
3 Epoxy grouting material
5.8.4 Tighten the Foundation Bolts
CAUTION
Deformation of crankgear due to premature pressure load of grouting
material.
 Tighten foundation bolts only after the grouting material has hardened
or has at least reached a resistance to pressure of 40 N/mm2.
1. Loosen the SUPERBOLT® tensioner of the foundation bolts.

2. Check the crankgear for perfect seating.
3. Slightly grease the threads of the foundation bolts, pressure screws
and seating faces of SUPERBOLT® tensioner by using MOLYKOTE®
G-N Plus.
You can use a number of commercially available graphite lubricant com-

pounds for re-lubrication in the field.
Nickel pastes are less suitable, copper bearing compounds have not per-
formed well as pressure screw lubricants.

4. Place dial gauge always next to the foundation bolt which has to be
tightened (see Fig. 5-23).
5. Start tightening in the middle of the crankgear and thereafter crosswise.
6. Tighten the SUPERBOLT® tensioners according to section 8.7.8 Ten-
sioner SUPERBOLT®.
7. If the sag of the crankgear exceeds 0.05 mm during tightening, the
crankgear must be releveled.
8. Fill half of the SUPERBOLT® protective cap with grease and put it over
the SUPERBOLT®.
PB_XX_0003b_01
Fig. 5-23 Tighten foundation bolt
1 Protective cap 5 Crankgear

2 Pressure screw 6 Foundation bolt
3 SUPERBOLT® tensioner 7 Sole plate
4 Hardened washer 8 Dial gauge
Readjust the Crankgear Releveling is only necessary, if the crankgear was stressed during tight-
ening the foundation bolts.

Check Crankshaft Deflection
Proceed as follows to readjust the crankgear:

1. Loosen the SUPERBOLT® tensioners for the foundation bolts ac-
cording to section 8.7.8 Tensioner SUPERBOLT®.
2. Lift the compressor by using a hydraulic jack or according to section 5.7

Lifting Procedure.
3. Add or remove shims.
4. Lower the compressor.
5. Finally tighten the SUPERBOLT® tensioners with the mandatory tight-

ening torque.
6. Check the leveling again.
7. Repeat this procedure, if necessary.
5.9 Check Crankshaft Deflection
1 2
XA_M0_0009b_01
y
4 3
Fig. 5-24 Measure crankshaft deflection
1 Crank in 12 o’clock position 4 Dial indicator

2 Crankshaft y Measuring distance (y) in mm
3 Measuring position of dial indicator
Prerequisites • Set the dial indicator (4) always at the same position (y), at the end of
the crank (opposite crankshaft journal).
• The crankshaft must be properly supported by its bearings (check with
a feeler gauge).
• Connecting rod on the drive end must be dismounted.
• Use a dial indicator with an accuracy of 0.01 mm.

Assemble Compressor
Measuring Procedure 1. Measure the crankshaft deflection on the drive end crank in 4 positions
according to Fig. 5-24. Record all measured values as well as the mea-
suring position (y) – i.e. offset from crankshaft journal – of the dial indi-
cator.
 The measured deflection must not exceed 0.01 mm.
5.10 Assemble Compressor
5.10.1 Prepare Assembly

Remove VCI Mats To protect the internal parts against corrosion, VCI (Volatile Corrosion In-
hibitor) mats are inserted into cylinder and crankgear for protection.
1. Remove all VCI mats from crankgear and cylinder.
5.10.2 Cylinder Support

Special Tools Spirit level, combination spanners
Installation
1
3
6 5 4
PB_C0_0031b_02
7 8 9
Fig. 5-25 Cylinder support
1 Cylinder 6 Fixation bolt (support–plate)

2 Fixation bolt (support–cylinder) 7 Shims
3 Cylinder support 8 Plate
4 Foundation bolt 9 Grout
5 Adjusting screw

Assemble Compressor
Preliminary Installation
1. Position the foundation bolt (4) and the plate (8) temporary.
Alignment of Cylinder
1. Remove cylinder cover.

2. Check the alignment of the cylinder (liner) and the crosshead bore by
using a spirit level (see Fig. 5-26).
Fig. 5-26 Check cylinder alignment with a spirit level

Assemble Compressor
PB_C0_0008a_01
Fig. 5-27 Temporary support with wood

PB_C0_0007a_01
Fig. 5-28 Temporary support with pipe and jackscrew

Assemble Compressor
3. Adjust the cylinder temporarily by fixing an temporary support (see

Fig. 5-27 and Fig. 5-28).
4. Arrange the shims (7) on both sides of the foundation bolts.
5. Tighten the fixation bolts (6).
Grout Foundation Bolts and Base Plate
6. Grout the foundation bolts according to 5.8.2 Grout Foundation Bolts.
A B
XA_XX_0036c_03
Fig. 5-29 Grout foundation bolts
1 Non-shrinking or epoxy grouting material

2 Foundation bolt
3 Foundation
7. Prepare encasing.
8. Make sure that the foundation bolts are held in correct position. When
grouting, do not offset the foundation bolts.
After grouting the foundation bolts, wait at least one day, then chip away
the grout on the top of the foundation bolt grout pockets (approximately 10
mm), as this grout is of bad quality.
9. Grout the base plate according to 5.8.3 Grout Supporting Surface of

Sole Plates.
10. Wait until the grouting has hardened.
CAUTION
Deformation of crankgear due to premature pressure load of grouting
material.
 Tighten foundation bolts only after the grouting material has hardened
or has at least reached a resistance to pressure of 40 N/mm2.

Assemble Compressor
5.10.3 Flywheel
Special Tools none
Transport and Lifting of For transport and lifting of flywheel, take care to avoid any damage; please
Flywheel refer to section 5.2.1 Safety of Transport.
DANGER
Suspended loads!
 Lift flywheel only in the correct manner as described and illustrated in
 Do not stand underneath suspended loads.
PA_L1_0002a_01
Fig. 5-30 Transport and lifting of flywheel
Assembly 1. Remove Tectyl® from crankshaft and from flywheel hub.

Tectyl® is used to protect blank compressor parts. The wax-like coating
can be removed without difficulty with any hydrocarbon.
2. Check contact surfaces on flywheel as well as on crankshaft for pos-
sible damage, unevenness or corrosion. Eliminate any unevenness
using a smooth file or a scraper.
3. Use a light oil with corrosion inhibitor to slightly lubricate flywheel hub
and crankshaft.
4. Attach carrying ropes in the safe manner as illustrated in this section
and lift flywheel.

Assemble Compressor
PB_L1_0004b_02
1 2 3
Fig. 5-31 Flywheel
1 Allen screw
2 Flywheel
3 Crankshaft flange
5. Carefully slide the flywheel (2) onto the crankshaft flange (3).
6. Slightly tighten the two Allen screws (1).
7. Align the holes for the coupling bolts.
8. Tighten the Allen screws firmly.
9. Tighten the coupling bolts (4) firmly.
Required Checks 10. Check radial and face runout as illustrated in Fig. 5-32.

Assemble Compressor
1 2 3 4
PA_L1_0001b_01
Fig. 5-32 Radial and face runout
1 Flywheel
2 Crankshaft
3 Dial gauge
4 Measuring head
Tolerance of radial and face runout must not exceed 0.04 mm.
When checking the face runout, push the crankshaft to the drive end side
up to its stop. The axial clearance of the crankshaft must be eliminated.

Assemble Compressor
5.10.4 Install Pneumatic Barring Device
PB_L1_0049b_01
1 Flywheel
2 Pawl
3 Proximity probe
4 Barring device
Install Barring Device 1. Install barring device according to manufacturer’s instructions.

• For grouting of foundation bolts see section 5.8.2 Grout Foundation
Bolts.
• For positioning and grouting the supporting surface of barring de-
vice, see section “Foundation” in chapter 13 Appendix.
For grouting of the supporting surface, Burckhardt Compression recom-

mends to use one of the epoxy grouting materials listed in Tab. 5-1.
2. Tighten the foundation bolts with the mandatory tightening torque, see
section “Compressor” in chapter 13 Appendix.
5.10.5 Turn Flywheel
1. Check compressor assembly by turning the flywheel min. 1 rotation by

means of the barring device in running direction.
2. Verify that everything is in proper mechanical condition.
3. While turning the flywheel, lavishly smear the piston rods below the oil
scrapers with the operating oil of the compressor.

Assemble Compressor
5.10.6 Cylinder Cover

Installation For detailed description see section 9.8 Cylinder Cover.
Measure Cylinder Proceed according to section 8.7.3 Cylinder Clearance Measurement.

Clearance

Install Electric Motor and Coupling
5.11 Install Electric Motor and Coupling
Installation of electrical parts must be performed by professionals.

Please refer to manufacturer’s instructions.
The electric motor is coupled directly (rigid coupling) with the compressor.
The alignment of the electric motor to the compressor must be done care-
fully and accurately. You have to connect the crank- and motorshaft, so that
neither of them is stressed and the axial clearance is distributed. Thus both
shafts attain free thermal expansion. The axial float of the motor shaft is
measured at a suitable point and the end positions are marked. Thus the
clearance distribution may be checked after coupling with the crankshaft.
5.11.1 Place Electric Motor

Check Runout Before the electric motor can be placed, check the runout of motor coupling
flange:
When checking the face runout, make sure to push the motor shaft to one
side up to its stop. The axial clearance of the motor shaft must be elimi-
nated.
 Maximum runout shown on dial gauge should not exceed 0.04 mm.
1. Make sure that the motor is kept absolutely horizontal in all directions
by using a precision spirit level.
2. Measure runout at the largest diameter of the coupling flange.

1 2 3
LA_L1_0004b_01
Fig. 5-34 Radial- and face runout
1 Dial gauge
2 Motor shaft
3 Coupling flange
Install Motor on Sole Plates
DANGER
Falling machine parts!
Serious injury or death
 The electric motor may only be lifted according to manufacturer’s in-
structions.
 The carrying capacity of the hoist must at least correspond to the
heaviest individual component weight.
 Protect carrying ropes against sharp edges!
3. To enable vertical realignment of the electric motor (after maintenance/

overhaul), insert thin stainless steel shims between the sole plates and
the support surfaces of the electric motor. These shims should have a
thickness of about 3 mm in total.
4. Clean the bottom side of sole plates, which comes into contact with the
grouting material. The supporting surface must be clean and absolutely
free of oil, rust, paint and grease. The epoxy grouting material must
stick to the sole plates.

5. Place the motor onto the sole plates.

6. Fix the sole plates to the motor.
Place Electric Motor
DANGER
 The electric motor may only be lifted according to manufacturer’s in-
structions.
7. In the same way as for the compressor, place electric motor including
sole plates and shims on four jackscrews, located between the founda-
tion bolts.
8. Approximately line up the electric motor.
5.11.2 Align Electric Motor
For electric motor installation and operating instructions refer to manufac-

turer’s instructions.
For electric motor drawings see section “Drive System” in chapter 13 Ap-
pendix.
Clean Coupling Parts 1. Prior to starting the assembly, the coupling parts must be cleaned thor-
oughly.
Alignment The alignment of the electric motor to the compressor must be done care-
fully and accurately.
In general, the magnetic/mechanical center of the electric motor is marked

on the motor shaft in respect to the housing.
 The permissible axial displacement of the motor shaft must be taken
into account during installation of the electric motor.
 For applicable crankshaft clearances: see “Compressor” in chapter 13
Appendix.
1. Measure crankshaft deflection on the crank at the drive end (flywheel

in a hanging position) with a dial indicator (see 5.9 Check Crankshaft
Deflection.

2. Adjust the dial indicator for the positions 3 o’clock and 9 o’clock to zero
(0).
3. Bring crank into 6 o’clock position by turning the flywheel. The position
of the dial indicator is now in 6 o’clock position.
4. In consideration of above taken readings, jack-up flywheel to eliminate

its sag.
5. Lift the flywheel, until dial indicator shows zero (0).
LA_L1_0027b_01
1 2 3 4
Fig. 5-35 Jack-up flywheel
1 Crankgear
2 Flywheel
3 Jack
4 Motor
6. Remove the jack.

7. Take a note of sag and angular movement.
8. Check the contact surfaces on the motorshaft (flange) as well as on the
flywheel for possible damage or unevenness.
9. Correct any unevenness by using a fine file or a scraper.
10. Check the bores of the coupling bolts for cleanliness and for damages.
 The bores of the coupling bolt are absolutely clean and free of any
damages.
11. Position the electric motor together with the sole plates on the leveling
spindles, which are located between the foundation bolts.
12. In relation to the flywheel, carefully align the motorshaft, by means of a
dial gauge, attached to the flywheel.
13. Rotate the flywheel.
14. Align the motor.

15. Consider the sag and angular movement and correct it, if necessary.
16. Lift the flywheel according to step 5.
17. Align the bores for the coupling bolts.
18. Remove the shaft-locking device and other devices provided for the
transportation safety.
When checking the face runout, make sure to push the motorshaft to one
side up to its stop. The axial clearance of the motorshaft must be elimi-
nated.
 Maximum runout shown on dial gauge shall not exceed 0.04 mm.
In general, the magnetic/mechanical center of the electric motor is marked

on the motor shaft in respect to the housing.
 The permissible axial displacement of the motor shaft must be taken
into account during installation of the machinery.
 For applicable crankshaft clearances: see section “Compressor” in
5.11.3 Grout Foundation Bolts

The top 1/3 of the foundation bolts should be wrapped with tape to prevent
binding of the grout with the foundation bolts.
Proceed as specified in section 5.8.2 Grout Foundation Bolts.
Make quite sure that no air bubbles are trapped within the poured-in con-
crete. To permit a possible realignment of the electric motor at a later date,
the foundation bolts must have equal clearance around them where they
pass through the motor frame during pouring of the concrete.
After you will have tightened the foundation bolts, check the crankshaft de-
flection once more and, if necessary, realign the electric motor with the sole
plates.

5.11.4 Check Crankshaft Deflection
1 2
XA_M0_0009b_01
y
4 3

a feeler gauge).
cator.
 For maximum permissible deflection on the dial indicator for a complete

turn of crankshaft see Fig. 5-37.

CD/mm
0.07
0.06
0.05
0.04
0.03
0.02
PA_M0_0001b_1
0.01
y/mm
0 100 200 300 400
Fig. 5-37 Maximum permissible crankshaft deflection
CD Crankshaft deflection in mm
y Measuring distance (y) in mm
2. If the deflection exceeds this limit, consult Burckhardt Compression

Services; address see section 1.6 Contact Address.
5.11.5 Grout Sole Plates

In general, proceed according to section , as for the compressor. Burck-
hardt Compression recommends to use an epoxy resin to grout the com-
pressor supporting surface (see Tab. 5-1).
CAUTION
Observe the corresponding product information (e.g. layer thickness, treat-
ment temperature etc.) or hire a specialized company.
Those surfaces of the sole plates which are getting into contact with the
sealing compound must be clean and absolutely free of oil, rust, paint and
grease. The epoxy resin sealing compound shall stick onto the sole plates.
With respect to manufacturer’s instruction, grout the supporting surface
across the entire length.
CAUTION
Tension cracks in the epoxy grout!
Thermal expansion of the sole plates may lead to tension cracks in the
epoxy grout.
 Provide expansion joints if the entire length exceeds 1.5 meter.
Thus avoiding that tension cracks in the epoxy grout develop due to
thermal expansion of the sole plates.

Install Plant Components
One week after grouting, nuts of the foundation bolts should be loosened.
Check the motor for perfect seating and finally retighten nuts of foundation
bolts. The thread of the foundation bolts and the seating faces of the nuts
must be slightly greased.
After tightening the foundation bolts, check the crankshaft deflection once
more and, if necessary, realign the electric motor.
5.12 Install Plant Components
5.12.1 Prepare Installation

Plant accessories (e.g. gas coolers and pulsation dampers) are normally
assembled after the compressor has been installed. Finally, the piping is
fitted.
Inaccurate installation of gas coolers and pulsation dampers must be cor-
rected by weld seams with length additions. This is often necessary when
the piping has not been made according to our isometries.
CAUTION
Bearings in the crankgear can be damaged by welding current!
 Never run welding current (grounding) through compressor parts.
 Attach the power clamp of the welding equipment to the piping/flanges
as close to the weld seams as possible.
 Carry out welding work according to national or international standards.
5.12.2 Damper
Before dispatch, the dampers have been blasted or sand-blasted,
degreased and passivated on their inside by the manufacturer.
The vessels are filled with dry nitrogen with a slight overpressure of
0.30 bar g/0.03 MPa g/0.30 kg/cm2 g before dispatch.
WARNING
Pressurized system part!
with dry nitrogen prior to dispatch.
 Take notice of the corresponding warning sign.
 Depressurize system part before you start installation work.
Check dampers before installation to make sure that they have not been
contaminated with oil or grease during handling.
If there are any doubts about cleanliness degrease dampers, separators
and gas coolers again!

WARNING
Plant components like coolers, pulsation dampers, separators can fall!
 Store them securely.
 Keep them from falling.
Install pulsation dampers according to the foundation drawings and general

arrangement drawings.
Align dampers carefully.
Check if inlet/outlet nozzles have been positioned correctly.
Distinguish between “firm” and “sliding” fixations, to allow free expansion of
coolers/dampers. Slotted holes in the feet of dampers and coolers are pro-
vided for such purpose.
XA_XX_0050b_01
1
Fig. 5-38 Firm fixation (typical view)
1 Foot of damper
2 Support
2
3
4
XA_XX_0051b_01
5
6
7
Fig. 5-39 Sliding fixation (typical view)
1 Stud bolts with 2 nuts

2 Sleeve/jacket
3 Belleville spring
4 Washer
5 Slotted hole
6 Foot of damper
7 Support

Supports The supports will be installed on the foundation as follows, see Fig. 5-40:
4
8
XA_XX_0121b_01
Fig. 5-40 Installation of support
1 Support 6 Foundation
2 HILTI® adhesive anchor 7 Grouting material
3 Nut and washer (above base plate) 8 Washer
4 Base plate of support 9 Leveling bolt
5 Nut and washer (below base plate)
1. Mark the bores for the support (1) exactly, use the base plate of the
support (4) or an appropriated jig as template.
2. Drill the bores for the HILTI® adhesive anchors (2) true to dimension
(preferably with a core drill).
3. Insert HILTI® adhesive anchors according to section 5.12.1 Prepare In-
stallation, observe the curing time.
4. Fit nuts and washers (5) onto the HILTI® adhesive anchors, pre-adjust
nuts to the required level.
5. Clean and degrease the lower side of the base plate of the support.
6. Place the support on the pre-adjusted nuts with washers.
7. Adjust the support to the final level.
8. Fit washers and nuts (3) and tighten the nuts.
9. Fit leveling bolts (9) into the base plate of the support and set washers
(8) below them on the foundation. Adjust the leveling bolts to the re-
quired level and apply a separating layer (adhesive tape or grease) to
the thread section below the base plate.

10. Turn the nuts (5) with washers down to the foundation (6) and tighten
nuts.
11. Grout the support in accordance with section 5.11.5 Grout Sole Plates.
12. After the grouting material (7) has cured completely, tighten the nuts (3)
with the mandatory tightening torque (see section “Compressor” in
chapter 13 Appendix).
13. To avoid vibration transfer between foundation and support, turn back
(loosen) the leveling bolts (9) some turns or remove the leveling bolts
completely and close the bores, e.g. with grouting material.
Dampers Dampers are shipped separately, i.e. they are not mounted on the cylinders
or compressor.
Prerequisites
• Compressor and main motor have been grouted in the foundation and
have been aligned to each other.
• Cylinders are mounted on the frame/crankgear.
• Damper supports have been previously installed (not grouted).
• Auxiliary piping has been fitted to the compressor (tested, cleaned,
painted etc.).
Procedure
Handle gaskets and orifice plates with care.
Do not align dampers with the support, rather align supports with the
dampers.
Respect sliding points. Make sure that there is sufficient space between the
bolt and the equipment. The bolt should be located in the middle of the
slotted/big hole (Fig. 5-39).
1. Install discharge dampers attached to the foundation.

2. Attach and grout the supports.
3. Starting from the compressor, fit the process gas piping between cyl-
inder and discharge damper (including orifice plates).
4. Starting from the compressor, fit the process gas piping between cyl-
inder and suction damper (including orifice plates).
5. Attach and grout the supports.

5.12.3 Oil Skid
DANGER
 The skid may only be lifted according to manufacturer’s instructions.
For details see section “Foundation” in chapter 13 Appendix.
The attachment of the oil skid on the foundation is in client's scope.
5.12.4 Local Instrument Board LIB
DANGER
Electrical danger!
Serious injury or death may occur.
 All individual units must be grounded according to local standards and
to IEC regulations.
DANGER
 The local Instrument board (LIB) may only be lifted according to man-
ufacturer’s instructions.
For details see section “Foundation” in chapter 13 Appendix.

XA_XX_0109b_01
Fig. 5-41 Installation of local instrument board (typical view)
1 Local instrument board (typical 5 Nut and washer

view) 6 Grouting material
2 HILTI® adhesive anchor 7 Foundation
3 Nut and washer 8 Bore
4 Support
1. Check the foundation (7), mark the bores (8) exactly, use the support
(4) as a template.
2. Drill the bores (8) true to dimension (preferably with a core drill).
3. Insert HILTI® adhesive anchors (2) according to section 5.12.1 Prepare
Installation, observe the curing time.
4. Fit nuts and washers (5) onto the HILTI® adhesive anchors, adjust nuts
to the required level.
5. Clean and degrease the lower side of the support.
6. Place the local instrument board (1) onto the HILTI® adhesive anchors,
realignment can be done with the nuts.
7. Fit washers and nuts (3) onto the HILTI® adhesive anchors, tighten
nuts.
8. Grout the local instrument board in accordance with section 5.8.3 Grout
Supporting Surface of Sole Plates.

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

cleaning of piping at the installation site. They are of a general, non-binding
character and in no way influence the agreements made with the customer
in the main contract.
• To prevent ingress of dirt and foreign matter, all openings of com-
pressor and plant components must be covered and sealed. Dust
blinds shall remain installed until final alignment.
• Piping for gas and water are usually pre-manufactured and delivered
with additions for assembly welding. Coolant pipes with diameters less
than 50 mm are delivered in separate pieces and must be adjusted and
welded on site.
Piping delivered in separate pieces means additional expenditures at
the installation site and additional personnel.
• Ensure stress-free installation of piping between compressor, plant
components and other piping. Otherwise, stress will build up leading to
vibration problems and pipe cracking. The lifetime of installed elements
such as control valves, safety relief valves, temperature and pressure

Install Pipe Work
transmitters and other instruments will be affected, too. Excessive wear

of parts may occur and satisfactory operation/running cannot be guar-
anteed.
• Piping must be welded by skilled personnel with suitable equipment.
Personnel must adhere to normal guarantees concerning material
quality and standard of work.
• Welding must be carried out according to local welding specifications.
• Pipes marked and provided with material certificates may only be sep-
arated, cut, re-welded and re-stamped according to local regulations in
the presence of quality control personnel.
• Paint and other protective coatings on the pipes, flanges, pipe bends,
preformed components, reducers etc. are to be removed before further
processing. A method suitable for the removal of the particular protec-
tive coating is to be used for cleaning, e.g. sandblasting, mechanical
action, burning off, acid pickling or solvent.
• Weld seams which cannot be ground internally have to be welded on
the root side using inert gas.
• Take care that sufficient flange pairs per piping run are provided. This
ensures that all piping pieces can be dismantled after fitting for acid
treatment and cleaning.
• Gas piping fitted to the compressor must be installed allowing for axial
removal. This is required to be able to clear the piping from the studs
on the cylinder block (i.e. by means of a spool piece or 90°-flanged con-
nection).
• Arrange the piping system in such a way that no liquid accumulation in
the gas pipes is possible even with closed isolating suction valve.
5.13.2 Fabricate Piping

• Lube oil pipes, with the exception of stainless steel pipes welded with
inert gas, must be cleaned with acid according to the following section
after completion.
• Dismantle and clean piping by sandblasting, with acid or mechanically
after it has been fitted.
• Some main pipe supports may be installed first to install the piping in
the right position.
• Weld ends of pipe sections must be parallel and fit together without any
misalignment. For a correct full penetration welding, the required size
of the root face must be fixed or tack-welded.
• As a rule, tack-welding is carried out in the same welding procedure as
for the root layer. If so stipulated, the same pre-heating temperatures
for welding also apply to tack-welding. Uneven and/or faulty tack-weld-
ings must be removed prior to welding of the root layer. Welded-on fix-
ations to pipe ends are not permitted.
• If welded connections are locally heat-treated (if applicable) make sure
that – at least for the length of the weld seam – the parameters for heat
treatment are observed on both sides of the weld seam and at the com-
plete circumference of the seam.

Install Pipe Work
Flange Face Alignment The following instruction only describes flange face alignment when flat
gaskets are used.
Two types of alignment are recognized:
• Lateral alignment, that is the offset of the aligned flange center lines,
applicable for the complete flange set as well as the relevant position
of bolt holes (Fig. 5-43).
• Parallelism, of the aligned flange faces, sometimes referred as angular
alignment (Fig. 5-42).
X1
XA_XX_0103a_03
Fig. 5-42 Parallelism of aligned faces
X1 Deviation X1
X2
X2
XA_XX_0073a_02
Fig. 5-43 Lateral alignment
X2 Deviation X2
Set-Up prior to • The flanges shall be lined up so that the bolts can be inserted without
Measurement force.
• A gasket and 25 percent of the bolts, at least four, shall be inserted. The
bolts shall be uniformly fastened using manual spanners to take out the
free slack, to ensure the real misalignment will be measured.
• The fitting of the pipes to the connections on the compressor (stub
ends) has to be carried out very carefully. Special attention is required
so that no distortion of the stub ends takes place due to welding, i.e.
due to thermal stress.

Install Pipe Work
Particularly for stainless stub ends:

In order to minimize thermal stress, screw two stub ends of the same size
together during welding (see fig. below).
XA_XX_0368b_01
4 3
Fig. 5-44 Stub-end welding
1 Pipe
2 Weld
3 Stup end
• Should, however, the sealing surfaces of the weld-on pieces be dis-

torted due to welding in spite of this measure, these surfaces are to be
faced up square and checked by means of a surface plate.
• Spare gaskets should be built in for pipe adjustments. Consider the set-
tlement of final gaskets when using spare gaskets for pipe adjustments.
• Consult pipe layout and dimension of piping. Stress-relieved with re-
gard to operating temperature, also consider the temperature during
assembly, i.e. install piping having been negatively or positively pre-
stressed in order to compensate for large temperature differences.
• Reference value, e.g. for carbon steel: t = 100 °C = 1 mm/m.
• The flange connections of the pipes, especially those on the gas cooler
and pulsation damper, have to be symmetrical and either square or ac-
curately aligned to the design angle with regard to each other. If this is
not done, high stresses occur which can lead to material fractures in
lines and vessels.
• While installing pipe sections, e.g. welding of T-pieces, special care
must be taken that no impurities (burnt out material, etc.) remain within
the bore of the pipe after treatment. Hence the line has to be cleaned
thoroughly before installing and welding in the next pipe. The same ap-
plies for the fitting of connections for thermometers, pressure gauges,
etc.

Install Pipe Work
5.13.3 Check Fabrication
Acceptance Criteria for Misalignment
Stub End Flange The stub end flange alignment at the cylinder side can not be checked
Connections to easily because of a recess. Procedure:
Compressor Cylinder • Install the piping to the cylinder with the other end free but aligned to
damper, etc.
• Do not remove the studs from cylinder.
• Snug tighten the nuts.
• Check the gap between the flange and cylinder.
• Check the opposite flange for parallelism and make sure the bolts are
inserted loosely.
• Consider the heat expansion of gas discharge pipes.
Flange faces shall be aligned parallel within 0.05 degrees in all directions.
Maximum deviation (X1) from parallel across flange diameter, see Tab. 5-3.
The measured lateral misalignment (X2) shall not exceed the values given
in Tab. 5-4.
Flange diameter [mm] Deviation X1

<300 0.2mm
300 to 600 0.3mm
600 0.5mm
Tab. 5-3 Deviation X1
Flange diameter [mm] Deviation X2

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

after welding of stub ends. The maximum flatness tolerance is 0.2 mm.

Install Pipe Work
Standard Flange
X
Connections 3
XA_XX_0074a_02
Fig. 5-45 Maximum deviation
X3 Deviation X3
• Lateral Alignment
For standard flanges, the free insertion of the bolts is generally suffi-
cient to demonstrate acceptable alignment. Lateral alignment may also
be checked by laying a straight edge along the outside diameter of the
flange. Measurements should be taken at locations 90 degrees apart
around the flange circumference.
The measured lateral misalignment (X2) shall not exceed the values
given in table Tab. 5-4.
Bolt holes shall straddle the natural center line unless specified other-
wise. The maximum deviation from the required theoretical bolt hole
position (X3), as measured along the bolt circle, shall be 1.5 mm
(Fig. 5-45).
• Parallelism
Flange face alignment shall be checked by measuring the distance be-
tween the mating flanges of the pre-assembled joint. Measurements
shall be taken around the circumference at equal distances from the
center line (the outside rim of the flange will normally be the most con-
venient position).
The difference between the measurements shall not exceed the fol-
lowing values: ASME B 16.5 flanges, all sizes, all ratings: 2.5 mm/m.
Flanged Accessories Accessories are flanged items which are rigid in themselves (e.g. valves,
strainers etc.). The individual flange face misalignment from the design
plane shall not exceed 2.5 mm/m. Also, the misalignment of the two flange
faces shall not exceed 2.5 mm/m.
Gap between Flanges Gasket type, material and size shall be checked. The gap between the
flanges shall be just sufficient to slide in the gasket without damaging the
gasket or the flange faces.
Decrease of Pipe Wall The maximum allowable decrease of wall thickness shall not exceed 10 %
Thickness and Pipe Bend of nominal wall thickness.
Flattening
Pipe wall thickness shall be in accordance with ANSI B 31.3.
Cleaning After the pipes have been fitted, they are to be dismantled and cleaned,
e.g. by sandblasting, acid treatment (see section 5.13.4 Pickle and Pas-
sivate Piping) or mechanical action.

Install Pipe Work
CAUTION
 Degrease and clean the process gas pipes with an oil and grease re-
moving solvent to required level of cleanliness.
CAUTION
Wrongly applied solvents!
 Observe the manufacturer’s instructions about the use of solvents!
Tests Radiographic and/or pressure tests are to be carried out according to local
regulations.
After assembly of the complete gas piping system incl. dampers, coolers
and all fittings, the system may be submitted to a leak test according to
local regulations and project procedures.
Final Checks After the compressor has been successfully test run, all flange connections
and pipe fastenings are to be thoroughly tightened up again.
Should pipe vibrations occur, please see section 5.16.9 Assess Vibrations.
5.13.4 Pickle and Passivate Piping
Not applicable for stainless steel pipes welded with inert gas.
Since oil and grease generally cannot be removed by acids, these contam-
inants – if present – must be removed with an organic solvent or alkaline
solution prior to acid pickling.
The following instructions describe acid pickling of pipings at the assembly

site. They are of a general, non-binding character and in no way affect the
agreements made with the customer and forming part of the main contract.
• Fabrication of the pipings and preparations. Please see section 5.13.2
Fabricate Piping.
• The final cleaning of the pipings takes place before final assembly, i.e.
after completion of any radiographic and pressure tests which may be
specified or after formal release of the pipes for the said final assembly.
A clear distinction is to be drawn between the matching/fitting of pipe com-

ponents which have undergone preliminary cleaning and those which have
not.

Install Pipe Work
Procedure for pipe components which have undergone preliminary

cleaning:
Pickling of the pipings can be dispensed with in cases where:
• the pipes were cleaned before welding together, i.e. the surfaces have
good metallic lustre and appear clean and
• the assembly welds were carried out under inert gas and/or ground in-
ternally.
Such pipings are to be hammered out, washed out with solvent and subse-
quently blown out with oil free air or oil free nitrogen.
DANGER
Where chlorinated hydrocarbons are used as cleaning agent, the safety
precautions given in section 10.3 Select Cleansing Agent are to be com-
plied with.
Procedure for pipe components which have not undergone prelim-

inary cleaning:
Where the pipings have not been fabricated from preliminary cleaned pipe
components, dismantling and acid pickling as described below are re-
quired.
Acid Pickling
Where possible, specialist firms are to be employed to pickle the pipings.
DANGER
Corrosion and toxic hazard!
 All safety precautions are to be strictly complied with when dealing with
acids and lyes.
 The instructions given in section 2.4.9 Handling Chemicals are to be
followed.
Since gases are formed during acid pickling, the pipings must be arranged
in such a way that there is no place where gas bubbles can collect, see
Fig. 5-46. The pipes can be pickled either by filling the piping completely or,
if a suitable pump is available, by circulation of the acid.

Install Pipe Work
3
2
XA_XX_0049b_01
1
Fig. 5-46 Pipe arrangement for pickling
1 Liquid
2 Gas
3 Emptying
Acid Mixtures
The following dilute acids can be used to pickle pipes made from carbon
steel, stainless steel or copper:
Acid mixture Concentration Temperature

Orthophosphoric-acid (H3PO4) 8–20% 20–60°C
Amino-sulphonic-acid (NH2SO3H) 5–15% 20–40°C
Sulphuric acid (H2SO4) 10–20% 20–60°C
*Hydrochloric acid (HCl) 5–20 % 20–60°C
* Do not use hydrochloric acid for the cleaning of pipe assemblies made of
carbon and stainless steels.
A corrosion inhibitor must be added to the pickling solution to protect the
base material.
To orthophosphoric and sulphuric Mulgoten 3482 0.4%

acids:
To hydrochloric acid: Rodine 213 0.3–0.4%
Propargylalcohol 0.4%
The time required for acid pickling depends on the solution temperature:
the higher the temperature of the acid solution the quicker the cleaning. De-
pending on the temperature and the concentration of the solution, acid
pickling requires two to twelve hours.
It is recommended that the required pickling time be determined by using

specimen pipes.

Install Pipe Work
Passivation
After acid treatment, neutralise immediately the pickling. Rinse with water
and passivate the pipings. For this purpose use the following solutions:
• 5 % sodium carbonate (soda) solution (Na2CO3)
• 5 % sodium hydroxide solution (NaOH)
• 5 % trisodium phosphate solution (Na3PO4)
Heat the solutions up to 60/70 °C. Passivation requires about one hour.
The arrangement of the pipings is the same as for acid pickling (Fig. 5-47).
3
2
XA_XX_0049b_01
1
Fig. 5-47 Pipe arrangement for passivation
1 Liquid
2 Gas
3 Emptying
After passivation, heat the pipings up with steam and subsequently blow
them dry using oil-free air or oil-free nitrogen.
Wherever possible, the cleaned pipings should be immediately assembled
in place and kept under a nitrogen blanket.
Should the assembly of the pipings be delayed, the ends of the pipes must
be sealed off with plastic in order to prevent the entry of atmospheric air.
CAUTION
Observe section 2.8 Safe Maintenance Practices.

Install Pipe Work
5.13.5 Sandblast Piping

Sandblasting is the preferred method to achieve grey, metallic surfaces for
carbon steel items such as gas piping. Except for thoroughly removing par-
ticles by blowing out, wiping or vacuum cleaning, no further cleaning is re-
quired. The term sandblasting includes shot, bead, and grit blasting.
WARNING
Sand deposits in gas pipes or vessels!
Risk of damage to piston and cylinder.
 After sandblasting, thoroughly clean gas pipes and vessels by wiping
or vacuum cleaning.
WARNING
Sand deposits within bearings!
Risk of bearing damage.
 Oil piping shall not be cleaned by sandblasting.
Oil piping, with the exception of stainless steel pipes welded with inert gas,
must be cleaned with acid according to section 5.13.4 Pickle and Passivate
Piping.
5.13.6 Recommendation for Pipe Support

Please refer to corresponding General Arrangement in section “General
Arrangement”, chapter 13 Appendix.
Pipe Support (Fixed Point) Burckhardt Compression recommends to use a pipe support of this type
for Oil and Coolant Piping (fixed point) for oil and coolant piping to max. DN150/6".
2
XA_XX_0075b_01
Fig. 5-48 Pipe support with u-bolt
1 U-bolt
2 Support beam

Install Pipe Work
Pipe Support (Gliding For gas piping from DN50/ 2" to DN600/ 24", Burckhardt Compression rec-
Point) for Gas Piping ommends to use a pipe support of this type (gliding point), consisting of 2
pipe clamps.
This type of pipe support with gliding points is used for pipes that are ex-
posed to strong thermal expansion.
2
Z1
3
XA_XX_0076b_01
4
Fig. 5-49 Pipe support (gliding point)
1 Pipe clamp
2 Shim
3 Plate
4 Support beam
5 Shim (non-metallic)
During installation, the gap Z1 (theoretically 5–6 mm) must be bridged with
2 shims (2). The pipe must remain movable in longitudinal direction.
After the fastening bolts have been tightened, the supporting surfaces of
the pipe clamps must be parallel to the support beam.
The fastening bolts must be tightened with two nuts.
A 3 mm plate (3) must be installed between pipe/pipe clamp and support
beam.
A non-metallic shim (5) must be installed between the pipe and the 3 mm
plate in order to absorb vibrations.

Install Pipe Work
Pipe Support (Fixed Point) For gas piping from DN50/2" to DN600/ 24", Burckhardt Compression rec-
for Gas Piping ommends to use a pipe support of this type (fixed point), consisting of 2
pipe clamps.
2
Z1
XA_XX_0077b_01
3
Fig. 5-50 Pipe support (fixed point)
1 Pipe clamp
2 Plate
3 Support beam
4 Shim (non-metallic)
During installation, the fastening bolts must be tightened to such extent that
the pipe is tightly in the piping support and cannot be moved in longitudinal
direction. The theoretical gap Z1 (5–6 mm) must remain open.
beam.
A non-metallic shim (4) must be installed between the pipe and the 3 mm
plate in order to absorb vibrations.

Install Pipe Work
Pipe Support (Fixed Point) For gas piping from DN15/ ½" to DN40/ 1½", Burckhardt Compression rec-
for Gas system ommends to use a pipe support of this type (fixed point).
2
Z1
XA_XX_0078b_01
Fig. 5-51 Pipe support (fixed point)
1 Pipe clamp
2 Plate
3 Support beam
During installation, the fastening bolts must be tightened to such extent that
the pipe is tightly in the piping support and cannot be moved in longitudinal
direction. The theoretical gap Z1 (1–2 mm) must remain open.
beam.
5.13.7 Recommendation for Tube Fittings

SERTO® Compression Design and Principle
Ferrule Unions
The compression ferrule is deformed as the nut is tightened, necking the
tube slightly without notching it. The deformation forces generate high spe-
cific contact pressure in the neck zone and the butt joint “compression fer-
rule/basic component”, ensuring a secure hold of the tubes, and a perfect
metal to metal sealing.
Thanks to the elasticity of the compression ferrule system, SERTO® unions
are extremely resistant to vibrations and pressure shocks, insensitive to
temperature change, and best suited to repeated dismantling and reas-
sembly.
An effective and safe connection is only guaranteed by using exclusively
SERTO® original component parts, assembled in accordance with the in-
stallation instructions.

Install Pipe Work
XA_XX_0052a_01
Fig. 5-52 SERTO® principle, radial dismantling
WARNING
An improper installation (loose or excessively tightened threaded connec-
tion) as well as leakage of fluid, may cause minor body injuries, injury to
eyes or environmental damages.
 Strictly follow installation instruction!
 Visually and periodically check pipes for leakage or for damages!
Installation Instructions
The SERTO® union is supplied assembled.

Install Pipe Work
XA_XX_0053b_01
d
Fig. 5-53 SERTO® union
1 Basic component
2 Compression ferrule
3 Nut
4 Stiffener sleeve
d Tube outside diameter
s Wall thickness
Procedure:
1. Preparation
XA_XX_0054a_01
Fig. 5-54 SERTO® preparation
• Cut tube in a right angle to length and deburr it.

• The end of the tube must be straight for an approximate length of
1.5 d and the surface free of damages.
• The union is prelubricated. The use of Burckhardt Lubrication
Grease BLG05, lube oil, MOLYKOTE® G-N Plus, Teflon® etc. facil-
itates the reassembly and assembly of bigger sized unions (thread,
compression ferrule).

Install Pipe Work
2. Reinforce Tube and Insert
XA_XX-0055a_01
Fig. 5-55 SERTO® reinforcement
• Stiffener sleeves are required to reinforce plastic tubes and thin

walled tubes.
Copper tubes from d 10 mm s < 1.0 mm

from d 12 mm s < 1.5 mm
Stainless steel tubes from d 6 mm s < 0.5 mm

from d 10 mm s < 1.5 mm
• Align tube and union.

• Insert tube up to the stop.
3. Tightening, Stress Relieving, Checking
XA_XX_0056a_01
Fig. 5-56 SERTO® tightening
• Tighten the nut with an open end spanner until an increased resis-
tance is felt.
• Slightly loosen nut in order to relieve possible stresses. Finally
tighten union against positive resistance.
• Check if nut is covering the connecting stem thread, then tube and
compression ferrule are properly deformed.

Install Pipe Work
4. Tubes
Use tubes with a clean smooth external surface and with an outside di-
ameter having tolerance of ± 0.1 mm.
5. Turnable Ferrule
There is no influence on the efficiency of the connection if, after as-
sembly, the ferrule can be turned on the tube or the tube in the union
nut.
Progressive Ring Fitting Description and Function

ERMETO® (EO)
XA_XX_0057a_01
Fig. 5-57 Before tightening the nut
A Front cutting edge

B Second cutting edge
C Stop cutting edge
D Collar end
The basic feature of the EO progressive ring is that the precisely designed
geometry permits the limited, progressive penetration of the ring into the
tube. The front cutting edge (A) has already begun to cut into the tube be-
fore the second cutting edge (B) contacts the tube. When the optimum pre-
scribed depth for both cutting edges has been reached, the stop edge (C)
prevents further penetration.
Because of the stop edge and the shape of the two cutting edges, the
forces arising are distributed along the entire taper length, thus increasing
joint strength. This distribution of the forces and the specially designed in-
ternal contour at the collar end (D) of the ring guarantee increased reli-
ability for flexure loading. Vibrations are thereby dampened at the entry into
the ring.
XA_XX_0058a_01
Fig. 5-58 After tightening the nut
E Collar end
During assembly, the stop edge causes the tightening forces to be in-
creased up to a clearly perceptible fixed point (assembly fixed point). After
assembly is completed, the visible thrown-up collar (E) must completely fill
out the space in front of the first cutting edge.

Install Pipe Work
Using original components (EO™), precise knowledge of their function and

the following of these instructions exactly guarantee the utmost reliability
even under heavy duty applications.
WARNING
An improper installation (loose or excessively tightened threaded connec-
tion) as well as leakage fluid, may result in minor body injuries, injury of
eyes or environmental damages.
 Strictly follow absolutely installation instruction!
Assembly Instructions
Preparation of tubes:
• Cut off tube square; lightly deburr at the internal and external edges (do
not bevel edge tube).
XA_XX_0059a_01
Fig. 5-59 Preparation of tube
• If a pipe cutter is used (not recommended), be sure to deburr both tube

ends at the inside and outside. Also file the tube face flat to ensure
complete contact of the tube end face with the stop shoulder inside the
taper of the fitting.
XA_XX_0060a_01
Fig. 5-60 Tube cut using pipe cutter: considerable burr formation/tube not cut off
square
XA_XX_0061a_01
Fig. 5-61 Sawn off tube: hardly any burr formation

Install Pipe Work
Preparation of Fitting Components:

• Oil thread and taper of fitting as well as EO progressive ring and thread
of nut.
XA_XX_0062a_01
Fig. 5-62 EO parts
• Slide nut and progressive ring onto end of tube.
XA_XX_0063a_01
Fig. 5-63 EO ring on tube
• Do not slide on progressive ring backwards!
1
XA_XX_0064a_02
Fig. 5-64 Correct/incorrect assembly
1 Correct assembly
2 Incorrect assembly
Direct Assembly in Fitting Body:

• Tighten nut by hand up to hand tight. Always press tube against stop in
inner cone of fitting body.

Install Pipe Work
XA_XX_0065a_01
Fig. 5-65 Tighten nut by hand
• Mark a line on nut and tube in order to observe the required number of
turns.
XA_XX_0066a_01
Fig. 5-66 EO parts
• Tighten nut by approximately 1 1/2 turns (tube is not allowed to turn

with nut).
Stop edge limits tightening by increasing force required.
XA_XX_0067a_01
Fig. 5-67 Tighten nut by spanner
Inspection of Assembly:
• Loosen nut; check to make sure that a visible collar fills out the space
in front of the 1st cutting edge (it does not matter if ring can be rotated
on top of tube end).

Install Pipe Work
XA_XX_0068a_01
Fig. 5-68 Loosen nut
Reassembly:
• After every reassembly, retighten nut without applying more force than
for the first assembly. Firmly hold fitting body during the assembly.
XA_XX_0069a_01
Fig. 5-69 Reassemble
Tube Fittings Description and Function

SWAGELOK®
SWAGELOK® Tube Fittings provide a leak-proof, torque-free seal at all
tubing connections and eliminate costly, hazardous leaks in instrumenta-
tion and process tubing.
All the action in the fitting moves along the tube axially instead of with a ro-
tary motion. Since no torque is transmitted from the fitting to the tubing,
there is no initial strain which might weaken the tubing.

Install Pipe Work
XA_XX_0070a_01
XA_XX_0048a_01
Fig. 5-70 SWAGELOK® union
Fig. 5-71 SWAGELOK® parts
CAUTION
Leaking pipes
Damages or injuries may result from interchanging or mixing parts of tube
fittings made by other manufacturers.
 Do not mix or interchange parts of tube fittings made by other manufac-
turers with SWAGELOK® Tube Fitting parts.
 An improper installation (loose or excessively tightened threaded con-
nection) as well as leakage of fluid, may cause in minor body injuries,
injury to eyes or the environmental damages.
 Follow absolutely the installation instruction!
Assembly Instructions
SWAGELOK® Tube Fittings are delivered completely assembled finger-
tight and ready for immediate use. Disassembly before use is not neces-
sary and can result in dirt or foreign material getting into fitting and causing
leaks.
SWAGELOK® Tube Fittings are installed in three easy steps:

Install Pipe Work
1. Simply insert the tubing into the SWAGELOK® Tube Fitting. Make sure
that the tubing rests firmly on the shoulder of the fitting and that the nut
is finger-tight.
XA_XX_0047a_01
Fig. 5-72 SWAGELOK® step 1
2. Before tightening of SWAGELOK® nut, mark nut at the 6 o’clock posi-

tion.
XA_XX_0046a_01
3. Now, while holding the fitting body steady with a backup spanner,
tighten the nut 1-1/4 turns. Watch the marking, make one complete
turn, and continue to the 9 o’clock position.
XA_XX_0045a_01
By marking nut at the 6 o’clock position as it appears to you, there will be

no doubt as to the starting position. When the nut is tightened 1-1/4 turns
to the 9 o’clock position, you can easily see that the fitting has been prop-
erly installed.
Check Gauge
Check gauges ensures added safety and reliability. It is an exclusive SWA-
GELOK® Tube Fitting feature which allows easy inspection for sufficient
pull-up, before a system is pressurized.

Install Pipe Work
XA_XX_0044a_01
Fig. 5-75 Check gauge
The SWAGELOK® check gauge is placed between the nut and body hex
or shoulder of a tube fitting after pull-up. If the check gauge does not fit be-
tween nut and body hex, the fitting nut is sufficiently tightened.
XA_XX_0043a_01
Fig. 5-76 Check gauge
If the check gauge fits between nut and body hex, additional tightening is
required!
Retightening Instructions
Connections can be disconnected and retightened many times. The same
reliable, leak-proof seal can be obtained every time the connection is re-
made.
1. Fitting shown in disconnected position.

XA_XX_0042a_01
Fig. 5-77 Disconnected fitting

Install Pipe Work
2. Insert tube with ferrule into fitting until it stops.
XA_XX_0041a_01
Fig. 5-78 Insert tube
3. Tighten nut by hand. Rotate nut to the original position using a spanner.
An increase in resistance will be encountered at the original position.
Then slightly tighten with spanner. Smaller tube sizes will take less
tightening to reach the original position, while larger tube sizes will re-
quire more tightening. The wall thickness will also have an effect on
tightening.
XA_XX_0040a_01
Fig. 5-79 Tighten nut
5.13.8 Final Assembly of Piping
Flange Connections
1. Clean nuts and bolt threads.
2. Grease stainless steel bolts with MOLYKOTE® G-N Plus.
3. Remove spare gaskets that were used for piping adjustments (as rec-
ommended in section 5.13.2 Fabricate Piping). Install final, undam-
aged gaskets for final assembly of pipe work.
4. Tighten nuts manually, do not use spanner. Make sure that the flanges
remain parallel.
5. In a first operation, tighten nuts to 1/5 of the mandatory tightening
torque according to Fig. 5-80.
6. Check the parallelism of the flanges.
7. If the flanges are not parallel to one another, start the second operation
at the position where the flanges are the furthest apart (see allowable
clearance).

Install Pipe Work
8. In the second operation, the nuts are tightened to 1/3 of the mandatory
tightening torque.
9. Check the parallelism of the flanges.
10. In a third operation, tighten nuts to 2/3 and then in a fourth operation to
the full amount of the mandatory tightening torque. Re-check the par-
allelism of the flanges after the third operation.
1 9
15 5
8 13
12 3
4 11
XA_XX_0083a_02
14 7
6 16
10 2
Fig. 5-80 Tightening sequence of nuts according to this figure
Gas pipes must be installed stress-free (see section 5.13.6 Recommenda-

tion for Pipe Support). Do not apply force to the flange bolts in order to pull
the pipes in their correct position.
For admissible clearances: refer to “Flange Face Alignment” in section
5.13.2 Fabricate Piping and “Acceptance Criteria for Misalignment” in sec-
tion 5.13.3 Check Fabrication.
Do not use more than one gasket between the flange contact faces.
Coolant Lines
When the coolant lines are fitted, make sure that the supply and discharge
lines to the cooling chambers are connected properly to the main coolant
supply (coolant inlet below), otherwise the respective spaces will not be
properly filled with water (no back pressure).
Ensure sufficient ventilation for the highest spots of closed cooling sys-
tems.
Arrange coolant piping in such a way that the system can quickly be
drained and easily ventilated.
Particular attention should be given to the internal coolant connections

when testing for tightness.

Non-Return Valve
5.13.9 Hydrostatic Pressure Test

Hydrostatic pressure tests of the pipe system must be carried out by trained
specialists only. Parts to be pressure tested must be air vented. Please ask
for our technical assistance (address see section 1.6 Contact Address) for
permitted design pressure on the gas side. Use approved pressure gauges
only. For the gas and oil pipes only treated water must be used.
WARNING
Pressurized plant components.
Incorrect pressure testing may result in bursting plant components!
 Do not exceed the maximum permitted pressure!
 Observe the correct measuring unit on the pressure gauge.
5.14 Non-Return Valve

Installation Install the non-return valve (in client’s scope) according to manufacturer’s
instructions.
• Verify that arrow on housing of non-return valve corresponds to the flow
direction of the process gas.
• Verify that correct gaskets are used.
Only use original spare parts.
5.15 Electrical Installation
DANGER
Electrical danger!
Serious injury or death may occur.
 All electrical installation and operations must be carried out by profes-
sional personnel only!
5.15.1 Fit Grounding Wire

Grounding connections are provided on the crankgear, cylinders, motor,
pipes, junction boxes in stainless steel and local instrument boards. Other
plant components such as skids (e.g. lubricating system) and vessels are
also provided with dual connecting points.

Electrical Installation
XA_XX_0081b_02
Fig. 5-81 Grounding connection (typical view)
1 Washer
2 Spring washer
3 Grounding wire

Electrical Installation
PB_M0_0006b_02
3
Fig. 5-82 Grounding connection on crankgear
1 Crankgear
2 Grounding connection
3 Spring washer
4 Washer
Facing the flywheel, the grounding connection (Fig. 5-82) is located on the
drive end on the right hand side of the crankshaft.
1. Connect compressor and its auxiliaries to ground. Assure full compli-

ance with national standards.
• Required wire cross-section of copper wire is 50 mm2 (minimum
16 mm2).
• Fit the grounding wire between the two washers and use a spring
washer as a nut-locking device. Do not paint bolt, nuts and
washers!
2. Prior to operation:
• Check all grounding connections.
• Check wiring connections of main motor as well as general condi-
tion of insulation and perform an insulation resistance check.

Pre-Commissioning of Compressor Plant
The insulation resistance check gives information about the condi-

tion of windings. In case the minimum value is not obtained, dry
and/or clean the main motor and then repeat the insulation resis-
tance check.
Consult corresponding manufacturer’s instruction manual (see
Technical Documentation).
• Check insulation resistance of other electrical machines/equip-
ment.
Prior to operation, check all grounding connections. The local electrician is

in charge of checking the ground wiring systems.
5.16 Pre-Commissioning of Compressor Plant
5.16.1 Prerequisite
Emergency Stop during To permit an immediate emergency shutdown of the compressor during
Pre-Commissioning pre-commissioning, the electrician must install a temporary emergency
stop push button with a sufficiently long cable around the compressor.
WARNING
An emergency situation may occur.
 Before pre-commissioning, check the emergency stop push button for
proper functioning.
Instruction of Operating Our field service engineer (FSE) will instruct your personnel which is in
Personnel charge of the monitoring of operation.
The chronological order of commissioning depends on site conditions and
must be discussed with our specialist. Usually, the pre-commissioning of oil
skids will be done first.
5.16.2 Cooling System

Check that all pipe screw connections are firmly tightened.
Fill the cooling system with coolant and make sure that the cooling system
is vented. Let the coolant circulate and visually check the tightness of the
system.
Do not operate any equipment at conditions which exceed those specified
on the name plate(s).
Consider manufacturer’s instruction first.

General Advice In all installations, take care to eliminate or minimize transmission of pulsa-
tions and mechanical vibrations to the coolers.
Avoid thermal shocks
• Open all vent valves.
• Open cold medium first.
In order to guarantee the formation of a perfect protective coating, the

cooling water shall circulate continuously (even if the compressor is not
running).
Bolted Joints All external bolted joints may require re-tightening after installation and, if
necessary, after the cooler has reached operating temperature.
Performance When performance does not meet specified requirements, investigate the
following:
• Fouled tube surfaces resulting from sludge or scale.
• Trapped air due to improper venting or lack of vents.
• Piping connections incorrect.
• Operating at conditions other than design, check performance data
sheet.
• Bypassing or short circuiting of either medium, check pass partition
gaskets, seal strips and baffle clearance.
5.16.3 Crankgear Lubricating System
1. Clean the crankgear and the lubricating oil tank with a new, unused
sponge (do not use any fibrous, fuzzy cloth).
2. Fill the lubricating oil tank with oil till the oil strainer is covered by about
30 mm.

Oil quality and viscosity must conform to the specifications as mentioned in

section “Lubricating System” in chapter 13 Appendix.
3. Open the crankgear covers to check tightness of all oil piping connec-
tions.
4. Switch on the prelubrication pump and immediately check rotation and

that the oil system is tight.
5. Purge piping, especially the oil cooler by shortly switching on of lubri-

cation pump until clean oil escapes.
6. Turn the flywheel min. 1 rotation by means of the barring device in run-
ning direction.
7. Check that lubricating oil is being distributed to all the bearing points of
the crankshaft and the crossheads.
8. Operate prelubrication pump for two hours and check oil temperature
and pressures.
9. Check tightness of oil system. If the oil system is tight, fill oil to about
3/4 of the sight glass.
10. Check that all instruments and safety devices are properly connected
and functioning.
5.16.4 Check Cleanliness of Gas System

Before pre-commissioning of the compressor, make absolutely sure that
the suction and discharge lines are properly cleaned (see section 5.13.4
Pickle and Passivate Piping). Small foreign bodies on the intake side
(welding beads etc.) may cause damage to valves and pistons.
If the pipe fitting has not been supervised by one of our specialists, the
cleanliness and quality of the pipe assembly will be sample checked before
compressor start-up.
5.16.5 Turn Flywheel
WARNING
Unlubricated crankgear parts.
Damage of bearings and guide bearings.
 Never turn compressor by electric motor. Just use barring device or bar
to turn flywheel!

Before switching on compressor for the first time, turn the flywheel min. 1
rotation by means of the barring device in running direction. Verify that ev-
erything is in proper mechanical condition.
PB_L1_0049b_01
1 Flywheel
2 Pawl
3 Proximity probe
4 Barring device
DANGER
Rotating components, drawing in and crush hazard!
 Check the correct position of barring device! Prevent the catch being
engaged into toothing of flywheel.
 Do not operate the compressor with flywheel guard removed.
5.16.6 Mechanical Test Run

Before initial operation of the compressor a mechanical test run must be
carried out.
Also applicable after maintenance or repair works (as repairs on cylinders

or crankgear where inner parts have been dismantled, reconditioned or re-
placed).

First Start without Load 1. Prepare the cylinders of all stages. Remove the valve covers, lanterns
and suction valves as necessary to prevent compression.
2. Remove inspection hole covers of the dampers.
3. Switch on the prelubrication pump.
4. Switch on the electric motor (= compressor start). Check immediately

the rotational direction of the electric motor. Stop the motor immedi-
ately, if it turns in the wrong direction.
5. Check the following:

• Listen at short intervals for abnormal sounds at the crankgear.
• Lubricating oil and cooling system for leakage, flow, temperature,
pressure.
• Instrumentation and safety devices for indicating values, switching
points.
6. Duration of test runs is as follows:

• 1 minute for the first run
• 5 minutes for the second run
• 10 minutes for the third run
• 15 minutes for the fourth run
CAUTION
Wear of compressor parts
Long duration of test run may lead to wear of compressor parts.
 Each test run may last for max. 15 min.
7. After each run, open crankgear covers and check bearing tempera-
tures.
5.16.7 Blowing out the Gas Piping System

Blow out the suction line – and its accessories – upstream of the 1st stage
with air/nitrogen.
The blowing-out method is defined on site. The chosen method depends

on the pipe system installed at the plant. The following “general procedure
of blowing-out” is a good guideline.
1. Blow out the suction line before the first stage:

• Insert blind flanges (5) with mounted distance pieces (4) on the
suction side of the first stage. The distance piece must guarantee
that the distance between cylinder and the valve covers is 5–8 mm.

• Install the valve covers on the suction side of the first stage. The
threaded bolts (2) of the valve covers must be tightened.
LA_CX_0005b_01
5 4 3 2
Fig. 5-84 Blind flange with distance piece (typical view)
1 Valve cover
2 Threaded bolt
3 Valve chamber
4 Distance piece (to be manufactured on site)
5 Blind flange (to be manufactured on site)
• Blow out the suction line before the first stage and the valve cham-
bers (3) of the first stage with nitrogen (if there is enough available).
You can also use air for blowing-out the suction line.
• Remove all valve covers and all blind flanges (with mounted dis-
tance pieces) from the suction side of the first stage.
• Install suction valves, lanterns and valve covers of the first stage.
2. Blow out the discharge line:

• Provide an opening in the suction line before the first stage. Fit a
fine stainless steel wire screen of 0.3 mm mesh size between the
opening and the first stage.
• Run the coolant to the compressor and coolers.
• Turn the flywheel min. 1 rotation in running direction.
• Switch on the lubrication pump and check the lubricating oil pres-
sure.
• After the prelubrication time has elapsed, switch on the electric
motor (= compressor start).
Check immediately the rotational direction of the electric motor.
Stop the motor immediately, if it turns in the wrong direction.
• Use a heavy wooden hammer or vibrator to create maximum
shocks on gas piping to break loose any scales.
• Listen carefully to the crankgear.
• Repeat bearing temperature check after 5, 10, 25 and finally after
40 minutes of compressor running. The maximum bearing tem-
perature is approximately 60 °C.

• Increase pressure to max. permitted value, after 10 minutes drop

pressure to min. permitted value.
• Run the compressor with low and high pressure until the blown out
air is clean.
• Shut down and check all bearing temperatures. The maximum
bearing temperature is approximately 60 °C.
3. Remove the steel wire screen from the suction line.

4. Adjust the safety instruments in accordance with section “Instrumenta-
tion” in chapter 13 Appendix and check their proper functioning.
5. The piston rod nut, the connection of crosshead with piston rod and the
connecting rod bolts must be checked for proper tightening. Check
tightening torque of piston rod nut in accordance with section “Com-
pressor” in chapter 13 Appendix.
6. Dry out all condensate in the valve chambers and gas pipes. All flanged
connections and pipe fastenings must be re-tightened. Due to pulsating
delivery of the gas through pipes, powerful forces and hence pro-
nounced vibrations may set up, especially on long gas lines with sev-
eral bends. Apart from damaging the weld seams, this may also lead to
the smooth running of the compressor being impaired. If necessary, ad-
ditional pipe supports must be fitted prior to start up of the plant.
7. Install the suction strainer.
5.16.8 Nitrogen Test Run

For the N2 test of the compressor and the system blowing out, follow the
instructions of Burckhardt Compression’s supervisor, and refer to section
“Control Description” in chapter 13 Appendix.
5.16.9 Assess Vibrations

Term Explanation A distinction is to be drawn between the piping with and without stress
raisers according to the following explanations.
Pipes with Possible Stress Raisers

• Pipe junctions from a small pipe into a larger pipe (large diametrical dif-
ference),
• valves with heavy driving elements,
• safety valves or relief valves set on pipes etc.
Examples of pipes with stress raisers (Fig. 5-85):

XA_XX_0072a_01
Fig. 5-85 Pipes with stress raisers
Pipes without Stress Raisers

• Long pipes without junctions with other pipes of large diametrical differ-
ences or
• pipes which have no heavy additional devices (safety valves, relief
valves, instrument etc.).
Examples of pipes without stress raisers (Fig. 5-86):
XA_XX_0071a_01
Fig. 5-86 Pipes without stress raisers
Accessories (e.g. Damper)

Although the diametrical differences between the accessories and the con-
necting pipe are usually large and would therefore represent a “pipe with
stress raisers”, high vibration velocity is permitted because the connections
are reinforced for elevated stress.
Maximal Vibration Velocity acceptable for the Compressor according to

ISO 10816-6.
Maximal values for process gas compressors are indicated on the founda-
tion drawing. These values represent the basis for the final determination
of the foundation by the civil engineer. The compressor is considered to be
a rigid body. Under these considerations the given values of amplitudes
apply to measurements made on the cylinder block and are below the
values in ISO 10816-6.

Effective Vibrations on the The maximum specified acceptable vibration velocity values are not ex-
Installation ceeded under normal circumstances, see Tab. 5-5. Burckhardt Compres-
sion guarantees the given values taking in consideration an internal
pulsation and vibration study for the installation.
However, it may occur that excessive vibration velocities are measured
during or after commissioning. Depending on the cause, gas pulsations or
mechanical excitation, corresponding countermeasures must be under-
taken, i.e. additional orifices or pipe supports fitted (examples of pipe sup-
ports, see section 5.13.6 Recommendation for Pipe Support).
Vibrations on Reciprocating Compressors

For the valuation of reciprocating compressors, an own VDI Standard was
created. The VDI Standard 3838 replaces the old VDI Standard 2063 and
is an addendum to DIN ISO 10816-6 that regulates the allowable vibration
at compressors on a rigid foundation.
The vibration velocities of the objects to be supplied have to be defined lo-
cally.
According to DIN ISO 10816-6 class 3 the limit for vibration velocity at the
crankgear is 8 mm/s (root mean square, RMS). Since there are only regu-
lations for the crankcase in the existing standards, Burckhardt Compres-
sion has defined additional limits for the cylinder 13 mm/s (RMS) and for
the components as follows: allowable vibration velocity of 30 mm/s (RMS)
and maximum displacement of 1mm peak to peak. These values have
been checked and are based on long experience with components on re-
ciprocating compressors which have been exposed to such vibrations
without any damage occurring.
The components used by Burckhardt Compression are chosen in such a
way that these guarantee a faultless operation under constantly occurring
vibrations in the range of the given limit values, without taking any damage.
The limit values for the individual parts are based on a limiting curve at the
foundation (machine fixation level). Should there be lower values regis-
tered at the foundation, then the other limiting values can be reduced ac-
cordingly.
Part Vibration velocity mm/s RMS

Foundation 3
Frame (top) 8
Cylinder 13
Components 30
Tab. 5-5 Maximum vibration values

5.16.10 Frame Vibration Measurement

Compressors can be equipped with different kinds of measuring instru-
ments for measuring frame vibrations.
If there is no description available of the setting procedure for the built-in
vibration sensors in chapter 13 Appendix, and the vibration sensor is not
connected to a Prognost monitoring system, proceed as follows:
1. Whether acceleration sensors or velocity sensors are installed, the

sensors have to be set according to the RMS values.
2. For setting the predefined preliminary alarm values H and HH see sec-
tion “Instrumentation” in chapter 13 Appendix.
We strongly recommend to perform commissioning under the supervision

of a specialist from Burckhardt Compression. The experience of our super-
visor allows him to judge the proper running of the compressor.
For damage caused by non-professional commissioning, Burckhardt Com-
pression will not assume any liability.
3. During commissioning special attention must be paid to vibration and

unusual noise. Use hand held vibration equipment for more detailed vi-
bration information.
4. During the first period of operation (max. 2 months) check all relevant
operation modes. A detailed monitoring should show the different
levels of vibration reached for each operation mode.
Pay special attention to values received during the transition phase be-
tween the different modes. Record all measured values.
Under normal circumstances the recorded maximum values are much,
much lower than the predefined alarm values H and HH.
5. Send the recorded values to Burckhardt Compression. Based on this
information Burckhardt Compression defines the specific alarm values
H and HH for the given compressor installation.
6. Adjust settings according to these final alarm values.
This procedure leads to an optimized vibration protection safety.
Never change these specific set values; except when the compressor has
to undergo a general overhaul. In this case, repeat the whole procedure
above starting at step 1.

5.16.11 Inspect Compressor Plant

• After assembly of the complete gas piping system incl. dampers,
coolers and all fittings, perform a system leak test according to local
regulations and project procedures.
• All safety and monitoring instruments must be connected. Their func-
tionality must be tested and ensured.
• Following the successful compressor test run, thoroughly retighten all
flange connections and pipe fixations applying applicable tightening
torque see “Compressor” in chapter 13 Appendix.
• Should pipe vibrations occur, please refer to section 5.16.9 Assess Vi-
brations.
Furthermore, it is advisable to check the following points:

• Suction strainer, separator or alternative means in the gas lines
• Some of the suction and discharge valves
• Visual check of the pistons
• Visual check of crankgear
5.16.12 Preserve Compressor Plant after Installation

Period of Standstill If a compressor plant cannot be put into operation for more than 2 months
Exceeds 2 Months after installation, the compressor and its auxiliary equipment should be pro-
tected against possible standstill damage by taking appropriate measures
for the respective period of time.
CAUTION
Standstill damage possible!
Due to the numerous possibilities of installation and employment of our
compressors, instructions on preservation depend on application.
 Please contact Burckhardt Compression Services, address see section
1.6 Contact Address.
General Procedure The following procedure is intended to provide general advice. Depending
on your application, our instructions on preservation are liable to amend-
ment or supplement at any time.
1. Drain the cooling chambers of the compressor and the coolers. Leave
the drain valve open.
2. Fill crankgear with lubricating oil.

A special corrosion protecting oil from a reputable supplier may be
used during the standstill period.
3. Oil the piston rods well by hand up to the oil shield. Turn the flywheel a
number of times.

Generally, the gas conducting compressor and plant components should

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

continuously through with nitrogen, or kept under a slight overpressure of
0.05 bar g/0.005 MPa g/0.05 kg/cm2.
DANGER
Pressurized vessel or pipe!
Plant/compressor under nitrogen pressure.
 Fit a corresponding warning sign on the installation.
 Depressurize plant before you start working.
Under all circumstances, prevent moist air from entering the compressor/
system.
DANGER
Health hazard!
symptoms.
5. Alternative solution:
To prevent corrosion in the vicinity of the cylinder, insert moisture ab-
sorbent agent – e.g. VCI mats (Volatile Corrosion Inhibitor) – in the cyl-
inder, valve spaces and distance piece.
Experience has shown that in the area of the lubricated crankgear, ab-
sorbent agents are not necessary.
CAUTION
Forgotten absorbent agent mats can damage the compressor!
 Record number and location of absorbent agent packs/mats in the
compressor.
 Make sure the flywheel can still be turned manually.

5.16.13 Maintain Plant during Decommissioning
1. Check condition of moisture absorbent agent every six months and re-
place if necessary.
2. To protect the bearings and to check that everything is in proper

working condition, switch on the prelubrication pump for about 5 to
10 minutes every week and, at the same time, turn the flywheel (min.
1 rotation).
Be careful of absorbent agent packs in the cylinders!
3. Large differences between day and night temperatures can lead to

condensation in the electric motor. Due attention should be given to this
occurrence during the standstill period and before putting into opera-
tion again (dry out, heat, ventilate, check insulation resistance, etc.).
motor manufacturer.
4. Annually conduct a condition check of the complete compressor

system.
5.16.14 Recommission Plant

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

when this work is carried out.
motor manufacturer.
Commission compressor/plant according to instructions in section 6.2

Commissioning.

Operation
6 Operation
6.1 Design Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.2 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.2.1 Prepare Operation . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3 Operation with Process Gas . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.3.1 Safety of Operation. . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.3.2 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3.3 Buffer Gas to Piston Rod Packing and Distance
Piece Packing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3.4 Monitor Operation. . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.4 Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 11
6.4.1 Control Unit with Solenoid Valve . . . . . . . . . . . . . 6 - 11
6.4.2 Controlled Suction Valve and Actuator . . . . . . . . . 6 - 12
6.5 Standstill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 13

Operation

Operation
Design Data
6.1 Design Data
Specification Value
Key word PENGERANG-09
Compressor type 2B1XC2.64_1
Serial no. 200322
Weight of compressor (without flywheel) 20340 kg
Year of manufacture 2016
Process gas Nitrogene (N2)
Mass flow 48503 kg/h
Standard volume 39691 Nm3/h
Suction volume 5948 m3/h
Suction temperature 50 °C
Suction pressure 8.0 bar a/0.8 MPa a/8.0 kg/cm2
a
Discharge pressure 15.0 bar a/1.5 MPa a/15.0 kg/
cm2 a
Shaft power (coupling) 1102 kW
Electric motor rating 1300 kW
Rotation speed 370 rpm

Operation
Commissioning
6.2 Commissioning
For detailed instruction about commissioning please refer to section “Con-

trol Description” in chapter 13 Appendix.
6.2.1 Prepare Operation

Carry out the following tasks before starting the compressor
• after pre-commissioning
• after maintenance
• when recommissioning
1. Make sure that all instruments are calibrated.

2. Check that all safety devices are fitted and operational.
3. Check all control loops for continuity.
4. Open all valves to safety instruments.
5. Open supply valves (from pneumatic medium) to all pneumatically con-
trolled valves.
6. Check dampers for liquid by briefly opening drain valves.
7. Open required coolant valves to the oil coolers.
8. Check that spectacle flanges (if applicable) have been set to position
for normal operation (gas flow open).
9. Check oil level in oil tank (must be roughly at 3/4 of oil sight glass(es)).
10. Check lubrication for motor bearings according to manufacturer’s rec-
ommendation.
After maintenance work or after long standstill periods:
DANGER
Unintended start-up of compressor is possible!
 Turn off the power at the switch box and padlock the switch in the OFF
position.
11. Turn flywheel of compressor min. 1 rotation by means of barring device

in running direction and verify that everything is in proper mechanical
condition.

Operation
Operation with Process Gas
DANGER
12. Open discharge line valve.
13. Check hook-up of suction valve actuators and verify that they are
working properly.
6.3 Operation with Process Gas
6.3.1 Safety of Operation

Safety Precaution Process gas may be dangerous. Read the detailed gas description and
warnings in section 2.9 Process Gas and Purge Gas.
WARNING
Limited operational safety!
components and/or their operational safety may be influenced negatively
(= increased risk) by improper actions.
WARNING
Hot surface – burn hazard!
Gas discharge pipes may have surface temperatures above 70 °C.
 Do not touch.
 To avoid possible skin burns, allow surface to cool down before main-
tenance.
CAUTION
High sound level!
 Be aware that communication in the plant may be impaired due to
noise.
 Wear hearing protection.

Operation
WARNING
Slip hazard!
 Watch your step.
6.3.2 Handling
Detailed information about starting and stopping of the compressor, see
section “Control Description” in chapter 13 Appendix.
WARNING
An emergency situation may occur.
 Before switching on the motor (= compressor start), check the emer-
gency stop push button for proper functioning.
Continuous Operation The compressor must be supervised by well-trained operators. To facilitate

checking, the readings of pressures, temperatures, etc. and inspections
listed below must be recorded in a log sheet (see example in section 6.3.4
Monitor Operation). Have a hour meter installed or record operating hours
in the log sheet. This guarantees better and more reliable care and main-
tenance of the compressor.
Check periodically:
• Suction, (intermediate, if applicable) and final pressure. The hands of
the pressure gauges must continuously oscillate slightly.
• Lubricating oil pressure.
• Gas temperatures at suction and discharge side of the compressor.
Process gas temperature can be affected by a change of operating or at-

mospheric conditions (e.g. warm cooling water, high ambient temperature)
or due to a technical defect.
• Ampere reading of electric motor.
6.3.3 Buffer Gas to Piston Rod Packing and Distance Piece

Packing
Components of Purge For layout of the purge and buffer gas system see section “P & I Diagram”
System in chapter 13 Appendix.
The purge and buffer gas system (e.g. orifice plates) and the purging pro-
cedure must be fine tuned during commissioning.

Operation
Purging during Normal Buffer gas (N2) is supplied to the piston rod packing and distance piece
Operation packing. The buffer/leak gas outlet (with traces of process gas) is con-
nected to the flare. To set the pressure of the buffer gas, a control valve with
a pressure indicator is installed. Additionally, there is a pressure transmitter
for pressure indication in DCS and an alarm in case of low pressure in the
buffer gas line.

Operation
6.3.4 Monitor Operation

Example of a Log Sheet:
Log Sheet TDO_2005678_E01_01.docx
Compressor S/N: Compressor Type: Order / Job No.:
Speed min-1: Gas: Operating hours:

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

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

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

Capacity mode %
By-pass 1st Stage open
%
(open=100%)
By-pass over all open
%
(open=100%)
XA_XX_0039a_0
Template : TDO 2005678 Rev. Dat. Sig. Ersatz für Seite 1 von 3
Erstellt / Prepared 01.04.2015 KAUFMANN_W Replacement for Page 1 of 3
Überprüft / Reviewed B 07.04.2015 WEISS_M Revision gedruckt / printed:
Freigabe / Approval DVS 07.04.2015 KAUFMANN_W vom / date 07.04.2015
Fig. 6-1 Example of a log sheet (first page)

Operation
Date
Time / Start
O Crankcase pressure barg / psig
I Pump suction pressure barg / psig
L Pump disch. pressure barg / psig
Pressure to bearing barg / psig
p to bearing barg / psig
p filter barg / psig
Temp. before cooler °C / °F
Temp. after cooler °C / °F
W Inlet pressure barg / psig

A Inlet temperature °C / °F
T Cylinder 1. Stage °C / °F
E Cylinder 2. Stage °C / °F
R Cylinder 3. Stage °C / °F
Cylinder 4. Stage °C / °F
Packing 1. Stage °C / °F
Guide bearing °C / °F
Crosshead °C / °F
Oil cooler °C / °F
Inter cooler 1. Stage °C / °F
C Main Bearing No. 1 °C / °F

R Main Bearing No. 2 °C / °F
A Main Bearing No. 3 °C / °F
N Main Bearing No. 4 °C / °F
K Main Bearing No. 5 °C / °F
G Main Bearing No. 6 °C / °F
E Main Bearing No. 7 °C / °F
A Main Bearing No. 8 °C / °F
R
Conn. Rod Bearing V1 °C / °F

XA_XX_0120a_03
Fig. 6-2 Example of a log sheet (second page)

Operation
Date
Time / Start
C Crosshead V1 °C / °F
R Crosshead V2 °C / °F
A Crosshead V3 °C / °F
N Crosshead V4 °C / °F
K Crosshead V5 °C / °F
G Crosshead V6 °C / °F
E Crosshead V7 °C / °F
A Crosshead V8 °C / °F
R
M Voltage kV
O Current A
T Cos
O Bearing temp. DE °C / °F
R Bearing temp. NDE °C / °F
Winding U °C / °F
Winding V °C / °F
Winding W °C / °F
Place: Signature / Name, BC:

Date: Signature / Name, Customer:
XA_XX_0D_0 1
Fig. 6-3 Example of a log sheet (third page)

Operation
Capacity Control
6.4 Capacity Control

For information about capacity control see “P & I Diagram” and “Control De-
scription” in chapter 13 Appendix.
Components for Capacity The controlled suction valves are equipped with actuators. The actuators
Control are controlled by the control unit.
6.4.1 Control Unit with Solenoid Valve

The electrical control unit is installed on the Local Instrument Board (LIB).
The capacity is altered by means of controlled suction valves. The neces-
sary gas to control the actuators of the controlled suction valves is led from
the control unit to the actuators.
Control Unit The control unit has the function of a 3-way valve. It is electrically activated.
Fig. 6-4 Control unit with solenoid valve (typical view)
CAUTION
Excessive wear of pistons!
 Limit the operation time on 0 % load to maximum 5 minutes.

Operation
Capacity Control
6.4.2 Controlled Suction Valve and Actuator

Functional Principle The controlled suction valves are equipped with actuators to operate the
compressor at 0 %, 50 %, 75 % or 100 % load.
1 2 3 4 5 6 7
XA_C3_0003b_01
Fig. 6-5 Controlled suction valve with actuator operated by medium
P Control pressure 4 Pressure pin

1 Controlled suction valve 5 Spring F
2 Finger unloader 6 Actuator piston
3 Pressure sleeve 7 Actuator
With spring configuration F, the valve opens and closes normally if control
pressure P = 0.
In the no-load position of the suction valve, the control pressure (P) is
pressing the pressure pin (4) through pressure sleeve (3) and finger un-
loader (2) towards the valve plate, which is pushed to the valve guard.
Thus, the process gas can flow back to the suction side.
Control Medium The actuators (7) are operated with nitrogen.

The required pressure for the control medium is 3.5 bar/0.35 MPa/
3.5 kg/cm2.
CAUTION
Too low control pressure leads to malfunction of the capacity control
system, thus results in damage on valves and pistons!
 Maintain control pressure at required value.

Operation
Standstill
6.5 Standstill
Period of Standstill During the whole standstill period, the plant/compressor should be kept
24 h to 2 Months under a slight overpressure of 0.05 bar g/0.005 MPa g/0.05 kg/cm2 g. If no
process gas is available, nitrogen shall be used. In this case, full isolation
from gas system may be required.
DANGER
Plant/compressor under process gas/nitrogen pressure.
system.
CAUTION
Deposits in piping!
 Avoid stationary coolant.
A minimal flow of coolant must always be maintained.

During longer standstill periods (exceeding a month):
If an antifreeze solution is used, drainage is not necessary under certain

circumstances.

1 rotation).
Large difference between day and night temperatures can lead to conden-
sation in the electric motor. Due attention should be given to this occur-
rence during the standstill period and before putting into operation again
(dry out, heat, ventilate, check insulation resistance, etc.).
Period of Standstill If the standstill period of the compressor exceeds 2 months, refer to section
Exceeds 2 Months 11.1 Preserve Compressor Plant or consult Burckhardt Compression Ser-
vices (address see section 1.6 Contact Address).

Operation
Standstill

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

7.2 Trouble Shooting List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.2.1 Process Gas System . . . . . . . . . . . . . . . . . . . . . . 7-4
7.2.2 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.2.3 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . 7 - 10
7.2.4 Compressor Noise . . . . . . . . . . . . . . . . . . . . . . . . 7 - 15
7.2.5 Compressor Vibrations . . . . . . . . . . . . . . . . . . . . . 7 - 19
7.2.7 Compressor Shutdown . . . . . . . . . . . . . . . . . . . . . 7 - 21
7.2.8 Compressor Start-Up Interlock . . . . . . . . . . . . . . . 7 - 23

Trouble Shooting

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

Use this trouble shooting list as soon as any faults or troubles have been
observed.
The first column from the left with the pictogram follows up the display and/
or control elements on the compressor.
The changes of operating conditions can be identified in the “Location”
column.
In the “Cause” column, the most common reasons for the origin of the
trouble are listed.
The “Trouble Elimination” column gives keywords for the settling of the
trouble, the column “See Section” refers to the respective detailed instruc-
tions.
If no Instruction Manual section is mentioned in this column, the documen-
tation as listed in these footnotes must be consulted:
BCS1) Please contact Burckhardt Compression Services, address see sec-

tion 1.6 Contact Address.
CD2) See “Control Description” in chapter 13 Appendix. If CD is not part of
this appendix, please refer to customer’s/operator’s approved operating in-
structions.
TD3) For detailed description see documentation of the manufacturer in
Technical Documentation.
4)
For tightening torques see “Compressor” in chapter 13 Appendix.
5) For orifice plates see “Technical Data” in chapter 13 Appendix.

7–4
Trouble Shooting List

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

Suction side of a stage (within Wear of piston rings • Check piston rings 8.9.3 Piston
IM 200322en
about 2 months) Wear of cylinder liner • Replace piston rings 8.9.4 Piston Nut SUPER-
Malfunction/wear of suction • Replace cylinder liner BOLT®
P
valve • Check/replace suction valve 8.10.2 Valve Failures (Mal-
function)
9.11 Piston and Piston Rod
9.15 Cylinder
BCS1)
Discharge side of a stage Increased suction pressure • Reduce suction pressure/flow CD2)
2B1XC2.64_1
rate
Suction temperature lower • Adjust gas cooler BCS1)
than designed
Piston rod packing Wear of piston rod packing • Replace piston rod packing 8.9.2 Piston Rod Packing
rings rings 9.13 Piston Rod Packing
st
Discharge pressure 1 stage Excessive suction pressure • Reduce suction pressure/flow CD2)
too high rate
Rev. 001/kalajdzisa_a
18.05.2016
18.05.2016
Pressure Drop Location Cause Trouble Elimination See Section

Piping Fracture • Repair/replace piping 5.13 Install Pipe Work
9.14 External Gas Pipes
P
Flange connection Defective gasket • Replace gasket 8.6.3 Flange Connections and
Pipe Fastenings
Loose connection • Tighten flange connection 8.6.3 Flange Connections and
Pipe Fastenings
Insufficient elongation length • Rework piping 5.13.3 Check Fabrication
through thermal stress
Suction side 1st stage Defective pressure gauge • Repair/replace pressure CD2)
gauge
Clogged suction strainer • Clean/repair suction strainer 5.16.11 Inspect Compressor
2B1XC2.64_1
Plant
Wrong position of shut-off • Adjust valve position TD3)
valve in suction pipe 1st stage • Check/repair control system
Wrong position of vent valve • Adjust valve position TD3)
• Check/repair control system
Leaking of pressure safety • Repair/replace PSV TD3)
valve (PSV)
IM 200322en

Trouble Shooting
7–5
7–6

Trouble Shooting
Temperature Rise Location Cause Trouble Elimination See Section
Suction side (general) Defective suction valve • Repair/replace valve 8.10.2 Valve Failures (Mal-
function)
8.10.3 Maintenance of Con-
trolled Suction Valves
T
9.7 Suction Valves and Dis-
IM 200322en
charge Valves
Suction side 1st stage Too hot process gas before 1st • Check function of previous 8.6.4 Cooling System
stage gas cooler (if applicable)
Insufficient cooling of bypass • Clean/repair cooler 8.6.4 Cooling System
cooler (if present)
Discharge side (general) Defective suction or discharge • Repair/replace valve 8.10.2 Valve Failures (Mal-
valve on corresponding stage function)
2B1XC2.64_1

charge Valves
Wear of piston rings on corre- • Replace piston rings 9.11 Piston and Piston Rod
sponding stage 9.15 Cylinder
Insufficient coolant flow • Adjust setting CD2)
through cylinder
Fouled cooling chamber of cyl- • Clean cooling chamber 8.6.4 Cooling System
inder
Cylinder defective parts inside cylinder • Repair cylinder 9.15 Cylinder
(pitting, crack)
18.05.2016
18.05.2016

Pressure difference, from sup- Restricted cross-section due • Clean cooling system (interior) 8.6.4 Cooling System
ply to return to fouling
Process gas cooler bundle de- • Repair/replace cooler bundle 8.6.4 Cooling System
fect, gas leakage into coolant

Coolant return Restricted cross-section due • Clean cooling system (interior) 8.6.4 Cooling System
2B1XC2.64_1
to fouling
Leakage • Repair/replace defect compo- 8.6.4 Cooling System
P
nents 8.6.3 Flange Connections and
Pipe Fastenings
Process gas cooler bundle de- • Repair/replace cooler bundle 8.6.4 Cooling System
fect, coolant leakage into gas
system (if coolant pressure
higher than gas pressure)
IM 200322en

Trouble Shooting
7–7
7–8

Trouble Shooting
Coolant supply Incorrectly maintained and/or • Service cooling system 8.6.4 Cooling System
adjusted cooling system • Adjust setting CD2)
T
IM 200322en
Not correct working valves • Replace valves 8.6.4 Cooling System

TD3)
Too high ambient temperature • Adjust setting CD2)
(summer)
Temperature difference from Insufficient flow in the respec- • Adjust setting CD2)
inlet to outlet of a cooling sec- tive cooling section
tion
Insufficient coolant differential • Adjust setting CD2)
2B1XC2.64_1
pressure
Restricted cross-section due • Clean cooling surfaces 8.6.4 Cooling System
to fouling
Piston rod packing Deposits in cooling chambers • Clean cooling chambers and/ 8.6.4 Cooling System
and/or cooling channels of pis- or channels 8.9.2 Piston Rod Packing
ton rod packing
9.13 Piston Rod Packing
Temperature Drop Location Cause Trouble Elimination See Section

Coolant supply Incorrectly maintained and/or • Service cooling system 8.6.4 Cooling System
adjusted cooling system • Adjust setting CD2)
Too low ambient temperature • Adjust setting CD2)

(winter)
•
18.05.2016
Coolant return Fouling in cooling chambers: Clean cooling system (interior) 8.6.4 Cooling System
deposits of mud, sand, algae,
calcium etc.
18.05.2016

Poor coolant quality (no or • Change coolant 8.6.4 Cooling System
wrong coolant treatment) • Correct coolant quality
Temperature difference from No coolant flow/too low flow • Clean cooling system (interior) 8.6.4 Cooling System
inlet to outlet of a cooling sec- rate in respective section • Adjust setting
tion through fouling
Excessive coolant flow in re- • Adjust setting CD2)

spective section
Liquid Level Drop Location Cause Trouble Elimination See Section

Cooling system Leak in cooling system • Repair cooling system 8.6.3 Flange Connections and
Pipe Fastenings
2B1XC2.64_1
IM 200322en

Trouble Shooting
7–9
7 – 10

Trouble Shooting
7.2.3 Lubricating System

External oil tank Too low ambient temperature • Change oil viscosity 8.6.6 Oil Change
IM 200322en
(oil too thick)
Unsuitable oil used • Change oil 8.6.6 Oil Change

8.6.7 Lubricating Oil Specifica-
tions
Pressure difference from inlet Clogged filter • Switch to the other filter ele- 8.6.5 Lubricating System
to outlet of duplex oil filter ment, clean/replace clogged TD3)
2B1XC2.64_1
filter element
Pressure control valve Wrong adjusted control valve • Adjust setting TD3)
Relief valve Wrong adjusted relief valve • Adjust setting TD3)

External oil tank Clogged oil strainer in external • Clean oil strainer TD3)
oil tank
Too low oil level • Refill oil 8.6.6 Oil Change

tions
Blocked lubrication pump • Remove foreign object TD3)
• Check lubrication pump com-
ponents for damages
18.05.2016
• Replace defect components

18.05.2016

Excessive oil loss at the crank- • Replace main bearing 9.26 Bearings
shaft bearing through exces-
sive bearing clearance
Excessive oil loss at the con- • Replace bearing shell 9.19 Connecting Rod Bearing
necting rod bearing through
excessive bearing clearance

Excessive oil loss at the cross- • Replace bearing bush 9.21 Crosshead Pin Bearing
head pin bearing through worn
bearing
Defective oil pressure gauge • Replace pressure gauge TD3)
Too low oil viscosity • Change oil 8.6.6 Oil Change
tions
CD2)
2B1XC2.64_1
Too high oil temperature due • Adjust setting of cooling

to insufficient coolant flow system
through oil cooler
Broken drive of gear oil pump • Repair pump drive 9.22 Gear Oil Pump
Pressure control valve Wrong adjusted control valve • Adjust setting TD3)
Relief valve Wrong adjusted relief valve • Adjust setting TD3)
Defective relief valve • Repair/replace relief valve TD3)
Lubrication pump and prelubri- Too long suction piping • Rework piping/suction system 5.13.3 Check Fabrication
IM 200322en
cation pump BCS1)

Too small piping cross-section • Rework piping 5.13.3 Check Fabrication
Air in the suction piping • Repair leak on piping 8.6.3 Flange Connections and
• Fill piping with oil (use lubrica- Pipe Fastenings

tion pump)
Trouble Shooting
Leaking or defective non-re- • Repair/replace valve 8.6.3 Flange Connections and
turn valve Pipe Fastenings
TD3)
7 – 11
Wrong adjusted relief valves • Adjust setting 8.6.8 Safety Devices

7 – 12

Trouble Shooting
Defective relief valves • Repair/replace valve 8.6.8 Safety Devices
After repair: wrong direction of • Correct electrical connection TD3)
rotation
Power failure • Repair power supply TD3)
Blocked lubrication pump • Remove foreign object TD3)
IM 200322en
• Check oil pump components

for damages
• Replace defect components
Cooler Fouled oil cooler (coolant side) • Clean oil cooler (interior) 8.6.4 Cooling System
Duplex oil filter Clogged duplex oil filter • Switch to the other filter ele- 8.6.5 Lubricating System
ment, clean/replace clogged
filter element
Drive system Wrong running direction of • Change running direction of 6.2 Commissioning
2B1XC2.64_1
compressor compressor

Crankgear Bearing defective • Replace bearing 9.26 Bearings
T
Lubricating oil too hot • Adjust water supply to oil TD3)

cooler
Oil cooler Insufficient coolant flow • Adjust setting of cooling CD2)
through oil cooler system
Fouled oil cooler (coolant side) • Clean oil cooler (interior) 8.2.2 Clean Compressor Plant
18.05.2016
18.05.2016

Oil temperature indicator Excessive cooling • Adjust setting of cooling CD2)
system
T
Level Drop Location Cause Trouble Elimination See Section

Crankgear Leaking oil scraper (into the • Replace wiper elements 9.18 Oil Scraping
distance piece)
Leaking oil piping • Repair/replace piping 8.6.3 Flange Connections and

Pipe Fastenings
2B1XC2.64_1
Leaking oil cooler • Repair/replace cooler 8.6.3 Flange Connections and

Pipe Fastenings
TD3)
Leaking flat gasket on bearing • Replace flat gasket 9.25 Crankshaft Seal
bracket drive end or non-drive
end
Crankshaft seal Cured/brittle shaft sealing • Replace sealing rings 9.25 Crankshaft Seal
rings
IM 200322en
Oil scrapers (leaking into the Too low oil viscosity • Change oil 8.6.6 Oil Change
distance piece) 8.6.7 Lubricating Oil Specifica-
tions
Wear of wiper elements • Replace wiper elements 9.18 Oil Scraping

Wear of spring plate • Replace spring plate 9.18 Oil Scraping
Trouble Shooting
7 – 13
7 – 14

Trouble Shooting
Level Drop Location Cause Trouble Elimination See Section
Insufficient tension force of • Replace garter springs 9.18 Oil Scraping
garter springs
Damaged piston rod surface • Repair/replace piston rod sur- 9.11 Piston and Piston Rod
(rough, scratched) face 9.18 Oil Scraping
• Check wiper elements BCS1)
IM 200322en
• Replace wiper elements

Incorrectly installed wiper ele- • Replace wiper elements 9.18 Oil Scraping
ments: rings tilted on piston
rod, no offset of inclined cuts
between the rings or contact
surface to piston rod too nar-
row
2B1XC2.64_1
18.05.2016
18.05.2016
7.2.4 Compressor Noise
Regular Dull Location Cause Trouble Elimination See Section

Knocking
•
Connecting rod Loose connecting rod bolts Tighten bolts 9.19 Connecting Rod Bearing
Excessive clearance of con- • Replace bearing shell 9.19 Connecting Rod Bearing
necting rod bearing
Excessive clearance of cross- • Replace bearing bush 9.21 Crosshead Pin Bearing
head pin bearing
2B1XC2.64_1
Crosshead Insufficient crosshead clear- • Rework crosshead 9.20 Crosshead and Connect-
ance ing Rod
BCS1)
Crankshaft Crankshaft bearing defective • Replace crankshaft bearing 9.27 Crankshaft Bearing
Piston rod Loose connection piston rod to • Tighten connection 9.11 Piston and Piston Rod
crosshead
Piston Cylinder clearance • Adjust top/bottom cylinder 9.11.9 Measure the Cylinder
IM 200322en
clearance Clearance
Loose piston nut • Tighten piston nut 8.9.4 Piston Nut SUPER-
BOLT®

Drive system Misalignment of compressor • Realign compressor and 5.11 Install Electric Motor and
Trouble Shooting
and motor motor Coupling
7 – 15
7 – 16

Trouble Shooting
Irregular Dull Location Cause Trouble Elimination See Section
Knocking
crosshead
IM 200322en
Connecting rod Loose connecting rod bolts • Tighten bolts 9.19 Connecting Rod Bearing
Piston Loose piston nut • Tighten nut 8.9.4 Piston Nut SUPER-
BOLT®
Excessive pretension of piston • Adjust pretension 8.9.4 Piston Nut SUPER-
BOLT®
2B1XC2.64_1
Liquid knock • Check piston or piston compo- 8.9.3 Piston

nents for cracks 8.9.4 Piston Nut SUPER-
• Check piston rod to crosshead BOLT®
connection for tightness 9.11 Piston and Piston Rod
• Check connection rod bearing 9.19 Connecting Rod Bearing
for tightness
18.05.2016
18.05.2016
Irregular Dull Location Cause Trouble Elimination See Section

Knocking
Cylinder Damaged suction or discharge • Replace/repair valve 8.10.2 Valve Failures (Mal-
valve function)

charge Valves
Loose valve lantern • Tighten lantern 9.7 Suction Valves and Dis-
charge Valves
Foreign object in the cylinder • Remove foreign object 8.9.3 Piston
• Check piston 8.9.4 Piston Nut SUPER-
• Replace piston or piston com- BOLT®
ponent 9.11 Piston and Piston Rod
2B1XC2.64_1
• Check cylinder 9.15 Cylinder

• Repair/replace cylinder BCS1)
Regular Metallic Location Cause Trouble Elimination See Section

Knocking
IM 200322en
crosshead
•

Piston Insufficient pretension of the Adjust pretension 8.9.4 Piston Nut SUPER-
piston crowns BOLT®
Trouble Shooting
7 – 17
7 – 18

Trouble Shooting
Regular Metallic Location Cause Trouble Elimination See Section
Knocking
Loose piston skirt • Adjust pretension 8.9.4 Piston Nut SUPER-
BOLT®
Cylinder Loose valve lanterns • Inspect lantern 9.7 Suction Valves and Dis-
IM 200322en
• Repair/replace lantern charge Valves

• Tighten lantern
Too small cylinder clearance • Adjust piston position 8.9.4 Piston Nut SUPER-
BOLT®
Regular High Location Cause Trouble Elimination See Section

Pitched Ringing
2B1XC2.64_1
crosshead
Cylinder Axial lantern clearance • Inspect lantern 9.7 Suction Valves and Dis-

• Tighten lantern
18.05.2016
18.05.2016
7.2.5 Compressor Vibrations
Vibrations Location Cause Trouble Elimination See Section

Process gas piping Inadmissible pulsations • Installation/replacement of ori- 5.13.3 Check Fabrication
fice plates 5.16.9 Assess Vibrations

• Elimination of stress raisers BCS1)
5)
Chafed areas on:– piping– Loose mounting parts • Repair/replace defective parts 8.6.3 Flange Connections and
supports– accessories • Check chafed parts for func- Pipe Fastenings
tion 8.5.1 Tightening Torques and
• Tighten loose parts Method
Cracks in:– piping, pipe junc- Loose mounting parts • Repair/replace defective parts 8.6.3 Flange Connections and
2B1XC2.64_1
tions– supports– accessories • Tighten loose parts Pipe Fastenings

8.5.1 Tightening Torques and
Method
Insufficient elongation length • Rework piping/supports 5.13.3 Check Fabrication
through thermal stress BCS1)
IM 200322en

Trouble Shooting
7 – 19
7 – 20

Trouble Shooting
High Guide Ring Location Cause Trouble Elimination See Section

(Rider Ring) Wear
•
IM 200322en
Piston Guide rings (rider rings) are Assess condition of guide 9.11 Piston and Piston Rod
worn out rings (rider rings)
• Replace guide rings (rider
rings) and piston rings, if nec-
essary
Wrong adjustment of proxim- • Check adjustment of proximity 9.11 Piston and Piston Rod
ity sensor sensor (if value of proximity
sensor was not recorded, only
installation of new piston rings
2B1XC2.64_1
can solve the problem)
High Peak to Peak Location Cause Trouble Elimination See Section

Values on Piston
Rod Position Mea-
surement
(Vibration)
Piston rod Loose parts • Check if piston is tightened in- 9.11 Piston and Piston Rod
cluding piston rod 9.15 Cylinder

• Check if piston is tightened to 9.20 Crosshead and Connect-
crosshead ing Rod
• Check crosshead clearance
• Check cylinder space for con-
tamination and foreign matter
18.05.2016
18.05.2016
7.2.7 Compressor Shutdown
Safety Shutdown Location Cause Trouble Elimination See Section

Instrumentation Failure of instrument air (con- • Repair control medium system TD3)
trol medium)
Failure of control voltage • Repair control voltage system TD3)

Failure of auxiliary supply • Repair control voltage system TD3)
Main motor Failure of main power supply • Repair power supply TD3)
Failure of motor purge system • Repair purge system TD3)
Vibration switch/sensor Damaged crankshaft bearing, • Replace bearing shell 9.19 Connecting Rod Bearing
2B1XC2.64_1
connecting rod bearing or • Adjust bearing installation

crosshead pin bearing
9.21 Crosshead Pin Bearing
Loose connecting rod bolts • Tighten bolts 9.19 Connecting Rod Bearing
Loose connection piston rod to • Tighten connection 9.11 Piston and Piston Rod
crosshead
IM 200322en
Loose piston nut • Tighten piston nut 8.9.4 Piston Nut SUPER-
BOLT®

Trouble Shooting
7 – 21
7 – 22

Trouble Shooting
Safety Shutdown Location Cause Trouble Elimination See Section
Axial lantern clearance • Inspect lantern 9.7 Suction Valves and Dis-
• Tighten lantern
Broken suction or discharge • Repair/replace valve 8.10.2 Valve Failures (Mal-
valve function)
IM 200322en

charge Valves
6)
Incorrect setting • Adjust setting
2B1XC2.64_1
18.05.2016
18.05.2016
7.2.8 Compressor Start-Up Interlock
Interlock Location Cause Trouble Elimination See Section

Control system Active restart interlock • Check control logic –
(not delivered by Burckhardt

Compression)
Electronic fault • Repair control logic –

Prelubrication pump Prelubrication time not yet • Operate prelubrication pump CD2)
elapsed for necessary duration TD3)
Capacity control Low pressure of control me- • Increase control medium pres- CD2)
dium sure TD3)
2B1XC2.64_1
Flywheel guard Not correctly closed • Close guard correctly TD3)

Incorrect position of safety • Adjust safety switch TD3)
switch
Main motor Failure of main power supply • Repair power supply TD3)
Failure of motor purge system • Repair purge system TD3)
For further defects, please re- • Consult technical documenta- TD3)
fer to main motor manufac- tion of manufacturer
IM 200322en
turer’s instruction

Trouble Shooting
7 – 23
Trouble Shooting
Preventive Maintenance
8 Preventive Maintenance
8.1 Importance of Preventive Maintenance . . . . . . . . . . . . . . . 8-3

8.2 Prerequisites for Maintenance . . . . . . . . . . . . . . . . . . . . . . 8-3
8.2.1 Depressurize and Purge Plant . . . . . . . . . . . . . . . 8-6
8.2.2 Clean Compressor Plant . . . . . . . . . . . . . . . . . . . 8-6
8.3 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.3.1 Standard Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.3.2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 10
8.4 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 17
8.4.1 Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 18
8.4.2 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 19
8.5 Plant in General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 21
8.5.1 Tightening Torques and Method . . . . . . . . . . . . . . 8 - 21
8.6 Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 23
8.6.1 Electric Motor and Coupling . . . . . . . . . . . . . . . . . 8 - 23
8.6.2 Gas System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 23
8.6.3 Flange Connections and Pipe Fastenings . . . . . . 8 - 23
8.6.4 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 24
8.6.5 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . 8 - 26
8.6.6 Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 28
8.6.7 Lubricating Oil Specifications . . . . . . . . . . . . . . . . 8 - 29
8.6.8 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 29
8.6.9 Hydrostatic Pressure Test. . . . . . . . . . . . . . . . . . . 8 - 30
8.7 Compressor in General. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 31
8.7.1 Dimensions, Weights, Space Requirement . . . . . 8 - 31
8.7.2 Marking of Compressor Components. . . . . . . . . . 8 - 31
8.7.3 Cylinder Clearance Measurement . . . . . . . . . . . . 8 - 31
8.7.4 Clearance Measurement Log Sheet. . . . . . . . . . . 8 - 34
8.7.5 Piston Rod Runout . . . . . . . . . . . . . . . . . . . . . . . . 8 - 39
8.7.6 Frame Alignment . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 40
8.7.7 Tightening Methods . . . . . . . . . . . . . . . . . . . . . . . 8 - 41
8.7.8 Tensioner SUPERBOLT® . . . . . . . . . . . . . . . . . . . 8 - 42
8.7.9 Locking of Threaded Connections with LOCTITE® 8 - 46
8.7.10 NORD-LOCK® Securing System . . . . . . . . . . . . . 8 - 47
8.8 Crankgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 49
8.8.1 Check Crankshaft Deflection . . . . . . . . . . . . . . . . 8 - 49
8.8.2 Main Bearing and Connecting Rod Bearing . . . . . 8 - 50
8.8.3 Crankshaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 50
8.8.4 Connecting Rod Bearing . . . . . . . . . . . . . . . . . . . 8 - 52
8.8.5 Crosshead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 55
8.8.6 Crosshead Pin Bearing. . . . . . . . . . . . . . . . . . . . . 8 - 56
8.8.7 Distance Piece Packing . . . . . . . . . . . . . . . . . . . . 8 - 56
8.8.8 Oil Scraper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 58
8.9 Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 59

8.9.1 Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 59

8.9.2 Piston Rod Packing . . . . . . . . . . . . . . . . . . . . . . . . 8 - 59
8.9.3 Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 61
8.9.4 Piston Nut SUPERBOLT® . . . . . . . . . . . . . . . . . . . 8 - 64
8.10 Suction Valves and Discharge Valves . . . . . . . . . . . . . . . . . 8 - 69
8.10.1 Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 8 - 69
8.10.2 Valve Failures (Malfunction) . . . . . . . . . . . . . . . . . 8 - 69
8.10.3 Maintenance of Controlled Suction Valves . . . . . . 8 - 70
8.11 Complete Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 73

Importance of Preventive Maintenance
8.1 Importance of Preventive Maintenance

By doing preventive maintenance at regular intervals, these improvements
arises:
• increased life time
• prevention of breakdowns and damages
• increased safety for man and machine
We strongly recommend to do all maintenance work under the supervision

of a specialist from Burckhardt Compression. For damage caused by non-
professional maintenance, Burckhardt Compression will not assume any li-
ability.
If you have any questions concerning maintenance procedures, please

contact your local Burckhardt Compression Office or Burckhardt Compres-
sion Agent. Address see section 1.6 Contact Address.
For details visit our website www.burckhardtcompression.com.
8.2 Prerequisites for Maintenance

Safety Precaution Process gas may be dangerous. Read the detailed gas description and
CAUTION

Prerequisites for Maintenance
Maintenance Guidelines • Carry out adjustments, preventive and corrective maintenance in due
time.
• Regularly check plant components like pressure vessels, coolers,
dampers, separators etc. for deposits and corrosion.
• Recondition loose contacts and damaged cables immediately.
• Protect all plant components such as main motor, oil and cooling
system pumps, pneumatic or hydraulic control systems etc. against un-
intended start-up.
• Before beginning any inspection or repair, turn the current off at the
switch box and padlock the switch in the OFF position.
• Always adhere to local and company safety regulations (e.g. warning
sign “Machine under maintenance or overhaul”, put up safe work plat-
forms, setting spectacle flange etc.).
• Depressurize and purge the compressor plant (see section 8.2.1 De-
pressurize and Purge Plant).
• Select “Maintenance” mode at the distributed control system (DCS).

For further details on maintenance action see section “Control Descrip-
tion” in chapter 13 Appendix.
Lockout and Tagging of

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

Prerequisites for Maintenance
Lubricants, Tightening
Torques and Methods
For applicable lubricants, mandatory tightening torques as well as appro-

priate tightening methods: see sections “Lubricating System” and “Com-
Restart Compressor Perform functional test on protective devices after maintenance.

Turn flywheel of compressor min. 1 rotation by means of the barring device
in running direction and verify that everything is in proper mechanical con-
dition.
PB_L1_0049b_01
1 Flywheel
2 Pawl
3 Proximity probe
4 Barring device
DANGER

Tools
8.2.1 Depressurize and Purge Plant

It is the superior authority’s responsibility to ensure safe working condi-
tions.
WARNING
Compressor/plant still pressurized
Severe injuries and damage to equipment can occur if maintenance is
started before the compressor and plant are completely depressurized.
 Completely depressurize compressor/plant before starting mainte-
nance work!
 Check relevant pressure indicators for atmospheric pressure on com-
pressor and pipe system.
Further information, see section “Control Description” in chapter 13 Ap-

pendix.
8.2.2 Clean Compressor Plant

Assure cleanliness and tidiness of compressor and surrounding area. Use
appropriate cleansing agents and materials. For safe use of cleansing
agents see section 10.3 Select Cleansing Agent.
Please take care of the environment!
When using leach, solvents and cleansing agents, observe manufacturer’s
instructions for use. When working on the compressor, make sure there is
sufficient circulation of fresh air.
8.3 Tools
CAUTION
Increased risk!
Damage to the equipment or risk of injury can occur.
 Only use original (OEM recommended) tools.
 Only use special tools delivered with compressor.
 Clean tools after use and store them in a closed and corrosion-resistant
cabinet nearby the compressor.
8.3.1 Standard Tools
Txxxxx = code no. for ordering special tools and standard tools.

Tools
XA_T9_0005a_01
Fig. 8-2 Combination spanners
T96100: Set of combination spanners 17–46 mm

XA_T9_0032a_01
Fig. 8-3 Ratchet
T96171: 1"
XA_T9_0007a_01
Fig. 8-4 Flogging spanner
T96114: 50 mm

Tools
LA_T9_0009a_01
Fig. 8-5 Eye bolt
T96061: 2 eye bolts M24

XA_T9_0025a_01
Fig. 8-6 Lifting ring VLBG
T96291: Lifting ring VLBG, No. 1, 5T, M30

PA_T9_0008a_01
Fig. 8-7 Torque wrench
T96254: Torque wrench, 40–200 Nm, Type 730R/20–1/2"

XA_T9_0009a_01
Fig. 8-8 Extension for sockets
T96031:

Tools
XA_T9_0010a_01
Fig. 8-9 Hexagonal socket
T96021: 46mm, 1"

T96022: 36mm, 1"
T96023: 16mm, 1/2"
XA_T9_0052a_01
X
Fig. 8-10 Hexagonal socket
T96141 Hexagonal socket 10mm–1/2"

PA_T9_0026a_01
Fig. 8-11 Pull-off device for removing crosshead pin
T97070
XA_T9_0051a_01
Fig. 8-12 Stepped mandril
T96311: Stepped mandril/arbor, 1x stepped, No. 1

Tools
XA_T9_0108a_01
Fig. 8-13 Set of reamers
T96600
8.3.2 Special Tools
Txxxxx = code no. for ordering special tools and standard tools.

Tools
4 3
PA_T9_0007b_01
Fig. 8-14 Dismantle cylinder cover
1 Eye bolt with rope

2 Cylinder cover
3 Bar
4 Cylinder
T97235: Bar dia. 30x1200 mm

XA_T9_0036a_01
Fig. 8-15 Pulling eye bolt
T97271: Pulling eye bolt, No. 1


Tools
PA_T9_0009a_01
Fig. 8-16 Valve mounting spanner
T97431: Valve mounting spanner, No. 1
11 1
2
10
9
3
8
4
7 5
6 2
PA_T9_0041c_01
4
11
Fig. 8-17 Valve dismantling and assembling device
1 Bottom plate 7 Ratchet

2 Additional guiding bar 8 Pick-up disc
3 Guiding bar 9 Centering bolt
4 Guiding plate 10 Spindle
5 Mandril 11 Allen screw
6 Clamping device (movable)
T97374: Valve dismantling and assembling device, No. 1

Tools
PB_T9_0077a_01
Fig. 8-18 Ratchet
T97392
PA_T9_0006a_01
Fig. 8-19 Dismantling and assembling device for connecting rod
T97460

Tools
PA_T9_0024a_01
Fig. 8-20 Stop for T97460
T97470
PA_T9_0022a_01
Fig. 8-21 Protective sleeve for piston rod
T97450

Tools
PB_T9_0144b_01
Fig. 8-22 Piston rod supporting device
1 Distance piece 4 Support for piston rod

2 Centering shaft 5 Cylindrical pin
3 Spindle 6 Oil scraper
T97455
4
PA_T9_0043a_01
Fig. 8-23 Piston rod assembly sleeve
1 Eye bolt 3 Piston rod

2 Piston rod assembly sleeve 4 Piston

Tools
T97451: M56
PB_T9_0007b_01
2 1
Fig. 8-24 Piston assembly steel sheet
1 Stopper
2 Piston assembly steel sheet
T97335: Piston assembly steel sheet, No. 1
1 2 3
PA_T9_0002b_01
Fig. 8-25 Dismantling and assembling device for piston
1 Piston rod
2 Piston
3 Dismantling and assembling device
T97440

Maintenance Schedule
8.4 Maintenance Schedule
The indications on the following tables serve as general guideline only. The
final schedule should be worked out together with Burckhardt Compression
Services. We refer to the specific maintenance requirements in this Instruc-
tion Manual.

8.4.1 Plant
Maintenance Work See Hours of operatio

section
4000 8000 16000 24000

Drain oil, clean oil strainer, oil tank, crankgear and duplex oil fil- 8.6.5,
x x x x
ter (if applicable). First time after 200 hours of operation. 8.6.5
Check set points of the safety devices; conduct function test 8.6.8
x x x x
and complete the corresponding life passports.
Piping: 8.6.3
Check bolted connections, flanges and pipe clamps for tight- x x x
ness
Damper(s): 3.3.4
x x x
Check proper condition of damper
Auxiliaries: 10
Clean compressor-related auxiliaries to avoid dust accumula- x x x x
tion on surfaces.
Safety and relief valves: 8.6.8
x x
Check proper functioning of safety valves

8.4.2 Compressor
Maintenance Work See Hours of opera

section
4000 8000 16000 24000

Foundation 5.4
Cleanliness: Visual check of oil and water
Foundation protection: Visual check for cracks and chipping x x x x
Vibrations: Vibration measurement of connections:
Compressor/Frame – Foundation
Safety and Control Instruments 3.7
Safety valves: Function, tightness, lead sealing
Interlock System: Performance test of control and safety instru-
ments. Check set points of the safety instruments Annually
PI and TI: Check by comparison instrument and if necessary
recalibrate or replace
Flow indicator: Check and, if necessary, repeat calibration
Valves: Check valves, valve lanterns, valve gaskets and valve 8.10, 9.7
x x x x
seats
Pistons: Check clearance of piston rings and wear of piston 8.9.3,
and guide rings (rider rings) 9.11, x x x
Piston rod: Check surface for scoring and wear 8.9.1
Cylinder(s) 9.11.9,
Cylinder liner: Measure diameter and check running surfaces 9.15.3 x x x
for scoring and surface flaking
Piston rod packing(s): Check sealing elements, wear and axial 8.9.2,
x x x
clearance 9.13
Cooling spaces: Clean cooling spaces of cylinder, cylinder 8.6.4 Every 8000–16000 hrs., depend
cover and packing (if any) treatment
Distance Piece(s) 8.8.7,
Distance piece packing: Check sealing elements as well as 9.17 x x x x
wear and axial clearance
Distance Piece 8.8.8,
9.18 x x x x
Oil scraping: Check oil scrapers
Crankgear 8.8.3,
3.7.6 x x x x
Breather: Clean and check condition
Crankshaft seal: Check condition of sealing and shaft surface 8.8.3,
x x x
9.25
Check bearing clearance: check bearing clearances with feeler 8.8.2,
gauge, without dismantling of bearings: 8.8.4,
- Crankshaft bearings 8.8.6,
9.27, x
- Connecting rod bearings
- Crosshead and crosshead liner 9.20,
- Crosshead pin and crosshead pin bearing 9.21

Maintenance Work See Hours of operation

section
4000 8000 16000 24000 3

Bearings 8.8.2,
Random check of bearings by dismantling of bearings as men- 8.8.4,
tioned 9.27,
9.21,
9.27,
9.28
Crankgear lubrication: 8.6.6,
Drain oil, clean oil strainer, crankgear and duplex oil filter (if ap- 8.6.5. x x x
plicable). First time after 200 hours of operation.
Oil cooler: 8.6.4,
Clean cooling spaces and replace gaskets (depending on foul- 8.6.5 x x
ing factor and water treatment)
Prelubrication pump: replace shaft seal 8.6.5 If shaft seal is leaking
Relief, shut-off and control valve(s): clean and replace sealings 8.6.5,
x
8.6.8
Drive 5.11
Alignment of coupling: Compare with manufacturer data (radial
x
and axial deviations)
Electric motor: Check insulation resistance
• If motor is rigidly coupled to crankshaft: check crankshaft 5.11.4
deflection by a crankshaft dial indicator,
• if a flexible coupling is installed: check correct coupling in-
stallation by checking crankshaft deflection. x
(Crankshaft dial indicators may be ordered from Burckhardt

Compression)
Clean compressor surfaces to avoid dust accumulation. 10 x x x x

Plant in General
8.5 Plant in General
8.5.1 Tightening Torques and Method

For specific tightening methods for the compressor please see section
8.7.7 Tightening Methods and a comprehensive table with tightening
torques can be found in chapter 13 Appendix.
Tightening Method I Bolted Connections of Secondary Level

• This category includes all bolts not being particularly stressed during
operation.
• Tightening is usually done using a standard-sized wrench without ex-
tension.
• Tightening torques depend on bolt size and material.
• Torque values are listed in the following table.
Bolt quality class and bolt material are marked on the head of a bolt (see
Fig. 8-26).
Should questions arise, please contact Burckhardt Compression Services

(address see section 1.6 Contact Address).
1
XA_XX_0111b_01
Fig. 8-26 Marking on bolts
1 Marking (quality class and material)
Data only applicable if no other tightening methods or torque values are

specified.
CAUTION
If gaskets are used, attentively follow the specifications of the gasket man-
ufacturer!

Plant in General
Tightening Method • Clean areas of support (connecting parts) free of grease

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

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

M12 25 2.5 18.4 39 4 28.8
M14 39 4 28.8 64 6.5 47.2
M16 59 6 43.5 93 9.5 68.6
M18 83 8.5 61.2 132 13.5 97.4
M20 113 11.5 83.3 177 18 130.6
M22 147 15 108.4 245 25 180.7
M24 186 19 137.2 324 33 239
M27 265 27 195.5 461 47 340
M30 343 35 253 638 65.1 470.6
M33 422 43 311.3 834 85 615.2
M36 530 54 390.9 1080 110.1 796.6
M39 667 68 492 1373 140 1012.7
M42 – – – 1766 180.1 1302.6
M45 – – – 2256 230 1664
Data valid only using MOLYKOTE® G-N Plus!

Plant
8.6 Plant
8.6.1 Electric Motor and Coupling

Electric Motor If electric motor has been removed for its overhaul and/or if the crankshaft
deflection of the compressor crankshaft is larger than the permitted limit
(see section 5.11.4 Check Crankshaft Deflection) the electric motor must
be realigned.
Realignment is simplified if the position of the main motor had been marked
with positioning pins during installation.
For realignment proceed according to section 5.11 Install Electric Motor
and Coupling.
8.6.2 Gas System

Cooler, Damper and Plant components under pressure, such as pressure vessels, coolers,
Separator dampers, etc. must be inspected periodically for deposits or corrosion ac-
cording to local and/or work regulations. If pressure test must repeated pe-
riodically, see section 8.6.9 Hydrostatic Pressure Test.
8.6.3 Flange Connections and Pipe Fastenings

Gaskets/Seals Check gaskets and seals on a regular basis and use them only once.
Flange Connections/Pipe Check all flange connections and pipe fastenings on a regular basis.
Fastenings
Retighten all flange connections and pipe fastenings according to specified
tightening torques.
Pipe Supports Defective or loose pipe supports can lead to vibrations and therefore inter-
fere with the smooth running of the compressor.
To avoid damage to welds, check coolers, dampers etc. periodically for
specified tightening torque.
Retighten bolted connections of their supports on a regular basis.
Check bolted connections for specified tightening torque on a regular
basis.
Fit additional pipe supports if necessary.
Examples for pipe supports, see section 5.13.6 Recommendation for Pipe
Support.
Information regarding admissible vibrations, see section 5.16.9 Assess Vi-
brations.
Pipe System To avoid damage to pipes, coolers, pulsation dampers etc. due to vibra-
tions, the bolts of the pipe connections must be checked for specified tight-
ening torque and if necessary re-tighten periodically. Loose pipe fastenings
may lead to pipe damage and/or to fractures of weld seams. This may also
lead to disturbances in the smooth running of the compressor.
Examples for pipe supports, see section 5.13.6 Recommendation for Pipe
Support.

Plant
For information regarding vibrations, see section 5.16.9 Assess Vibrations.

Gas leakage must be repaired immediately. Gaskets may become hard
and brittle after a certain time; they must be replaced periodically. Gaskets
should be used once only. Pipe connections must be accurately aligned to
the design angle with regard to each other. Damaged surfaces of flanges
must be re-machined. Flange connections must be checked periodically for
specified tightening torque and re-tightened if necessary.
Process gas may be dangerous. Read the detailed gas description and

Periods of Standstill Avoid stationary coolant.
A minimal flow of coolant must always be maintained. During longer pe-
riods of standstill (exceeding a month), the system must be purged and the
coolant spaces be dried with compressed air.
Contamination of the coolant leads to deposits in the piping (reduction of
pipe diameter) and to deposits in the cooling chambers. This prevents
proper heat transfer and results in insufficient cooling.
Increasing discharge gas temperatures, increasing lubricating oil tempera-
tures and decreasing coolant temperatures are a clear sign of deposits in
the cooling chambers.
To avoid overheating of critical points, cooling chambers must be inspected
regularly; the length of the inspection intervals depends on the quality of
the coolant.
Bubbles in the cooling water indicate that either ambient air or process gas
enter the cooling water.
Oil in the cooling water indicates leaky oil coolers (if any).
WARNING
If the ambient temperature and/or process gas temperature drops below
0°C, the cooling water can freeze. If the wrong antifreeze solution is used,
the cooling water can freeze in spite of the antifreeze solution.
 Add a suitable antifreeze solution.
Inspecting Cooling Drain the cooling system(s) and open the covers on each cylinder leading
Chambers to the cooling chambers.
Inspect the cooling chambers of the cylinders and clean them if necessary.
If there are deposits of sand, chalk or algae in the cooling chambers, we

recommend to subcontract a specialized company to remove them and to
clean the cooling chambers, as they have the necessary know-how and the
required materials and equipment.

Plant
Cleaning of cooling chambers and removal of deposits can be carried out

by the maintenance personnel as well (this is, however, not recom-
mended). Cleaning is described in the following sections “Removing De-
posits of Calcium Carbonate”, “Removing of Algae” and “Removing
Deposits of Sand”.
Proceed according to following section “Leak Test”.
Removing Deposits of Circulate the cleaning agent by means of a pump in order to ensure a reli-
Calcium Carbonate able decomposition of the deposit.
WARNING
Consult manufacturer’s instructions.
Remove calcium carbonate deposits with (for example):

Diluted formic acid (HCOOH)
or
Diluted sulphamic acid (NH2SO3H) with inhibitor.
CAUTION
Cast iron, steel, nonferrous heavy metals and aluminum must not be cor-
roded by these chemicals.
Removing of Algae If the coolant is not properly treated with chemicals, the growth of algae
may result. This is particularly the case in open coolant circuits and in
cooling towers.
WARNING
Consult manufacturer’s instructions.
Remove algae with (for example):

• BIOSPERSE 250, DREW AMEROID
• NALFLOC 7330, NALFLOC
• VARICID AC, SCHILLING CHEMICAL
The treatment time depends on the extent of algae growth. After removal
of algae, the coolant must be carefully filtered and properly treated by a
specialized company.
Removing Deposits of Remove solidified crusts of sand manually and flush out the cooling cham-
Sand bers afterwards.

Plant
CAUTION
Chemicals for dissolving deposits of sand are too aggressive for the me-
tallic components of compressors.
Leak Test After each cleaning operation, a leak test must be performed. Special at-
tention must be given to the internal cooling pipes and connections.
CAUTION
Water in the lubricating oil!
Do not exceed the maximum permitted coolant pressure!
For set pressure of the relief valve in the coolant line (if installed) see cor-
responding P&I Diagram in chapter 13 Appendix.
8.6.5 Lubricating System

Prelubrication Pump
For detailed description of the prelubrication oil pump refer to the documen-
tation of the manufacturer (see Technical Documentation).
Non-Return Valve
For detailed description of the non-return valve refer to the documentation

of the manufacturer (see Technical Documentation).
Relief, Shut-off and

Control Valve
For detailed description of the relief, shut-off and control valve(s) refer to
the documentation of the manufacturer (see Technical Documentation).

Plant
Duplex Oil Filter

The duplex oil filter consists of two
filter housings and is equipped with
a differential pressure indicator (or
optional with switch). During normal
operation, the oil flows through one
of the two filter elements. If the de-
gree of contamination exceeds the
tolerance threshold (differential
pressure between filter inlet and
outlet) the operator must switch to
the other filter element. The con-
XA_P0_0001a_01
taminated filter element can be
cleaned/replaced whilst the plant
continues operating.
Fig. 8-27 Duplex oil filter (typical view)
For detailed description of the duplex oil filter refer to the documentation of
the manufacturer (see Technical Documentation).
Check differential pressure and clean/replace filter element if necessary:

1. Check differential pressure on indicator (for tolerance value see section
“Instrumentation” in chapter 13 Appendix).
 If pressure exceeds the given tolerance continue to step 2, other-
wise no cleaning is necessary.
2. Switch to second filter element (which should be clean) by turning the
switch lever.
 The second filter element is now active.
3. Open the cover of the first filter element and dismantle it. Clean/replace
the filter element according to manufacturer’s documentation.
 After reassembling the first filter element, it is ready for the next
turn-over by switching back from second to first element.
Oil Cooler
For detailed description of the oil cooler refer to the documentation of the
Oil Strainer
For detailed description of the oil strainer refer to the documentation of the

Plant
Instrumentation
For detailed description of the instrumentation refer to the documentation

of the manufacturer (see Technical Documentation).
8.6.6 Oil Change

For lubricating oil specifications see section “Lubricating System” in
For oil change interval see section 8.4 Maintenance Schedule. Analyze the
oil periodically to check if the oil still fulfills the qualitative requirements.
Burckhardt Compression recommends to regularly obtain oil analysis from
an appropriate lubricant laboratory.
In any case the oil must be changed if:
• coolant has penetrated into the oil (oily emulsion).
• the oil has been diluted by condensation.
• bearings have been replaced (due to material of damaged bearings in-
side the oil).
Permissible Values
Water content Neutralisation value Viscosity Metallic traces of wear

(kinematical, at 40 °C)
max. 0.3% max. 0.2mg KOH/g not less than 80% max. 150ppm
(for mineral oil) of the new oil
Tab. 8-1 Permissible values of lubricating oil in use (reference values)
Oil Quantity The oil reservoir is in the oil tank. The level may be checked at the oil sight
glass. When the compressor is at standstill, 3/4 of the oil sight glass must
be covered.
The working capacity of the oil tank is 425 liters.
Additional oil for associated pipes, and auxiliaries as e.g. oil cooler and fil-
ters is required. The total oil quantity is approximately 765 liters.
When the compressor is running, 1/2 of the oil sight glass should be cov-
ered.
Procedure Proceed as follows when changing oil:

1. Shut down the compressor.
Depressurize the compressor plant (see section 8.2.1 Depressurize and

Purge Plant).

Plant
Drain
2. Drain the oil from the oil tank.
3. Drain the piping of the lubricating system.
Clean
4. Remove and clean the oil strainer of the oil tank.

5. Clean the oil tank with a new, unused sponge (do not use fibrous tex-
tile).
6. Replace (clean) the duplex oil filter in accordance with the manufac-
turer’s instructions (see Technical Documentation).
Refill
Check for proper lubricating oil quality and quantity see sections 8.6.6 Oil
Change and 8.6.7 Lubricating Oil Specifications.
7. Shut oil outlets, refit oil strainer, etc. and fill the oil tank with fresh oil.
Use the prelubrication pump to fill the complete oil system.
8.6.7 Lubricating Oil Specifications

Oil Quality Reference is made to the list of recommended lubricating oils in section
“Lubricating System”, chapter 13 Appendix.
8.6.8 Safety Devices

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

Plant
Control and Shut-Off Maintenance for control and shut-off valves should be carried out regularly
Valves according to manufacturer´s instructions.
CAUTION
Observe instructions of the manufacturer (see Technical Documentation).
8.6.9 Hydrostatic Pressure Test

Hydrostatic pressure tests of the pipe system must be carried out by trained
specialists only. Parts to be pressure tested must be air vented. Please ask
for our technical assistance (address see section 1.6 Contact Address) for
permitted design pressure on the gas side. Use approved pressure gauges
only. For the gas and oil pipes only treated water must be used.
WARNING
Pressurized plant components.
Incorrect pressure testing may result in bursting plant components!
 Do not exceed the maximum permitted pressure!
 Observe the correct measuring unit on the pressure gauge.

Compressor in General
8.7 Compressor in General
8.7.1 Dimensions, Weights, Space Requirement

Please see section 5.3 Dimensions, Weights, Space Requirement for de-
tails.
8.7.2 Marking of Compressor Components
Compressor parts which must always be fitted in the same position are
numbered.
On the assembled compressor, these markings must lie on the right hand
side when looking from the drive end towards the non-drive end.
The numbering of the individual parts starts with no. 1 from the drive end
and ascends to no. 2, 3 etc. towards the non-drive end. Furthermore, the
serial no. is marked on important compressor components.
Some parts are only marked with a matching number, like the following:
• Connecting rod – connecting rod bearing halves
• Crankshaft bearing cover – crankshaft bearing
• Distance piece
• Cylinder – piston (if pistons of identical size)
• Piston rod packings
8.7.3 Cylinder Clearance Measurement

General Remarks The top cylinder clearance is the gap between the piston and the cylinder
cover, if the piston is positioned in the top dead center (TDC).
The bottom cylinder clearance is the gap between the piston and the cyl-
inder bottom, if the piston is positioned in the bottom dead center (BDC).
Measure Cylinder
Clearance
Prior to measuring, clean all measuring tools, according to chapter 10

Clean and Degrease Plant and Compressor Components.
Option for measuring: You can also measure the cylinder clearances by
using a feeler gauge.
 Position the piston in the top or bottom dead center.
 Insert the feeler gauge into the chamber of the cylinder.

CAUTION
Use of wrong lead wire
Wrongly measured or adjusted cylinder clearances can cause major com-
pressor failure.
 Use lead wire of appropriate thickness or use a feeler gauge.
 Using too thick lead wire can lead to wrong measurement of cylinder
clearance.
1. Dismantle one upper valve.

2. Dismantle one lower valve.
3. Insert a soft lead wire at the upper dead center.
4. Insert a soft lead wire at the lower dead center.
5. Move the piston through the lower dead center by turning the crank-
shaft with the barring gear.
6. Move the piston through the upper dead center by turning the crank-
shaft with the barring gear.
7. Remove the lead wires.
8. Measure their thickness.
 The thickness of the lead wires represent the upper and lower cyl-
inder clearances.
9. Record measured values in the corresponding log sheet (see 8.7.4
Clearance Measurement Log Sheet).
10. Compare the cylinder clearances that you have measured with the set
values in section “Compressor” in chapter 13 Appendix.
 You have installed the piston correctly, if the measured values of
the cylinder clearance correspond with the set values.
11. If necessary, adjust the cylinder clearance.
Admissible Tolerances not Achieved?
Adjust the cylinder clearance by the distance ring between crosshead and
hydraulic nut:
1. Move the piston to the upper dead center by turning the crankshaft with
the barring gear.
2. Dismantle the piston rod by the hydraulic nut.
3. Move the crosshead by turning the crankshaft with the barring gear
until you can remove the flange.
4. Change the distance disc (choose the correct thickness).
5. Mount in reverse order.
6. Measure the cylinder clearance.

7. Compare the cylinder clearances you have measured with the set
values in section “Compressor” in chapter 13 Appendix.
 You have installed the piston correctly, if the measured values of
the cylinder clearance correspond with the set values.

8.7.4 Clearance Measurement Log Sheet
TDO_2007034_E01_02.docx
PL2 Clearance Measurement
All Measurements in mm
Bearing clearance
Measured values Specified clearance
As found according Instruction
Radial Axial Manual
6 5 4 3 2 1 Radial Axial
Main bearing
Measured values Specified clearance

As built according Instruction
Radial Axial Manual
6 5 4 3 2 1 Radial Axial
Main bearing
As found Measured values

C8 C7 C6 C5 C4 C3 C2 C1
Crankshaft Radial Axial Radial Axial Radial Axial Radial Axial Radial Axial Radial Axial Radial Axial Radial Axial
journal
bearing
Crosshead
pin bearing
Crosshead
As built Measured values

C8 C7 C6 C5 C4 C3 C2 C1
Crankshaft Radial Axial Radial Axial Radial Axial Radial Axial Radial Axial Radial Axial Radial Axial Radial Axial
journal
bearing
Crosshead
pin bearing
Crosshead
Specified clearance according Instruction Manual

Crankshaft journal
Radial Axial
bearing
Crosshead pin bearing Radial
Crosshead Radial
PA_XX_0020a_03
Erstellt / Prepared 03.06.2014 WEISS_M Replacement for Page 1 of 5
Überprüft / Reviewed B 20.10.2014 KAUFMANN_W Revision gedruckt / printed:
Freigabe / Approval DVS 20.10.2014 STAEHLI_P vom / date 15.12.2014
Fig. 8-28 Example sheet for clearance measurement (first page)

TDO_2007034_E01_02.docx
Piston rod diameter
HE C CE HE C CE
HE Head end
C Center
CE Crank end
Manufacture size of Piston rod dia. mm, Minimal allowable dia. by wearing out; dia. mm
Diameter of packing area Diameter of oil scraper area

HE C CE HE C CE
0°
C1
90°
0°
C2
90°
0°
C3
90°
0°
C4
90°
0°
C5
90°
0°
C6
90°
0°
C7
90°
0°
C8
90°
PA_XX_0021a_03
Fig. 8-29 Example sheet for clearance measurement (second page)

TDO_2007034_E01_02.docx
Piston- / Guide ring clearance
Joint clearance; P, L Axial clearance; N, F Ring thickness; O, K Number

Ring type
of Number of
Crank
Stage
Required Required
Actual Actual Minimal installed installed
clearance, clearance,
clearance clearance Actual size allowable re-used new rings.
from / to or from / to or rings.
from / to from / to thickness
max. value max. value
V
Table above to complete as following example:

All rings, meant all rings of the same sorts who are mounted on the same piston, need to be checked and recorded like example
below. C2, ring type PR, (for Piston rings or GR for Guide rings) at stage 2, are installed with a joint gab clearance between
12.6mm – 13.0mm, required 12.5 – 13.5mm.
Additional fill in the actual measure of axial clearance, ring thickness and the amount of rings which are new or re-used.
As it shows below, use a second line for the next type of ring on the specific piston. GR, 2. Stage, axial clearance between
8.3 - 8.5mm, required 8.1 – 8.75mm and all rings (GR) replaced by new once.
The individual required tolerances are mention in the instruction manual.
C2 PR 2 12.6 – 13.0 12.5 – 13.5 0.2 – 0.3 0.166 – 0.364 18.50 – 18.70 15.58 3 1
C2 GR 2 8.3 – 8.5 8.1 – 8.75 0.7 – 0.8 0.6 – 0.846 8.0 7.0 0 2
PA_XX_0022a_03
Fig. 8-30 Example sheet for clearance measurement (third page)

TDO_2007034_E01_02.docx
Piston dead space

TDC – Top dead center BDC – Bottom dead center
Specified dimension Measuring Specified dimension
Crank Measuring Actual dimension device
Actual dimension
according Instruction according Instruction
device
As found As build Manual As found As build Manual
C1
C2
C3
C4
C5
C6
C7
C8
Dead space checked by: 1 Lead wire 2 Feeler gauge 3 Depth gauge / slide gauge 4 Dial indicator 5
Cylinder liner bore diameter
Head end
Center
Crank end
Crank C C C C C C C C
Stage
Manufacture Ø
of cylinder bore
Admissible bore
Ø of cylinder by
wearing out
(Measure of internal dia. of cylinder bore, 90° offset see direction of measurement in the above sketch)
Heat end
VS - VS
90°
Center
VS - VS
90°
Crank end
VS - VS
PA_XX_0023a_03
90°
Fig. 8-31 Example sheet for clearance measurement (fourth page)

TDO_2007034_E01_02.docx
Packing / Oil scraper

Axial clearance of each packing element / oil scraper
Pressure breaker, S1
Specified C C C C C C C C
clearance
S1
R1 Packing located in cylinder, S2

S2
R2
Packing located in flange / leak gas

S4
R4
R4
S4
Gas barrier packing / distance piece

S4
R4
S4
R4
Oil scraper, S6
S6
Oil
scraper
replaced;
R6 (yes / no)
Note: If any packing element are being re-used (R); mark above as: R 0.35 – 0.43
Place : Name / Signature BC:

Date: Name / Signature Customer:
PA_XX_0062a_01
Fig. 8-32 Example sheet for clearance measurement (fifth page)
Table of clearances see section “Compressor” in chapter 13 Appendix.

8.7.5 Piston Rod Runout
TDO_2007033_E01_05.docx
PL2 Piston Rod Runout
Rod Run-out in [mm] Peak-to-Peak

Crank Direction of Piston rod Position Design Lower Upper „As found“ „As built“
measurement condition (Code): tolerance limit Tolerance limit measurement measurement
C
Vertical
1 D
Horizontal 0.00 -0.03 +0.03
C
Vertical
2 D
Horizontal 0.00 -0.03 +0.03
C
Vertical
3 D
Horizontal 0.00 -0.03 +0.03
C
Vertical
4 D
Horizontal 0.00 -0.03 +0.03
C
Vertical
5 D
Horizontal 0.00 -0.03 +0.03
C
Vertical
6 D
Horizontal 0.00 -0.03 +0.03
C
Vertical
7 D
Horizontal 0.00 -0.03 +0.03
C
Vertical
8 D
Horizontal 0.00 -0.03 +0.03
Condition of Piston rods, Code:

1 = New condition 2 = Re-conditioned, (circular grinding) 3 = Used, (Not machined!)
Place: Name / Signature BC:

PA_XX_0019a_04
Template TDO 2007033 Rev. Date Sign. Ersatz für

Page 1 / 1
erstellt / prepared 04.12.2014 KAUFMANN_W Replace for
überprüft / reviewed D 12.12.2014 STOCKER_H Revision
15.12.2014
Freigabe DVS 12.12.2014 KAUFMANN_W vom / date
Fig. 8-33 Example sheet for piston rod runout

8.7.6 Frame Alignment
PL2/PL4 Frame Alignment TDO_2030215_E01_01.docx
Compressor S/N: Compressor type: Order / Job No.:

All level measurements are in mm/m
This view is schematic, measurement faces may vary on different machine types. The delegated person of BC will define
adequate measurement location.
(Y axis): + = cyl. level or frame to cyl. direction is rising / - = cylinder level or frame to cyl. direction is decreasing
(X axis): + = frame level toward coupling is rising / - = frame level toward coupling is decreasing
Cyl.no Cyl.no
Shims
a)
d) b)
a)
e)
c)
f)
Zero Line X
Zero Line Y
Measurement faces:
d)
a)
e)
b)
f)
c)
Dimensional accuracy of spirit level: mm/m ambient temperature during measuring: approx. °C
Place: Name / Signature BC:

PA_XX_0051a_02
Überprüft / Reviewed A 20.10.2014 KAUFMANN_W Revision gedruckt / printed:
Fig. 8-34 Example sheet for frame alignment

8.7.7 Tightening Methods
Please note that just a few methods mentioned here are used on your com-
pressor.
Tightening torques for nuts, screws and bolts that are not specified in the
“List of Tightening Torques” in chapter 13 Appendix are to be handled ac-
cording to section 8.5.1 Tightening Torques and Method.
Preparation • Clean areas of support (connecting parts) free of grease

• Apply lubricant to gliding surfaces of bolt (thread, head support and nut
support)
Lubricant • MOLYKOTE® G-N Plus
Tightening Method II Bolted Connections with Specified Torque Values

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

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

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

• For tightening of SUPERBOLT® tensioner on crankgear and/or frame
see section 8.7.8 Tensioner SUPERBOLT®.
• For tightening of piston nut SUPERBOLT® see section 8.9.4 Piston Nut
SUPERBOLT®.
Tightening Method VI Bolted Connections with Specified Hydraulic Pressure

• Tighten nut according to specified hydraulic pressure.
For mandatory tightening torques, appropriate tightening methods and ap-

plicable lubricants: see section “Compressor” in chapter 13 Appendix.

8.7.8 Tensioner SUPERBOLT®

(Tightening Method V)
XA_M0_0006a_01
Fig. 8-35 SUPERBOLT® Tensioner
Description This section of the Instruction Manual gives directions for the use of SU-
PERBOLT® nuts at the exterior and in the crankgear of compressors.
The nut must be tightened carefully with the supplied tools (see following
section “Tightening Procedure”).
The nut is prelubricated with the lubricant MOLYKOTE® G-N Plus. The
stamped tightening torque applies for this lubricant only.
CAUTION
Please contact our Customer Support Service in case:
• a unlubricated connection is required,
• the admitted lubricant MOLYKOTE® G-N Plus is not available.
Maintenance and SUPERBOLT® tensioners do not loose their preload force even after sev-
Revisions eral years in service providing that they are correctly tightened. Neverthe-
less, we recommend to check the preload force during each revision. Use
a torque wrench adjusted to 100 % of the permitted tightening torque.
Should some pressure screws unexpectedly have lost some of the preload
force the following procedure is recommended:
1. Relieve tension of the tensioner slightly by loosening the pressure

screws (1/4 turn only) according to following section “Loosening Proce-
dure”. Thus, the tensioner remains tensioned.
2. Now tense according to following section “Tightening Procedure”, i.e.
tighten in circular sequence with full tightening torque, until all pressure
screws are tightened.

Preventive Maintenance i.e. removal for maintenance purposes:
1. Relieve according to following section “Loosening Procedure”.

2. Treat thread and end of pressure screws with admitted lubricant.
3. A hardened washer may be re-used only once!
Before re-installing a used hardened washer by turning it over,
• thoroughly deburr the previously used side with a grinding stone
• check the hardened washer for indentations. Eliminate indenta-
tions by dressing washer with a grinding stone.
4. Tighten again according to following section “Tightening Procedure”.
Loosening Procedure Loosening requires an exact procedure. The pressure screws must be re-
lieved stepwise!
Never relieve single screws completely. The remaining screws would have
to carry the entire load, which would make it difficult to loosen them. In ex-
treme cases, the pressure screws could jolt and make loosening impos-
sible!
1. Starting with no. 1, loosen every

1/4 pressure screw in circular se-
quence by 1/4 turn at most. Do
not loosen beyond break loose
point. After the first round, pres-
1 sure screw no. 1 will again be
8 2
tightened, however, on a lower
level of loading.
2. Repeat step 1 in a 2nd round.
7 3 3. Repeat step 1 in a 3rd round.
XA_T9_0023a_01
4. Relieve pressure screws com-

pletely. Now the tensioner can
6 4 be removed by hand.
5
Fig. 8-36 Loosening of pressure

screws
CAUTION
Follow previous section “Preventive Maintenance” and the following sec-
tion “Trouble Shooting” before reusing the pressure screws!

Tightening Procedure
Required Tools
• Torque wrench
• Socket
• Lubricant MOLYKOTE® G-N
Plus
XA_T9_0016a_01
Fig. 8-37 Required tools
The marked tightening torque is the maximum permitted value.

For applicable tightening torques: see section “Compressor” in chapter 13
Appendix.
Preparation
Make sure that:
• pressure screws do not protrude from the nut.
• pressure screws are well lubricated.
Procedure
1 Hardened washer
1 2 3 4
2 Pressure screw
3 Bolt
4 SUPERBOLT® tensioner
X Gap approx. 1–3 mm
XA_T9_0017b_02
X
Fig. 8-38 Gap “X”
1. Clean main thread and contact areas.

2. Lubricate main thread and contact areas with admitted lubricant.
3. Firmly tighten the tensioner by hand.
4. Afterwards turn back approx. 1/4 turn. Depending on size the gap will
be approx. 1–3 mm.

Tightening of Nuts Having The tightening must take place gradually:

8 (Eight) Pressure Screws
1 1
8 2
3 4 7 3
XA_T9_0019a_01
XA_T9_0020a_01
6 4
2 5
Fig. 8-39 Tighten 4 pressure screws Fig. 8-40 Tighten all pressure screws
1. Tighten 4 pressure screws crosswise with 50 % of the recommended

tightening torque.
2. Tighten the same 4 pressure screws crosswise with 100 %.
3. Now change to circular tightening and tighten all pressure screws with
100 % until all pressure screws are equally tightened.
Tightening of Nuts Having The tightening must take place gradually:

6 (Six) Pressure Screws
1 1
6 2
XA_T9_0021a_01
XA_T9_0022a_01
3 2 5 3
Fig. 8-41 Tighten 3 pressure screws Fig. 8-42 Tighten all pressure screws
1. Tighten 3 pressure screws with 50 % of the recommended tightening

torque.
2. Tighten the same 3 pressure screws with 100 %.
Trouble Shooting Pressure Screws Cannot Be Loosened
1. Try to free at least one pressure screw.

2. Remove pressure screw, lubricate with admitted lubricant and tighten
with 110 % of the permitted tightening torque.

3. The two neighboring pressure screws should become free. Remove

these two pressure screws, lubricate and tighten with 110 %.
4. The next two pressure screws should become free.
5. And so on.
6. Afterwards relieve all pressure screws according to previous section
“Loosening Procedure”.
Hardened Washers Are Damaged, i.e. after a Long Time in Service

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

Exchange against original (OEM) pressure screws SUPERBOLT®.
CAUTION
Do not use commercial screws because they are not suitable for such high
loads!
Other Problems?
Please contact Burckhardt Compression Services (address see section 1.6
Contact Address).
8.7.9 Locking of Threaded Connections with LOCTITE®

LOCTITE® screw locks are one-component adhesives in liquid or semi-
solid form. They prevent the loss of preload and secure screw connections
against loosening caused by vibration and shock loads.
The applied product quality for each locked bolted connection is given by
the corresponding tightening specification. For detailed information about
the fields of application of LOCTITE® products, please refer to the manu-
facturer’s data sheets, e.g. on the Internet.
LOCTITE® can only be stored for a limited period of time. For complete in-
formation, see instruction on LOCTITE® bottle.
Apply LOCTITE® according to the following instructions:
1. Bolt and thread must be degreased thoroughly, if possible with chloro-

thene or with gasoline.
2. If the bolt was locked before using LOCTITE®, it should be replaced ei-
ther by a new one or it should be thoroughly cleaned from all LOC-
TITE® residues using a wire brush. Also clean thread of nut from all
LOCTITE® residues.

3. The greaseless bolt and nut must be absolutely dry, then fill in the liquid
LOCTITE® into the thread turns. All turns of thread, (bolts and nuts)
must be filled with LOCTITE®.
4. Screw in and tighten as specified.
5. Generally after 1 hour, threaded connections locked by LOCTITE® are
ready for operation. For complete information, see instruction on LOC-
TITE® bottle.
Loosening of locked threaded connections is best done by heating them

up, since LOCTITE® disintegrates at about 200 °C.
8.7.10 NORD-LOCK® Securing System

The NORD-LOCK® securing system consists of a pair of washers with a
wedge-locking action meeting DIN 25201. This method uses tension in-
stead of friction.
NORD-LOCK® washer pairs positively lock fasteners in a joint which is
subjected to vibrations or dynamic loads. Therefore a NORD-LOCK®
washer pair may be used only once!
CAUTION
Wrong installation/reuse of NORD-LOCK® washer pair
Cap nut or nut for valve rotates loose. Damage to valves and loss of ca-
pacity possible.
 Use NORD-LOCK® washer pairs only once!
 Install new, unused NORD-LOCK® washer pair every time a cap nut or
nut for valves is loosened.
 Follow the instructions in this Instruction Manual.
If correctly installed (see Fig. 8-43, Fig. 8-44 and Fig. 8-45), the NORD-
LOCK® washer is locked in place, only allowing movement across the face
of the cams. Any attempt from the bolt/nut to rotate loose is blocked by the
wedge effect of the cams.
The rise of the cams between the

NORD-LOCK® washers () is
greater than the pitch of the bolt
(). In addition, there are radial
teeth on the opposite side. The
XA_CX_0040a-01
washers are installed in pairs, cam

face to cam face.
= locking effect
Fig. 8-43 NORD-LOCK® locking principle

XA_CX_0039b_01
XA_CX_0074b_01
1 2
1 Cams
2 Radial teeth
Fig. 8-44 NORD-LOCK® washer pair Fig. 8-45 Correct assembly of NORD-
LOCK® washer pairs
For lubrication of bolts, please refer to section 8.7.7 Tightening Methods.

Crankgear
8.8 Crankgear
8.8.1 Check Crankshaft Deflection
1 2
XA_M0_0009b_01
4 y 3

a feeler gauge).
cator.
 For maximum permissible deflection on the dial indicator for a complete

turn of crankshaft see Fig. 8-47.

Crankgear
CD/mm
0.07
0.06
0.05
0.04
0.03
0.02
PA_M0_0001b_1
0.01
y/mm
0 100 200 300 400
Fig. 8-47 Maximum permissible crankshaft deflection
CD Crankshaft deflection in mm
y Measuring distance (y) in mm
2. If the deflection exceeds this limit, consult Burckhardt Compression

Services; address see section 1.6 Contact Address.
8.8.2 Main Bearing and Connecting Rod Bearing

The bearings do not normally call for any maintenance. With regular oil
changes they sustain only slight wear.
We recommend that the bearings are not checked too often by dismantling.
Reliable inspection is possible without removal:
• measure the clearance between the bearing and crankshaft journal,
• check oil tank, crankgear, oil strainer and/or duplex oil filter for deposits
of white metal.
For applicable clearances see section “Compressor” in chapter

13 Appendix.
If abrasive components of the process gas get in the distance piece/crank-

gear, they may cause excessive wear of bearings. Consult Burckhardt
Compression Services, address see section 1.6 Contact Address.
8.8.3 Crankshaft Seal

The crankshaft seal is fitted at the drive end of the compressor and pre-
vents
• oil from leaking to the surrounding area (inner ring)
• dirt from entering the crankgear (outer ring).

Crankgear
6 7
PB_M1_0002b_01
Fig. 8-48 Components of crankshaft seal
1 Flat gasket 5 2-piece cover

2 Fastening bolt 6 Centering pin
3 2-piece oil trap cover 7 Seal ring (2 pieces)
4 Allen screw
The seal must be replaced if it has grown brittle and therefore leaky. It
cannot be replaced without disassembling the flywheel. If, for any reason,
the main motor is removed, the seal should be replaced as well.
The shaft seal may begin to leak after a while due to heat and poor crank-
gear ventilation. This is due to the pump effect of the crosshead at altered
ambient conditions (for example cooling, oil, and ambient temperatures)
which may lead to somewhat increased pressure in the crankgear.
Remedy: clean breather installed on frame cover.

Crankgear
8.8.4 Connecting Rod Bearing
1
2
3
4
5
6
PB_M4_0010b_02
Fig. 8-49 Components of connecting rod
1 Connecting rod 4 Connecting rod cover

2 Crosshead pin bearing 5 Tensioner SUPERBOLT®
3 Connecting rod bearing 6 Threaded bolt
Apart from the maintenance work specified in the maintenance schedule,

no special maintenance of the connecting rod is required. The connecting
rod bolts must be tightened to a certain elongation (). For applicable tight-
ening torque (elongation) see section “Compressor” in chapter 13 Ap-
pendix.
We recommend, checking the correct tightening of the connecting rod bolts
periodically, every 16000 operating hours.
WARNING
Loose connecting rod bolts!
After a liquid knock, the connecting rod bolts must be checked immediately
for mandatory tightening torque!

Crankgear
Check Connecting Rod Measure clearance of connecting rod bearing.

Bearing Clearance
1. Move the connecting rod in horizontal position by turning the crank-
shaft.
2. Measure vertical clearance:
• By means of a feeler gauge
Measure the clearance outside the chamfer, at least 20 mm from
center line (see Fig. 8-50)
• By means of a dial gauge
Lift up connecting rod and measure the clearance with the dial-
gauge (see Fig. 8-50)
PA_M4_0014b_02
20 20
Fig. 8-50 Connecting rod bearing
1 Dial gauge

Crankgear
3. Lift up connecting rod by halve the value of measured vertical clear-

ance and maintain connecting rod in this position.
4. Push the connecting rod forward and backward and measure the hori-
zontal clearance on the dial gauge (Fig. 8-51). Compare it with bearing
table.
5. Measuring horizontal clearance using feeler gauge, push connecting
rod only in one direction and measure the horizontal clearance. Com-
pare it with bearing table.
PA_M4_0013b_01
X
Fig. 8-51 Connecting rod bearing
1 Dial gauge

Crankgear
8.8.5 Crosshead
PB_M3_0036b_01
4 3
Fig. 8-52 Crosshead
1 Crosshead shoe 4 Set screw

2 Crosshead 5 Circlip
3 Set collar 6 Crosshead pin
Clearance Check 1. Move connecting rod/crosshead in Top Dead Center (TDC) by turning
the crankshaft.
2. Check clearance between crosshead and crosshead bore with the
feeler gauge.
3. Move connecting rod/crosshead in Bottom Dead Center (BDC) by
turning the crankshaft.
4. Check clearance between crosshead and crosshead bore with the
feeler gauge.
5. Keep a record of measured clearances in a log sheet.

13 Appendix.

Crankgear
8.8.6 Crosshead Pin Bearing

Clearance Check The crosshead pin bearing clearance can only be checked in running direc-
tion of the piston (Fig. 8-53). The piston/piston rod must be removed.
PA_M3_0009b_03
1 2 3
Fig. 8-53 Crosshead pin bearing
1 Jackscrew
2 Dial gauge
3 Dial gauge
1. Move connecting rod/crosshead in Top Dead Center (TDC) by turning

the crankshaft.
2. Secure connecting rod in this position, for example, with a jackscrew
(1).
3. Place dial gauge according to position (2) against connecting rod-
bearing cover.
4. Place dial gauge according to position (3) against crosshead.
5. Move crosshead forward and backward to its running direction.
6. Read the horizontal clearance of the crosshead pin bearing on dial-
gauge (3). The hand of the dial gauge (2) must remain at zero position.

13 Appendix.
8.8.7 Distance Piece Packing

Check Distance Piece The distance piece packing is installed in the separating plate of the two
Packing Ring Clearance distance piece chambers (see Fig. 8-54).
The packing rings of the distance piece packing can be dismantled/re-
placed, without removing the piston rod.

Crankgear
The description in section 8.9.2 Piston Rod Packing concerning the as-
sembly of the packing of “Zone C” also apply to the distance piece packing.
PB_M6_0002b_03
9 8 7 6
1 Housing 6 Seal element (step bridge cut)

2 Cylindrical pin 7 Pressure ring
3 O-ring 8 Spring
4 Cover 9 Material code
5 Garter spring

Crankgear
8.8.8 Oil Scraper

As the oil-free operation (if without cylinder lubrication) of the compressor
depends to a large extent on the satisfactory condition of the wiper ele-
ments and the way they are assembled, these rings must be handled with
great care. The same applies to the surface of the piston rod in the area of
the wiper elements.
Inspection of Wiper The wiper elements shall not show any sign of damage and must lie snug
Elements against the piston rod along their entire circumference. The scraping edge
(3) must be as sharp as possible (Fig. 8-55). The assembled wiper ele-
ments must have a slight pretension when pushed onto the piston rod.
1 2 3 4 1
PB_M5_0007c_01
7 6 5
9 8
Fig. 8-55 Oil scraper
1 Rollpin 6 Wiper element

2 Garter spring 7 Support ring
3 Scraping edge 8 Cylinder side
4 Contact area 9 Crankgear side
5 Seal element

Cylinder
8.9 Cylinder
8.9.1 Piston Rod

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

ational safety of an overhauled piston rod, only perform overhauls after
consultation with Burckhardt Compression Services.
8.9.2 Piston Rod Packing

The packing rings must be inspected every year by dismantling the piston
and piston rod. Inspections at shorter intervals are recommended in case
there are the following indications that the rings are badly worn:
• leakage of process gas into the distance piece below the packing,
• reduced discharge rate,
• changes in the intermediate pressure,
• increase of packing temperature, etc.
Packing Cups and Rings The packing cups are marked with numbers (see Fig. 8-56, Pos. 1). Cups
of the same design have the same numbers.
For exact configuration of packing rings see section 9.13.4 Assemble the
Piston Rod Packing.

Cylinder
1st Stage
1
5 4 3 2.2 1
C B2 B1 A
PB_C5_0081a_02
Fig. 8-56 Piston rod packing 1st stage
A Zone A 1 Markings
B Zone B 2 Gas flow
C Zone C
Zone C B2 B1 A
[mm] [mm] [mm] [mm]
Axial clearance 0.700–0.902 0.300–0.493 0.300–0.493 0.100–0.230
Tab. 8-2 Axial clearances of packing rings 1st stage

Cylinder
WARNING
Wrongly modified or non-genuine spare parts.
Operational safety may be impaired!
 Do neither modify parts nor spare parts.
 Do not influence clearances on compressor.
 Exchange worn parts.
8.9.3 Piston
Check the Pretension of The pretension of the piston crowns to the piston skirt is measured when a
Piston Crowns piston part is replaced or after the interval indicated on the maintenance
schedule. This applies also, if a piston nut came loose.
Pretension is the value by which the piston crowns are bent inwards when
the piston nut is tightened, thereby clamping the piston skirt. Measure dis-
tance “A” with the piston crowns clamped together without the piston skirt
as shown in the following figure.
Pretension = Dimension B - Dimension A
PB_C1_0022b_01
1 2 3 4 5 6
Fig. 8-57 Piston pretension (typical view)
1 Lower piston crown 4 Piston nut SUPERBOLT®

2 Centering ring 5 Upper piston crown
3 Piston rod 6 Piston skirt

Cylinder
Stage (Compressor) Dia. nominal of piston Pretension (mm)

(mm)
1st stage 640 0.08 – 0.54
Tab. 8-3 Piston pretension (3-piece piston)
WARNING
Risk of piston seizure or loose piston skirt!
 The measured values must be within the tolerances given above.
 Tighten piston nut in accordance with section 8.9.4 Piston Nut SUPER-
BOLT®.
Measure Cylinder
Clearance
CAUTION
pressor failure.
clearance.
6. Check the cylinder clearance according to section 8.7.3 Cylinder Clear-

ance Measurement. Record measured values in the compressor check
list of section 8.7.4 Clearance Measurement Log Sheet.
Measure Wear of Piston 1. Check the gap “Y” by inserting the piston rings into the cylinder.
Rings

Cylinder
Fig. 8-58 Piston rings inserted into cylinder
Y Y
Y
1 1 2
PB_C1_0083b_01
Fig. 8-59 Gap “Y” of piston rings
1 Piston ring with scarf joint

2 Guide ring (rider ring)
2. Check the wear of the piston rings by measuring the radial thicknesses
according to section “Compressor” in chapter 13 Appendix.
3. Check the dimension of the running surface at the cylinder liner ac-
cording to section “Compressor” in chapter 13 Appendix.
4. Check the condition of the running surface at the cylinder liner ac-
For details concerning piston ring assembly see section 9.11.5 Piston
Rings.

Cylinder
8.9.4 Piston Nut SUPERBOLT®
Fig. 8-60 Piston nut SUPERBOLT®
1 Admitted lubricant 5 Size

2 Pressure screw 6 Bore for piston nut wrench
3 Groove for O-ring (used with con- 7 Tightening torque with
taminated gas) MOLYKOTE® G-N Plus
4 Hardened washer 8 Piston nut SUPERBOLT®
Piston nuts SUPERBOLT® do not loose their preload force even after sev-
eral years in service providing that they are correctly tightened. Neverthe-
less, we recommend to check the preload force during each revision. Use
a torque wrench adjusted to 100 % of the permitted tightening torque.
Should some pressure screws unexpectedly have lost some of the preload
force the following procedure is recommended:
1. Relieve tension of the piston nut slightly by loosening the pressure

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

2. Treat thread and end of pressure screws with admitted lubricant.
3. A hardened washer may be re-used only once!
Before re-installing a used hardened washer by turning it over,

Cylinder
• thoroughly deburr the previously used side with a grinding stone

• check the hardened washer for indentations. Eliminate indenta-
tions by dressing washer with a grinding stone.
4. Tighten again according to following section “Tightening Procedure”.
Loosening Procedure Loosening requires an exact procedure. The pressure screws must be re-
lieved stepwise!
Under no circumstances relieve single screws completely. The remaining
screws would have to carry the entire load, which would make it difficult to
loosen them. In extreme cases, the pressure screws could jolt and make
loosening impossible!
1. Starting with no. 1, loosen every pressure screw in circular sequence

by 1/4 turn at most. Do not loosen beyond break loose point. After the
first round, pressure screw no. 1 will again be tightened, however, on a
lower level of loading.
2. Repeat step 1 in a 2nd round.

1/4 3. Repeat step 1 in a 3rd round.
4. Relieve pressure screws com-
pletely. Now the piston nut can
1 be removed by hand or using
the piston nut wrench.
8 2
Due to dirt or a pretensioned pis-

ton, it may still not be possible to
7 3 loosen the piston nut. In this case,
use the piston nut wrench carefully
XA_T9_0023a_01
to loosen the nut.

6 4
Fig. 8-61 Loosening of pressure

screws
Follow subsection “Trouble Shooting” in this section before reusing the

pressure screws!
Tightening Procedure Required Tools

• Torque wrench
• Socket
• Extension for sockets
• Lubricant “MOLYKOTE® G-N Plus”
The marked tightening torque is the maximum permitted value. For appli-
cable tightening torques: see section “Compressor” in chapter 13 Ap-
pendix.

Cylinder
Preparation
Make sure that:
• pressure screws do not protrude from the bottom of the nut,
• pressure screws are well lubricated.
Procedure
1. Clean main thread and contact areas.

2. Lubricate main thread and contact areas with admitted lubricant.
3. Tighten the piston nut manually.
X
LA_T9_0025b_01
6 5 4 3
Fig. 8-62 X = gap, approx. 1 mm
1 Groove for O-ring (with contami- 4 Piston rod

nated gas) 5 Pressure screw
2 Piston nut SUPERBOLT® 6 Piston
3 Hardened washer
4. Afterwards turn back approx. 1/4 turn. Depending on the piston size the
gap “X” will be approx. 1 mm. If a small piston is used, the 1/4 turn back-
wards may eliminate the pretension partially or entirely (this does not
affect the tightening procedure).
Tightening of Piston Nuts The tightening must take place gradually:

Having 8 Pressure Screws
1. Tighten 4 pressure screws crosswise with 25 % of the recommended
tightening torque.

Cylinder
1 1
8 2
3 4 7 3
XA_T9_0019a_01
XA_T9_0020a_01
6 4
2 5
Fig. 8-63 Tighten 4 pressure screws Fig. 8-64 Tighten all pressure
screws
4. Tighten the remaining pressure screws crosswise with 50 % of the rec-

ommended tightening torque.
5. Repeat step 4 with 100 %.
Tightening of Piston Nuts 1. Tighten 3 pressure screws with 25 % of the recommended tightening
Having 6 Pressure Screws torque.
2. Tighten the same 3 pressure screws with 50 %.
1 1
6 2
XA_T9_0021a_01
XA_T9_0022a_01
3 2 5 3
Fig. 8-65 Tighten 3 pressure screws Fig. 8-66 Tighten all pressure
screws
4. Tighten the remaining pressure screws with 50 % of the recommended

tightening torque.
5. Repeat step 4 with 100 %.

Cylinder
Trouble Shooting Pressure Screws Cannot Be Loosened
1. Remove possible existing dirt from the piston and SUPERBOLT®

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

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

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

Residue caused by dirty process gases can obstruct the nut even though
the pressure screws are loosened. In this case, use the piston nut wrench
to loosen the piston nut carefully.
Other Problems?
Please contact Burckhardt Compression Services (address see section 1.6
Contact Address).

Suction Valves and Discharge Valves
8.10 Suction Valves and Discharge Valves
8.10.1 Valve Maintenance

Since the compressor valves are among the most delicate components of
the compressor, they should be inspected every 6000–8000 hours of ser-
vice at normal conditions i.e. continuous operation.
If the compressor is not running continuously and/or with different gases,
the valves must be inspected at shorter intervals.
The intervals must be adjusted according operating experience and/or in
cooperation with our specialists.
Valve Service
CAUTION
We strongly recommend having valve overhauls carried out by our special-
ists on site or in one of our Burckhardt Compression licensed Service Cen-
ters. We assume no liability for damage caused by inexpert valve
overhauls. We also reject liability for wrongly assembled valves, or when
non-genuine spare parts are used.
WARNING
Wrongly modified or non-genuine spare parts.
Operational safety may be impaired!
 Do neither modify parts nor spare parts.
 Do not influence clearances on compressor.
Valves can be sent to the nearest Burckhardt Compression Service Center

to be reconditioned at a competitive price. Address see section 1.6 Contact
Address.
For dismantling and assembling of valves see section 9.7 Suction Valves
and Discharge Valves.
8.10.2 Valve Failures (Malfunction)

If uniform service conditions are accompanied by pronounced fluctuations
of the interstage pressure, this may indicate broken or clogged valve
plates. The temperature fluctuations which follow a broken valve plate may
lead to dangerous failures (malfunction) on the compressor. Therefore, de-
fective valve components should be replaced as soon as they occur.
If repeated valve failure (malfunction) occurs, the lift of the valves can be
reduced or stronger springs be fitted. Such modifications are only to be car-
ried out with Burckhardt Compression’s consent. Since computer programs

can simulate valve behavior at a specific operating point within the oper-
ating range, therefore a set of actual readings (temperatures and pres-
sures) is needed in order to determine the necessary modification.
Possible Causes of Valve • Dirt in the process gas lines

Failures (Malfunction) • Broken valve springs
• Broken parts of piston rod packing
• Gas pulsations
• Controlled suction valve is blocked
Incorrect valve assembly:

• Loose pressure screws  loose valve lantern (broken valve guard)
• Loose nut of center bolt
• Valve seat of Burckhardt Plate Valve™ has been re-machined too
much  pinhole has not sufficient depth (see section 9.7 Suction
Valves and Discharge Valves).
• Center cuts of metallic valve plate and damper plate for Burckhardt
Plate Valve™ plate do not coincide (see section 9.7 Suction Valves and
Discharge Valves).
• Valve springs for Burckhardt Plate Valve™ not fitted correctly (see sec-
tion 9.7 Suction Valves and Discharge Valves).
8.10.3 Maintenance of Controlled Suction Valves

The clearance “X” (see following illustration) between the tips of the finger
unloader and the sealing element must be checked every time before fitting
a valve. The fingers of the finger unloader should be adjusted to move
freely through the gaps of the valve seat.

X
3 1
2 LA_C3_0018b_02
A B
Fig. 8-67 Tolerances and clearances of controlled Burckhardt Plate Valve™

(typical view)
A Valve with metallic valve plates X Clearance

B Valve with non-metallic valve plates Y Clearance
1 Non-metallic valve plate Z Clearance
2 Damper plate
3 Metallic valve plate
Instructions Regarding Blocked suction valves on multi-stage compressors are bound to lead to
Failures (Malfunction) on changes in the interstage pressure and hence to dangerous temperature
Controlled Suction Valves increases and overloading of the properly working stage. All moving valve
components are to be given a light application of a process gas compatible
grease.

The purpose of the following is to indicate the faults which may occur, par-
ticularly in the case of the controlled suction valves. The measures to be
taken to resolve them are also described briefly.
1. Irregular knocking (hammering) of the piston against the cylinder wall

may be the result of the controlled suction valves not operating in the
correct manner. This can lead to increased wear of piston. This is as-
sociated, in particular, with compressors with large piston diameters
and a high pressure ratio.
Dismantle the valves and check their compliance with the assembly in-
struction in this section.
2. Nitrogen supply pressure too low.
3. Differential pressure of control medium for suction valve actuator too

low, e.g. back pressure from flare.
4. Even though the actuator operates in a uniform manner, the suction

valve does not change to the no load position when the control medium
pressure is off:
Too much clearance “X” between the tips of the finger unloader and the
sealing element (i.e. valve plate or valve disc or poppet), or too much
clearance “Z” between pressure pin and pressure sleeve.
Replace finger unloader and/or pressure pin or pressure sleeve.
5. One of the suction valves is blocked, i.e. the pressure pin does not
move.
Dismantle the actuator and the nipple and check pressure pin for ease
of movement. Check guiding band and the STEPSEAL®. Replace it if
needed.
6. After overhauls: Wrong valve assembly!
Wrong actuator and/or pressure pin fitted. Check number and correct di-
mensions of springs (F) and check correct assembly mode of actuator
piston according to table Tab. 9-1 in section 9.5 Suction Valve Actuator.
Even though the controlled suction valve components are assembled cor-
rectly and control medium pressure is correct, they do not switch from no
load to load position or vice versa.
This symptom could occur when the complete built length (total assembly)
in installed condition is not correct (Distance “Z” in Fig. 8-67). Check for the
correct thickness of the valve gasket, the correct length of the pins (see
table Tab. 9-1 in section 9.5 Suction Valve Actuator, as well as pressure
sleeve.
It is advisable to assemble the complete control valve set, valve, lantern,
gasket and actuator in a suitable compression device (i.e. press, large vise
etc.). Use nitrogen or air to operate the actuator to verify the function of the
controlled valve set.

Complete Maintenance
8.11 Complete Maintenance

Commissioning.

Complete Maintenance

Dismantle and Assemble Compressor Components
9 Dismantle and Assemble Compressor

Components
9.1 Prerequisites and Safety Requirements . . . . . . . . . . . . . . . 9-5

9.2 Switch Off Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.3 Switch Off Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.4 Non-Return Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.4.1 Status and Special Tools. . . . . . . . . . . . . . . . . . . . 9-6
9.4.2 Dismantle Non-Return Valve . . . . . . . . . . . . . . . . 9-6
9.4.3 Assemble and Install Non-Return Valve . . . . . . . . 9-6
9.5 Suction Valve Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.5.1 Status and Special Tools. . . . . . . . . . . . . . . . . . . . 9-6
9.5.2 Piston Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.6 Controlled Suction Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 15
9.6.1 Status and Special Tools. . . . . . . . . . . . . . . . . . . . 9 - 15
9.6.2 Dismantle Controlled Suction Valve . . . . . . . . . . . 9 - 15
9.6.3 Assembly of Controlled Burckhardt Plate Valve™ 9 - 15
9.7 Suction Valves and Discharge Valves. . . . . . . . . . . . . . . . . 9 - 20
9.7.2 Dismantle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 24
9.7.3 Disassembly and Repair of Burckhardt Plate
Valve™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 33
9.7.4 Assembly of Burckhardt Plate Valve™ . . . . . . . . . 9 - 37
9.7.5 Installing the Valve . . . . . . . . . . . . . . . . . . . . . . . . 9 - 41
9.8 Cylinder Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 56
9.8.2 Dismantle Cylinder Cover. . . . . . . . . . . . . . . . . . . 9 - 56
9.8.3 Install Cylinder Cover . . . . . . . . . . . . . . . . . . . . . . 9 - 58
9.9 Frame Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 59
9.9.2 Dismantle and Assemble Frame Covers . . . . . . . 9 - 59
9.10 Drain Lubricating Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 60
9.10.2 Drain and Refill Lubricating Oil . . . . . . . . . . . . . . . 9 - 60
9.11 Piston and Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 61
9.11.2 Dismantle Piston and Piston Rod . . . . . . . . . . . . . 9 - 62
9.11.3 Dismantle the Piston. . . . . . . . . . . . . . . . . . . . . . . 9 - 65
9.11.4 Assemble the 3-Piece Piston . . . . . . . . . . . . . . . . 9 - 65
9.11.5 Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 70
9.11.6 Install Piston and Piston Rod . . . . . . . . . . . . . . . . 9 - 73
9.11.7 Adjust Piston Rod Runout . . . . . . . . . . . . . . . . . . 9 - 81
9.11.9 Measure the Cylinder Clearance . . . . . . . . . . . . . 9 - 86
9.12 Internal Pipes (Distance Piece) . . . . . . . . . . . . . . . . . . . . . 9 - 87

9.12.1 Status and Special Tools . . . . . . . . . . . . . . . . . . . . 9 - 87

9.12.2 Dismantle and Assemble Internal Pipes . . . . . . . . 9 - 87
9.13 Piston Rod Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 88
9.13.2 Piston Rod Packing Design . . . . . . . . . . . . . . . . . . 9 - 89
9.13.3 Dismantle the Piston Rod Packing . . . . . . . . . . . . 9 - 90
9.13.4 Assemble the Piston Rod Packing . . . . . . . . . . . . 9 - 93
9.14 External Gas Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 100
9.15 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 100
9.15.2 Dismantle and Assemble Cylinder. . . . . . . . . . . . . 9 - 101
9.15.3 Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 104
9.16 Distance Piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 107
9.16.2 Dismantle and Install Distance Piece . . . . . . . . . . 9 - 107
9.17 Distance Piece Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 108
9.17.2 Dismantle and Assemble Distance Piece Packing 9 - 108
9.18 Oil Scraping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 110
9.18.2 Dismantle the Wiper Elements . . . . . . . . . . . . . . . 9 - 110
9.18.3 Assemble the Wiper Elements . . . . . . . . . . . . . . . 9 - 111
9.19 Connecting Rod Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 113
9.19.2 Dismantle the Connecting Rod Bearing . . . . . . . . 9 - 114
9.19.3 Assemble the Connecting Rod Bearing. . . . . . . . . 9 - 117
9.20 Crosshead and Connecting Rod . . . . . . . . . . . . . . . . . . . . . 9 - 120
9.20.2 Check the Clearance of Crosshead. . . . . . . . . . . . 9 - 120
9.20.3 Dismantle Connecting Rod and Crosshead . . . . . 9 - 121
9.20.4 Clearance of Connecting Rod Bearing . . . . . . . . . 9 - 123
9.20.5 Parallelism of Connecting Rod Bores . . . . . . . . . . 9 - 124
9.20.6 Rework of a New Crosshead. . . . . . . . . . . . . . . . . 9 - 126
9.20.7 Assemble Connecting Rod and Crosshead. . . . . . 9 - 127
9.21 Crosshead Pin Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 130
9.21.2 Dismantle the Crosshead Pin Bearing. . . . . . . . . . 9 - 131
9.21.3 Assemble the Crosshead Pin Bearing. . . . . . . . . . 9 - 132
9.21.4 Check Clearance of Crosshead Pin Bearing . . . . . 9 - 136
9.22 Gear Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 138
9.22.2 Dismantle Gear Oil Pump . . . . . . . . . . . . . . . . . . . 9 - 138
9.22.3 Assemble Gear Oil Pump . . . . . . . . . . . . . . . . . . . 9 - 138
9.23 Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 139
9.23.2 Dismantle Electric Motor . . . . . . . . . . . . . . . . . . . . 9 - 139

9.23.3 Assemble Electric Motor. . . . . . . . . . . . . . . . . . . . 9 - 139

9.24 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 139
9.24.2 Transport and Lifting of the Flywheel . . . . . . . . . . 9 - 139
9.24.3 Dismantle the Flywheel . . . . . . . . . . . . . . . . . . . . 9 - 140
9.24.4 Assemble the Flywheel. . . . . . . . . . . . . . . . . . . . . 9 - 141
9.25 Crankshaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 142
9.25.2 Dismantle and Assemble the Crankshaft Seal . . . 9 - 142
9.25.3 Trigger Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 144
9.26 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 145
9.26.2 General Checks for Fitting New Bearings . . . . . . 9 - 145
9.27 Crankshaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 147
9.27.2 Dismantle Crankshaft Bearing . . . . . . . . . . . . . . . 9 - 147
9.27.3 Assemble Crankshaft Bearing . . . . . . . . . . . . . . . 9 - 151
9.27.4 Measuring the Clearance . . . . . . . . . . . . . . . . . . . 9 - 154
9.28 Axial Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 156
9.28.2 Dismantle Axial Bearing . . . . . . . . . . . . . . . . . . . . 9 - 157
9.28.3 Assemble Axial Bearing . . . . . . . . . . . . . . . . . . . . 9 - 158
9.29 Dismantle Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 158


Prerequisites and Safety Requirements
9.1 Prerequisites and Safety Requirements

Chapter Structure The structure of this chapter follows a step by step philosophy to explain
the complete dismantling or assembling. It starts with the procedure to
switch off the compressor and ends up with the dismantling of the crank-
shaft as the last unit.
Prerequisites before Before you start any inspection or repair activity take all safety measures
Dismantling according to section 8.2 Prerequisites for Maintenance.
DANGER
 Before beginning any inspection or repair, switch off the power at the
Prerequisites before
Assembly
CAUTION
9.2 Switch Off Compressor

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

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

• the compressor and the surrounding plant components are in good
condition,
• all compressor parts are fixed correctly and
• no personnel is staying within danger zones.
Switch On 1. Re-insert the safety switch.

2. Start the compressor according to section “Control Description” in

Switch Off Cooling System
Final Checks See section “Control Description” in chapter 13 Appendix.
9.3 Switch Off Cooling System

Status Completed activities:
• 9.2 Switch Off Compressor
Special Tools none
Switch Off 1. Switch off the cooling system by turning the main switch to off position.
 The compressor is now switched off and ready for maintenance
2. If the dismantling of the coolant pipes is required, then drain the
coolant.
Please remember to collect the glycol mixture if used in your cooling
system!
Switch On and Please see section 5.16.2 Cooling System.

Final Checks
9.4 Non-Return Valve
9.4.1 Status and Special Tools

Special Tools none
9.4.2 Dismantle Non-Return Valve

Dismantle the non-return valve according to manufacturer’s instructions.
9.4.3 Assemble and Install Non-Return Valve

Assemble and install the non-return valve according to manufacturer’s in-
structions.
9.5 Suction Valve Actuator


Suction Valve Actuator
Special Tools Small hook or prepared screw driver as shown in Fig. 9-1.
XA_C3_0011a_01
Fig. 9-1 Special tool
1 2
XA_T9_0030b_01
Fig. 9-2 Mounting device for TURCITE® STEPSEAL®
1 Bar
2 Bush
T97182: (can be ordered from Burckhardt Compression)

9.5.2 Piston Actuator

Dismantle
Option (18) 19 1
17
16
15
Mode B 3
14
2 (F) 4
13
12
11
10
Option 7
XA_C3_0053b_01
Fig. 9-3 Suction valve actuator
1 Cover to actuator 11 Pressure pin

2 Spring 12 Guiding band
3 Piston ring GLYD 13 USIT ring
4 Housing 14 Actuator piston (Mode B)
5 Vent valve 15 O-Ring
6 TURCITE® STEPSEAL® 16 Screw
7 Circlip (Option) 17 Vent
8 Scraper ring (Option) 18 Position indicator (Option)
9 O-Ring 19 Plug
10 Nipple (guiding piece) F Lower spring

Dismantling Procedure
1. Disconnect piping of control medium.

2. Remove actuator from valve cover.
3. Mark position of cover to actuator (1) against housing (to remount the
cover in the right position afterwards).
4. Remove 2 diametrically located screws (16) of cover to actuator (1).
5. Fit screws of extended length to handle the actuator spring(s) (2) being
under tension.
6. Remove all screws (except the two long ones).
7. To release the tension of the spring(s), loosen the two long screws
crosswise.
8. Mark/record position of piston (14) assembly, i.e. the assembly mode
(A/B).
9. Record position of spring (F).
10. Remove piston (14) with pressure pin (11).
11. Disassemble the upper TURCITE® STEPSEAL® (6) as shown in (see
Fig. 9-4). To remove the TURCITE® STEPSEAL® use a small hook or
a prepared screw driver (see Fig. 9-1).
XA_C3_0012a_01
Fig. 9-4 Disassemble TURCITE® STEPSEAL®
12. Disassemble the lower TURCITE® STEPSEAL® (6) after you have re-
moved the nipple (10) as shown in Fig. 9-4.
Do not reuse the dismantled notched ring, mount a new one.
13. If necessary: remove guiding band (12).
Required Checks Check for correct dimensions and number of springs “F” and for correct as-
sembly mode of actuator piston as follows:

1st Stage
Item Dimension in mm
Spring C -
D -
F 4x40x71
Pressure Pin Dia. 14

LT 345
Actuator piston Mode B
Tab. 9-1 Dimensions of spring(s) for suction valve actuator
LT Total length of pressure pin (pin dismantled)
Assemble New
or Used Parts
Prior to assembly, slightly lubricate all parts exposed to friction.
1. Check all seals/O-rings and replace them if necessary.

2. If the piston ring GLYD (3) is worn, the complete piston (14) must be
replaced. During loosening of the piston nut, do not damage pressure
pin surface (11).
3. If the pressure pin (11) shows corrosion spots, polish or replace it.
4. Install new USIT ring (13) and piston (14) according to marked surface.
5. Consider correct mounting of TURCITE® STEPSEAL® by using the
special mounting device (see Fig. 9-5).
Do not reuse a dismantled TURCITE® STEPSEAL®, mount a new one.

XA_T9_0030c_02
Fig. 9-5 Assembly device for TURCITE® STEPSEAL®
6. Install spring (2) and disk (if applicable) at its correct position.
7. Fit cover to actuator (1) by means of the screws with extended length.
Required Checks When the suction valve actuator is assembled, and before continuing with
the installation, do the following checks:
1. Determine the clearance KVG (see Fig. 9-6) by using a depth gauge
and compare value with Tab. 9-2.
2. Determine the reference dimension KS (see Fig. 9-6) and compare

value with Tab. 9-2.
Note: The actuator must be in the released state during this measure-
ment.
1st Stage
Item Dimension in mm
Pressure Pin KS 229.0
Clearance KVG 233.3
Tab. 9-2 Dimensions for installation of suction valve actuator
KS Reference dimension of actuator when actuator is dismantled

KVG Clearance between edge of valve cover and pressure sleeve for con-
trolled suction valve

1st Stage
LT
4
KS 6
KVG 8
10
11
XA_C3_0028e_01
Fig. 9-6 Controlled suction valve with actuator (typical view)
LT Total length of pressure pin 5 –

KS Reference dimension actuator 6 Threaded bolt
KVGClearance valve cover–pressure 7 Pressure screw
sleeve 8 Valve cover
1 Cover to actuator 9 Lantern
2 – 10 Cylinder
3 Housing 11 Controlled suction valve
4 Pressure pin
Install Suction Valve 1. Fit and tighten all screws.

Actuator
2. Replace both long screws by the original ones.
3. Attach actuator to valve cover.
4. Connect the piping.

Required Checks Checks at Hydraulics and Pneumatics
1. Check connections for leakages.
PB_C3_0001b_02
Fig. 9-7 Water drain (cylinder: typical view)
1 Cylinder
2 Actuator
3 Plug with vent
4 Vent downwards: water can drain off
2. Close unused connection for control pressure with plug. Mount actu-
ator in a manner that water cannot enter and condensation water can
drain off (downward, see Fig. 9-7).
3. Check differential pressure of control medium – pressure difference be-
tween above and below the actuator pistons – using a pressure gauge.
The differential pressure must reach at least the specified control pressure!
4. Check during released state: no differential pressure must be mea-

sured.

1st Stage
XA_C3_0069b_01
2 2 1
Fig. 9-8 Connecting arrangement for one piston actuator operated by medium
1 Control medium line

2 Equalizing line

Controlled Suction Valve
9.6 Controlled Suction Valve

• 9.5 Suction Valve Actuator
Special Tools none
9.6.2 Dismantle Controlled Suction Valve
DANGER
 Heavy equipment may only be lifted according to manufacturer’s in-
structions.
Carefully dismount controlled suction valves.
9.6.3 Assembly of Controlled Burckhardt Plate Valve™
Fig. 9-9 Controlled Burckhardt Plate Valve™ (typical view)

Assembly of Controlled
Suction Valve
1
14
13
12
11
10 7
8
LA_C3_0017b_01
Fig. 9-10 Components of controlled Burckhardt Plate Valve™ (typical view)
1 Pressure sleeve 8 Cylindrical pin

2 Rollpin 9 Valve guard
3 Cap nut 10 Center bolt
4 Compression spring 11 Damper plate
5 NORD-LOCK® washer pair 12 Valve plate
6 Lift washer 13 Valve seat
7 Valve spring 14 Finger unloader

Assemble New
or Used Parts
For installation of NORD-LOCK® washer pairs see section 8.7.10 NORD-

LOCK® Securing System.
1. Check for correct parts (compression spring, finger unloader).
2. Clean all parts according to chapter 10 Clean and Degrease Plant and
Compressor Components.
3. The suction valve must be assembled in accordance with section 9.7

Suction Valves and Discharge Valves, but without the hexagonal nut
(will be substituted by cap nut).
Assembly Procedure:
4. Assemble compression spring (Fig. 9-10, 4), finger unloader (14),

NORD-LOCK® washer pair, and cap nut (3).
5. Tighten cap nut (3). For tightening torque refer to Tab. 9-4.
6. Consult enlarged view for correct fitting position of the rollpin (see
Fig. 9-11).
7. Mount pressure sleeve (1) with rollpin (2).

GH
5
LA_C3_0019c_02
Fig. 9-11 Assembly sequence of controlled suction valve (typical view)
1 Pressure sleeve 6 NORD-LOCK® washer pair

2 Rollpin 7 Valve seat
3 Cap nut 8 Valve guard
4 Finger unloader GH Overall length
5 Compression spring
Required Checks
The clearances X and Y must be checked every time before fitting a con-
trolled suction valve.

X
3 1
2 LA_C3_0018b_02
A B
Fig. 9-12 Tolerances and clearances of controlled Burckhardt Plate Valve™

(typical view)
A Valve with metallic valve plates X Clearance

B Valve with non-metallic valve plates Y Clearance
1 Non-metallic valve plate Z Clearance
2 Damper plate
3 Metallic valve plate
Checking Procedure:
1. Check clearances X and Y, compare with values of Tab. 9-3.
2. If clearance X or Y is beyond the tolerance, use space washers to meet

the tolerances.

3. Check overall length GH of assembled valve.
4. Functional check: actuate the controlled suction valve using a hand

press or pneumatic device.
 The finger unloader must be able to completely open the valve.
1st Stage
Dimension in mm
Overall length GH 173.7
Range
Clearance X 1.2–2.2
Clearance Z 1.0–6.0
Clearance Y 0.3–0.8
Tab. 9-3 Dimensions of controlled suction valve
GH see Fig. 9-11
Clearance X, Y, Z see Fig. 9-12.
Thread size Center bolt torque in Nm Torque for nut in Nm
min. max. min. max.

M8 5 6 11 13
M10 11 13 21 26
M12 19 23 38 47
M16 42 53 95 116
M20 84 105 189 231
M24 126 158 315 368
Tab. 9-4 Tightening torques, only valid if “Burckhardt Lubrication Grease” BLG05
is used
9.7 Suction Valves and Discharge Valves

• 9.6 Controlled Suction Valve

Special Tools
XA_T9_0036a_01
Fig. 9-13 Pulling eye bolt
PA_T9_0009a_01
Fig. 9-14 Valve mounting spanner
11 1
2
10
9
3
8
4
7 5
6 2
3
PA_T9_0041c_01
11
Fig. 9-15 Valve dismantling and assembling device
1 Bottom plate 7 Ratchet

2 Additional guiding bar 8 Pick-up disc
3 Guiding bar 9 Centering bolt
4 Guiding plate 10 Spindle
5 Mandril 11 Allen screw
6 Clamping device (movable)

PB_T9_0077a_01
Fig. 9-16 Ratchet
XA_T9_0051a_01
Fig. 9-17 Stepped mandril

Recommended Tools (Not Recommended: valve service device (for assembly and disassembly)
Delivered with
Compressor)
Fig. 9-18 Valve service device (T98000)
The valve service device can be ordered from our Spare Parts Division.
The device is not included in the delivery. This tool has the following advan-
tages:
• simple handling
• it prevents the valve seat and valve guard as well as the valve plate and
damper plate from twisting against each other.
• following valves can be dismantled and assembled with this device:
– Burckhardt Plate Valve™
– Burckhardt Poppet Valve™
– Manley® Valve
– non-Burckhardt Compression valve
• can be fixed in a simple bench vise

• noncorrosive design
• delivered in a handy transport box

9.7.2 Dismantle Valve

Special Tools For special tools please refer to section 9.7.1 Status and Special Tools.
Dismantle Removal of Suction Valves (Top of Cylinder)
1. Remove cap nut for pressure screws.

2. Remove valve cover nuts.
3. Remove valve cover.

4. Remove gasket.
5. Remove lantern.
CAUTION
Heavy material!
Cover, lantern and valve are heavy: Prevent them from falling down.
 Don’t remove any nut from threaded bolt until lantern and valve are re-
moved.
6. Install valve mounting spanner.

7. Remove valve.
Removal of Discharge Valves (Bottom of Cylinder)
Vertical dismantling of discharge valves

For cylinders with vertical dismantling of the discharge valves, the valve
dismantling and assembling device is simplified:
• no Allen screws for fixation of pick-up disc,
• no additional guiding bar.
These components are not needed and therefore not delivered with the
valve dismantling and assembling for the corresponding stage(s).
WARNING
Heavy valves and lanterns!
Incorrect handling of valves and lanterns through inappropriate use of
valve dismantling and assembling device may lead to defective equipment
and malfunctioning of compressor/plant. In addition severe injuries are
possible.
 The valve dismantling and assembling device must be operated with
care and technical expertise.
 It is recommended that the tool is operated by 2 people.
 In case of heavy valves and lanterns, 2 operators are a must.
Additional required tools:

In addition to the valve dismantling and assembling device, have the fol-
lowing tools at your disposal
• 1 Allen key: 8 mm,
• 1 combination spanner: 24 mm,
• 1 combination spanner per stage, size: appropriate for the respective
valve cover nuts,
• MOLYKOTE® G-N Plus (for lubrication of the pick-up disc).
Procedure:
1. Select the proper valve dismantling and assembling device for the
valves to be dismantled.
2. Remove cap nut for pressure screws (if applicable).
3. Remove valve cover nuts.
4. Remove valve cover and gasket.
5. Fit the base unit of the valve dismantling and assembling device onto
the bolts for the valve cover (see Fig. 9-19).
 The spindle (1) of the valve dismantling and assembling device
must be on the bottom right or left.
6. Push the base plate (4) upwards (5) to its stop (perpendicular to valve
cover bolts (see Fig. 9-19).
Reason: later on, the weight of the tool, valve and lantern will press the en-
tire packet slightly down and the tool will be centered.

7. Install valve cover nuts (2) to fix base unit of tool.
1 2 3 4 5
PB_T9_0091b_03
6
Fig. 9-19 Correctly installed base unit (spindle on bottom left)
1 Spindle 4 Base plate

2 Nut (for valve cover, here used for 5 Direction of pushing
base plate) 6 Guiding plate
3 Locking pin (for lantern)
8. Lubricate the thread and contact surfaces (3) of the pick-up disc (2)
with the guiding plate (1) with MOLYKOTE® G-N Plus (see Fig. 9-20).
 The pick-up disc will be easily turnable.

9. Put the lubricated pick-up disc into the base unit.
1 2
PB_T9_0092c_02
Fig. 9-20 Install pick-up disc
1 Guiding plate 3 Grease contact surface with

2 Pick-up disc MOLYKOTE® G-N Plus
10. Fit the additional guiding bar (Fig. 9-21, 2) to base plate and tighten
slightly with a bolt.
1 2
PB_T9_0091c_03
Fig. 9-21 Fit additional guiding bar
1 Bore for bolt 2 Additional guiding bar

11. Push up guiding plate by hand and secure it with the movable clamping
rings on the guiding bars. Then screw up the nut of the spindle (nut is
below the guiding plate).
You may also move up the guiding plate with the ratchet.
12. Insert centering bolt (2) from below into pick-up disc (see Fig. 9-22).
1 2
PB_T9_0095b_02
Fig. 9-22 Insert centering bolt
1 Mandril 2 Centering bolt
13. Push the centering bolt (Fig. 9-23, 1) up to the valve center bolt (2) and
screw it on by 2 or 3 turns with the mandril.
1
PB_T9_0096b_02
Fig. 9-23 Connect centering bolt to valve center bolt
1 Centering bolt 2 Valve center bolt

CAUTION
Centering bolt screwed in too much!
If the centering bolt is screwed right up to the valve center bolt, it may not
be possible to loosen it later on. In addition, the center bolt of the valve may
become loose and the valve risks to become disassembled while being dis-
mantled.
 Screw in centering bolt by 2 or 3 turns only!
14. Fit washer and nut (Fig. 9-24, 1) to centering bolt (at lower side of
guiding plate) and tighten hand-tight.
PB_T9_0097b_02
Fig. 9-24 Tighten centering bolt
1 Washer and nut for centering bolt
15. Slightly move up the guiding plate (with lantern and valve) by 0.5 to
1.0mm – by turning the spindle with the ratchet.
 Lantern and valve become loose from the locking pin (2) and can
be rotated.
1 2 3 4
PB_T9_0103b_02
Fig. 9-25 Lift guiding plate to unlock lantern
1 Pick-up disc 3 Lantern groove

2 Locking pin 4 Base plate

16. Carefully align the groove in the lantern (2) and the locking pin (1) in the
cylinder by turning the guiding plate (including lantern and valve) with
the big mandril.
1 2
PB_T9_0102b_02
Fig. 9-26 Align lantern groove and locking pin
1 Locking pin 2 Lantern groove
 Lantern and valve can be removed now.

17. Loosen clamping rings on guiding bars.
18. Begin to move down guiding plate (with lantern and valve) by turning
down the nut on the spindle (Fig. 9-27, 1) with the ratchet.
Stop immediately when the locking pin reaches the lantern groove.
19. Loosen the nut for the centering bolt (2).
PB_T9_0100c_02
2 1
Fig. 9-27 Loosen the nut for the centering bolt
1 Nut for spindle 2 Nut for centering bolt
 Lantern and valve can move more freely.

20. Slowly move down guiding plate (with lantern and valve) with the
ratchet (Fig. 9-28, 2).
1 2
PB_T9_0099b_02
Fig. 9-28 Move down guiding plate with ratchet
1 Clamping ring (movable) 2 Ratchet
21. Loosen and remove the centering bolt with the mandril.
PB_T9_0104a_02
Fig. 9-29 Remove centering bolt

22. Remove additional guiding bar (Fig. 9-30, 2) from base plate.
PB_T9_0090b_03
3 2 1
Fig. 9-30 Valve and lantern are dismantled
1 Valve 3 Lantern
2 Additional guiding bar
23. Carefully remove valve (1) and then lantern (3).
CAUTION
Heavy material!
Lantern and valve together are heavy: Prevent them from falling down.
 Carefully remove them one at a time.

9.7.3 Disassembly and Repair of Burckhardt Plate Valve™

Disassembly of Valves
This compressor is equipped with
original Burckhardt Plate Valves™.
Fig. 9-31 Burckhardt Plate Valve™

(typical view)
1. Order the valve service device from Spare Parts division, including
booklet on how to handle valves with this device or send defective
valve(s) to the nearest Burckhardt Compression Service Center for re-
pair. Contact address: see section .
XA_T9_0029a_02
Fig. 9-32 Incorrect handling

Never clamp valve in a vise to disassemble or to loosen the locking nut

from the center bolt.
2. Disassemble the valve according to the instructions provided with the

valve service device.
3. With the NORD-LOCK® washer pair removed, separate the seat from
the guard. Keep the seat and sealing elements the way they came
apart.
Required Checks after 1. Clean all components. Use a cleaning fluid and a soft brush, taking par-
Dismantling ticular care to free the ports of the seat and the guard from all foreign
matter to ensure full seat area in operation. Never use wire brushes or
tools with sharp edges to clean the seats and plates.
2. Check the valves, inspect individual components for damage and wear
and replace them, if necessary.
3. Inspect lanterns, they shall not be cracked or have any damage to the
seating faces.
4. Generally, the valve gaskets should be replaced.
5. Replace NORD-LOCK® washer pair with new, unused NORD-LOCK®

washer pair every time a cap nut or nut for valves is loosened.
If valve components are only inspected but not replaced, they must be re-
assembled with the same valve seat and installed in the same location as
before removal.

Repair of Valve Seats If the accurately machined surfaces of the seal ridges on the valve seat be-
come damaged due to hammering, etc., they can be machined on a lathe
according to Tab. 9-5 and Fig. 9-33.
C
B
A
3
N6
Min.
D
0.5 mm
1 2 3 4
0.5 mm
XA_CX_0043b_01
8 5
0.5 mm
0.5 mm
3 7 1 6
Fig. 9-33 Valve seat
1 Pinhole 5 Discharge valve seat with tapped

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

Valve Plate A B C Min.

Diameter [mm] [mm] [mm] [mm]
[mm]
60–196 4.00 4.50 5.50 2.50
212–266 5.00 5.50 7.00 3.50
310 6.50 7.00 9.00 4.50
D = Re-machining of surface is not permitted
Tab. 9-5 Re-machining limits
Re-machining quality of surface (3): N6 fine machined. Check pinhole (1)

for sufficient depth, drill deeper if necessary.
For controlled suction valves only: check clearance X according to Tab. 9-3
in section 9.6.3 Assembly of Controlled Burckhardt Plate Valve™.
Repair of Valve and

Damper Plates
Neither valve nor damper plates may be reworked, e.g. by grinding.

Only lapping-in with the associated valve seat is possible.

9.7.4 Assembly of Burckhardt Plate Valve™

Key to Valve Type Example:

Designations
XA_CX_0008b_01
122.YYY.YYY.200 CSV 202 - 100 - BC - X - S - 80 - 32 - 300 - T
1 2 3 4 5 6 7 8 9 10 11
Fig. 9-34 Valve type designation
1 Drawing number 7 Type of damper plate:

2 Valve: S = standard damper plate,
CSV = controlled suction valve, P = Belleville damper plate,
SV= suction valve, D = double damper plate,
DV = discharge valve O = without damper plate
3 Valve size 8 Dia. spring wire (in 1/100 mm)
4 Pressure class 9 Number of springs
5 Valve type: 10 Lift (in 1/100 mm)
BC = Burckhardt Plate Valve TM 11 Special design:
6 Valve plate material: S = standard,
X = 5CrNiCuNb174, T = low temperature,
H = HASTELLOY C, I = indicator
I = Polyimid,
F = FP,
C = customized specification
Number Valve type Size of Lift washer Lift in Spring Wire dia.
thread for mm in mm
per stage center bolt piece x mm piece

1st Stage
Suction 8 308-16-32-BC M24 3 x 0.7 2.1 24 0.9
Discharge 8 308-16-32-BC M24 3 x 0.7 2.1 24 0.9
Tab. 9-6 Valve design
If failures (malfunction) occur repeatedly, valve lifting can be reduced or

stronger springs fitted. Such modifications are only to be carried out with
our approval. Please contact Burckhardt Compression Services, address
see 1.6 Contact Address.
General Remarks
Clean all parts according to chapter 10 Clean and Degrease Plant and
Compressor Components.

CAUTION
The valve configuration was simulated by a computer program and opti-

mized for each compressor/application.
The configuration of the valve components is dictated by its application.
Therefore, it is not advisable to change parts and configuration without con-
sultation of Burckhardt Compression Services.
The proper functioning of the valves depends largely on the correct as-
sembly. The most important factors are the lift of the valve and the spring
force of the valve springs.
Required Checks Check the marking “X5”:
HS 1
2
HS 2
HS 3
3
4
XA_CX_0027b_01
HS
Fig. 9-35 X5 Marking
1 Valve guard 4 Valve seat

2 Damper plate 5 Marking X5
3 Valve plate HS Lift washer
Assemble New Instruction for Fitting of Valve Springs

or Used Parts
To prevent the valve springs from rotating around their longitudinal axis
during operation, they seat flush in the valve guard. Usually, these springs
must be slightly pressed in when fitting into the appropriate spring guide.
The springs must be adjusted vertically in the cylindrical part of the guide
of the valve guard. Take care that they do not interfere with damper plate.
For assembly, push the springs in a counterclockwise motion into the guide
of the valve guard.

1 2 3 4 5 6
XA_CX_0028b_01
Fig. 9-36 Correct position of valve springs
1 Valve plate 4 Spring

2 Incorrect position 5 Correct position
3 Valve guard 6 Damper plate
It is essential, that valve parts are always assembled in accordance with

the following instructions:
Tab. 9-7 – For tightening torques
Fig. 9-36 – For fitting of the valve springs
The nuts must be tightened thoroughly.
For installation of NORD-LOCK® washer pairs see section 8.7.10 NORD-

LOCK® Securing System.
The center slanting cuts on valve and damper plates must coincide (see
Fig. 9-37).
1 2
XA_CX_0030b_02
Fig. 9-37 Positioning of damper plate and valve plate
1 Correct position
2 Incorrect position

Thread size Center bolt torque in Nm Torque for nut in Nm
min. max. min. max.

M8 5 6 11 13
M10 11 13 21 26
M12 19 23 38 47
M16 42 53 95 116
M20 84 105 189 231
M24 126 158 315 368
Tab. 9-7 Tightening torques, only valid if “Burckhardt Lubrication Grease” BLG05
is used
1 Nut
A
2 NORD-LOCK® washer pair
1 3 Valve seat, suction side
2 4 Valve plate
5 Lift washers
6 Center bolt
3 7 Damper plate
8 Cylindrical pin
9 Springs
10 Valve guard, suction side
4
5
6
7
5
8
9
XA_C2_0007b_01
10
Fig. 9-38 A Suction valve

1 Nut
B
2 NORD-LOCK® washer pair
1 3 –
2 4 Valve plate
5 Lift washers
11 6 Center bolt
7 Damper plate
9 8 Cylindrical pin
8 9 Springs
10 –
11 Valve guard, discharge side
5
12 Valve seat, discharge side
XA_C4_0009b_01
12
Fig. 9-39 B Discharge valve
9.7.5 Installing the Valve

Fit Valves into Cylinder The sealing surfaces between the valves and the cylinders are lapped in.
Avoid damages of the sealing surfaces during installation of valves. The
lanterns on the suction side are shorter than those on the discharge side.
Important General Remarks
STOP
XA_CX_0031a_01
Fig. 9-40 Correct installation of valves

WARNING
Wrongly installed valves can lead to compressor damage.
Observe the following information to install the valves on the correct side of
the compressor:
• A suction valve cannot be inserted in a valve cavity on the discharge
side, because its diameter is larger than the diameter of a valve cavity
on the discharge side.
• A discharge valve, however, can be inserted into a valve cavity on the
suction side, because its diameter is smaller than the diameter of a
valve cavity on the suction side.
A discharge valve that has been inserted into a valve cavity on the suc-
tion side can nonetheless not be properly installed, because its lantern
can then not be moved into its correct position.
• In suction valves, the center bolt is threaded in the guard.

• In discharge valves, the center bolt is threaded in the seat.
• Due to valve design, the lanterns for the suction side are shorter than
those for the discharge side.

S G D
5
ø<
ø> 6
PB_CX_0001b_01
G
Fig. 9-41 Suction valve diameter > discharge valve diameter
S Installed suction valve 3 Valve cover

D Installed discharge valve 4 O-ring
G Gas flow 5 Discharge valve
Ø Valve diameter 6 Lantern
1 Cap nut for pressure screw 7 Suction valve
2 Pressure screw 8 Locking pin
Install Suction Valves
1. Insert valves with their lanterns into the correct valve cavities (use eye
bolts). In general, proceed in reverse order to dismantling of suction
valves.
 The inserted lantern must fit properly. The inserted lanterns must
stand approx. 10 mm back from the cylinder face.
Install Discharge Valves
Vertical installation of discharge valves

For cylinders with a vertical installation of the discharge valves, the valve
dismantling and assembling device is simplified:
• no Allen screws for fixation of pick-up disc,
• no additional guiding bar.
These components are not needed and therefore not delivered with the
valve dismantling and assembling for the corresponding stage(s).

WARNING
Heavy valves and lanterns!
Incorrect handling of valves and lanterns through inappropriate use of
valve dismantling and assembling device may lead to defective equipment
and malfunctioning of compressor/plant. In addition severe injuries are
possible.
 The valve dismantling and assembling device must be operated with
care and technical expertise.
 It is recommended that the tool is operated by 2 people.
 In case of heavy valves and lanterns, 2 operators are a must.
Additional required tools:

In addition to the valve dismantling and assembling device, have the fol-
lowing tools at your disposal
• 1 Allen key: 8 mm,
• 1 combination spanner: 24 mm,
• 1 combination spanner per stage, size: appropriate for the respective
valve cover nuts,
• MOLYKOTE® G-N Plus (for lubrication of the pick-up disc).
Procedure:
1. Select the proper valve dismantling and assembling device for the
valves to be dismantled.
2. Remove valve cover and gasket (if not already done).
3. Fit the base unit of the valve dismantling and assembling device onto
the bolts for the valve cover (see Fig. 9-42).
 The spindle (1) of the valve dismantling and assembling device
must be on the bottom right or left.
4. Push the base plate (4) upwards (5) to its stop (perpendicular to valve
cover bolts (see Fig. 9-42).
Reason: later on, the weight of the tool, valve and lantern will press the en-
tire packet slightly down and the tool will be centered.

5. Install valve cover nuts (2) to fix base unit of tool.
1 2 3 4 5
PB_T9_0091b_03
6
Fig. 9-42 Correctly installed base unit (spindle on bottom left)
1 Spindle 4 Base plate

2 Nut for valve cover 5 Direction of pushing
3 Locking pin (for lantern) 6 Guiding plate
6. Mark the position of the locking pin in the cylinder on the base plate with
a felt tip pen.
 The marking facilitates inserting the lantern into the cylinder later
on (locking pin – lantern groove).
7. Grease the thread and contact surfaces (see Fig. 9-43, 3) of the pick-
up disc (2) with MOLYKOTE® G-N Plus.
 The pick-up disc will be easily turnable.
8. Put the pick-up disc into the base unit as shown in Fig. 9-43.
9. Fix the pick-up disc to the guiding plate with 3 Allen screws (1).
The Allen screws will only be delivered for really heavy valves. If they are
not delivered, it means that lantern and valve can be installed without them.
Proceed with the next step.

1 2
PB_T9_0092b_02
Fig. 9-43 Install pick-up disc
1 Allen screw 3 Grease contact surface with

2 Pick-up disc MOLYKOTE® G-N Plus
 Lantern and valve will be more easily inserted into the cylinder be-
cause the tool is more stable. No getting jammed.
10. Put lantern (see Fig. 9-44, 1) on pick-up disc.
1 2
PB_T9_0093b_02
Fig. 9-44 Install lantern
1 Lantern 2 Groove
11. Carefully align the groove (see Fig. 9-44, 2) in the lantern and the
locking pin in the cylinder.

12. Carefully put valve on lantern (see Fig. 9-45).
PB_T9_0094a_02
Fig. 9-45 Install valve
 The nut for the center bolt must face downwards.

13. Insert centering bolt (2) from below into pick-up disc (see Fig. 9-46).
1 2
PB_T9_0095b_02
Fig. 9-46 Insert centering bolt
1 Mandril 2 Centering bolt

14. Push the centering bolt (see Fig. 9-47, 1) up to the valve center bolt (2)
and screw it on by 2 or 3 turns with the mandril.
PB_T9_0096b_02
Fig. 9-47 Connect centering bolt to valve center bolt
1 Centering bolt 2 Valve center bolt
• It may be necessary to press lantern and valve upwards manually

in order to fix the centering bolt of the tool to the thread of the valve
center bolt.
CAUTION
Centering bolt screwed in too much!
If the centering bolt is screwed right up to the valve center bolt, it may not
be possible to loosen it later on. In addition, the center bolt of the valve may
become loose and the valve risks to become disassembled while being dis-
mantled.
 Screw in centering bolt by 2 or 3 turns only!

15. Fit washer and nut (see Fig. 9-24, 1) to centering bolt (at lower side of
guiding plate) and tighten hand-tight.
PB_T9_0097b_02
Fig. 9-48 Tighten centering bolt
1 Washer and nut for centering bolt
16. Check that lantern groove and locking pin in cylinder are still aligned.
Correct if necessary.
17. Fit the additional guiding bar (see Fig. 9-49, 2) to base plate and tighten
slightly with a bolt.
PB_T9_0098b_02
Fig. 9-49 Fit additional guiding bar
1 Additional guiding bar 2 Bore for bolt

18. Slowly move up guiding plate (with lantern and valve) by turning the nut
on the spindle upwards with the ratchet (see Fig. 9-50, 2).
The clamping rings (1) on the guiding bars can be used to lock the packet
in any position.
1 2
PB_T9_0099b_02
Fig. 9-50 Move up guiding plate with ratchet
1 Clamping ring (movable) 2 Ratchet
19. Remove the 3 Allen screws (see Fig. 9-51, 1) shortly before the lantern
grooves reaches the locking pin in the cylinder. Lock packet with the
clamping rings.
20. Align lantern groove and locking pin by turning the guiding plate with
the mandril (see Fig. 9-51, 2).
21. Continue to move up guiding plate (with lantern and valve) with the
ratchet. Stop immediately when the locking pin reaches the lantern
groove.
22. Check that locking pin really is in the groove by turning the guiding plate
slightly to the right and left using the mandril.
 The lantern must be blocked on both sides after a couple of milli-
meters.

23. Loosen the nut for the centering bolt (3).
PB_T9_0100b_03
3 2
Fig. 9-51 Insert valve and lantern into cylinder
1 Allen screw 3 Nut for centering bolt

2 Mandril
 Lantern and valve are freely movable. They will not get jammed in
the cylinder or the valve cavity.
24. Continue to move up guiding plate (with lantern and valve) with the
ratchet.
• If lantern and valve get jammed in the cylinder, slightly move the
guiding plate back down.

• When it gets free, continue to move it up again.

• To increase the play of lantern and valve even more, the nuts on
the base plate (see Fig. 9-52, 1) may be loosened slightly.
1 2
PB_T9_0101b_02
Fig. 9-52 Loosen nuts on base plate slightly
1 Nut on base plate 2 Combination spanner
25. As soon as the locking pin (see Fig. 9-53, 2) in the cylinder becomes
visible beneath the lantern (3), remove the ratchet.
1 2 3
PB_T9_0102c_02
Fig. 9-53 Locking pin becomes visible beneath lantern
1 Marking with felt tip pen 3 Lantern

2 Locking pin
26. Tighten nut for centering bolt again (beneath guiding plate).

27. Rotate guiding plate (with lantern and valve) with the mandril.
1 2 3 4
PB_T9_0103b_02
Fig. 9-54 Lock lantern with locking pin
1 Pick-up disc 3 Lantern groove

2 Locking pin 4 Base plate
• If the guiding plate (with lantern and valve) has been moved up all
the way to its stop, the valve seat is pressed against the valve
cavity of the cylinder. As a result, it can not be rotated as required.
• Slightly move down the guiding plate (with lantern and valve) by 0.5
to 1.0mm with the ratchet. Make sure that the lantern is still behind
the locking pin.
• Now rotate guiding plate (with lantern and valve) by a couple of de-
grees by means of the mandril.
 Valve and lantern are locked. The locking pin (see Fig. 9-54, 2) pre-
vents them from falling out.
28. Loosen nut for centering bolt again (see Fig. 9-55).
29. Loosen and remove the centering bolt from the valve center bolt with
the mandril.
PB_T9_0104a_02
Fig. 9-55 Remove centering bolt
30. Lock guiding plate by means of the clamping rings (if not already done).
31. Turn down nut of spindle manually.

32. Carefully loosen the clamping ring(s) while securing the guiding plate
manually. Then move down the guiding plate by hand.
PB_T9_0105a_02
Fig. 9-56 Move down guiding plate
Alternatively, the guiding plate can be moved down with the ratchet.
33. Remove pick-up disc.

34. Remove nuts on base plate.
35. Carefully remove base unit of valve dismantling and assembling de-
vice.
Install Valve Covers

Installed valves and their lanterns are pressed to their seating surfaces by
pressure screws (6). There is a gap between valve covers and installed lan-
terns/valves.

1 7
PA_CX_0004b_02
2 3 4 5 6
Fig. 9-57 Valve cover
1 O-ring 5 Valve cover

2 Nut 6 Pressure screw
3 Flat gasket 7 Lantern
4 Plug screw
1. Turn back pressure screws (6) of valve covers until they no longer pro-
trude from the inner surface of the valve cover. Lubricate all parts to
avoid fretting of bolts and sealing surface of cap nut.
2. Put O-ring (1) and valve cover (5) on cylinder and tighten the nuts (2)
slightly.
3. Tighten the nuts diagonally, applying specified torque.

4. Tighten pressure screws (6), applying specified torque.
5. Fit gaskets for cap nuts.
6. Fit cap nuts and tighten them firmly.
For mandatory tightening torques: see section “Compressor” in chapter 13

Appendix.

Cylinder Cover
9.8 Cylinder Cover

• 9.3 Switch Off Cooling System
Special Tools Bar 30 x 1200mm, mandril
LA_T9_0009a_01
Fig. 9-58 Eye bolt
9.8.2 Dismantle Cylinder Cover

Measure Cylinder 1. Dismantle a valve at the Bottom Dead Center (BDC) and a valve at the
Clearance Top Dead Center (TDC) of the cylinder.
 The cylinder clearance is now accessible
CAUTION
pressor failure.
clearance.

Dismantle Dismantle Cylinder Cover
3. Remove all nuts of the cylinder cover.

4. Fit an eye bolt to the cylinder cover.
5. Remove cylinder cover according to Fig. 9-59.

Cylinder Cover
4 3
PA_T9_0007b_01
Fig. 9-59 Dismantle cylinder cover
1 Eye bolt with rope

2 Cylinder cover
3 Bar dia. 30 x 1200 mm
4 Cylinder

Cylinder Cover
9.8.3 Install Cylinder Cover

Required Checks 1. Check if all O-rings are in perfect condition.
2. Replace O-rings if required.
Assemble New Prepare Cylinder Cover

or Used Parts
3. Install O-rings.
4. Install eye bolt on cylinder cover and attach it to the crane.

5. Install cover as shown in Fig. 9-59 by using the crane and the bar.
Install Nuts for Cylinder Cover
6. Tighten the nuts slightly.

7. Tighten the nuts diagonally, applying specified torque.
Required Checks Measure Cylinder Clearances
CAUTION
pressor failure.
clearance.

list of section 8.7.4 Clearance Measurement Log Sheet. Compare them
to the values in section “Compressor” in 13 Appendix.

Frame Covers
9.9 Frame Covers

Special Tools none
9.9.2 Dismantle and Assemble Frame Covers

Dismantle and Assemble 1. Remove all screws at the margin of the covers.
2. Lift off the covers according to following figure and stow them away.
PB_M0_0037a_01
Fig. 9-60 Frame cover removal

Drain Lubricating Oil
9.10 Drain Lubricating Oil

Special Tools none
9.10.2 Drain and Refill Lubricating Oil

For further information about handling the oil skid and its elements, i.e.
drain from oil tank, quantities, etc., please see “Technical Documentation”.
Drain For details about the draining procedure, please refer to section 8.6.6 Oil
Change.
Refill For details about the refilling procedure, please refer to section 8.6.6 Oil
Change.
Check for proper lubricating oil quality and quantity see sections 8.6.7 Lu-
bricating Oil Specifications and 8.6.6 Oil Change.

Piston and Piston Rod

• 9.7 Suction Valves and Discharge Valves
• 9.8 Cylinder Cover
• 9.9 Frame Covers
Special Tools barring gear, mandril, spirit level, assembly cone, assembly sheet
PA_T9_0022a_01
Fig. 9-61 Protective sleeve for piston rod

PB_T9_0078a_01
5
Fig. 9-62 Piston rod supporting device
1 Distance piece 4 Spindle with height adjusting screw

2 Piston rod supporting device 5 Support for piston rod
3 Base bracket
1 2 3
PA_T9_0002b_01
Fig. 9-63 Dismantling and assembling device for piston
1 Piston rod
2 Piston
3 Dismantling and assembling device
9.11.2 Dismantle Piston and Piston Rod

Preparation 1. Record value of proximity probes with the piston in BDC on the installed
monitoring system before dismantling.
Dismantle 1. Remove the leak gas and the piping of the lubricating oil, if necessary.
2. Remove the distance piece cover.

 You can reach the crosshead.

3. Position the crosshead to the top dead center by turning the flywheel
with the barring device.
 You can reach the connection between the crosshead and the
piston rod.
4. Dismount the piston rod nut SUPERBOLT® (6). See section 8.9.4
Piston Nut SUPERBOLT® for detailed description.
5. Position the crosshead to the bottom dead center by turning the fly-
wheel with a barring gear.
6. Fit the dismantling and assembling device to the piston.
Information.
For assembling the new piston, you also need the installed protective
sleeve.
 Do not remove it, after you will have dismantled the worn piston.
7. Pull the piston out of the cylinder (see Fig. 9-64).
Fig. 9-64 Pull-out the piston (typical view)
8. Remove the dismantling and assembling device from the piston.

Required Checks • Check the alignment of the cylinder (liner) and the crosshead bore by
using a spirit level (see Fig. 9-65).
Fig. 9-65 Check cylinder alignment with a spirit level
1 Cylinder
2 Spirit level

9.11.3 Dismantle the Piston

Special Tools torque wrench
Dismantle
3 4 5
1 2 6
PB_C1_0180b_01
Fig. 9-66 Dismantled piston
1 Piston rod
2 Center ring
3 Lower piston crown
4 Piston skirt
5 Upper piston crown
6 Piston nut SUPERBOLT®
For loosening procedure of piston nut SUPERBOLT® see 8.9.4 Piston Nut
SUPERBOLT®.
Piston Rings
9. Remove piston rings (for required checks, see section 9.11.5 Piston
Rings).
9.11.4 Assemble the 3-Piece Piston

Special Tools torque wrench
Check the Pretension of The pretension of the piston crowns to the piston skirt is measured when a
Piston Crowns piston part is replaced or after the interval indicated on the maintenance
schedule. This applies also, if a piston nut came loose.
Pretension is the value by which the piston crowns are bent inwards when
the piston nut is tightened, thereby clamping the piston skirt. Measure dis-
tance “A” with the piston crowns clamped together without the piston skirt
as shown in the following figure.
Pretension = Dimension B - Dimension A

PB_C1_0022b_01
1 2 3 4 5 6
Fig. 9-67 Piston pretension (typical view)
1 Lower piston crown 4 Piston nut SUPERBOLT®

2 Centering ring 5 Upper piston crown
3 Piston rod 6 Piston skirt
Stage (Compressor) Dia. nominal of piston Pretension (mm)

(mm)
1st stage 640 0.08 – 0.54
Tab. 9-8 Piston pretension (3-piece piston)
Assemble the Piston 1. Put one piston crown onto a suitable support.
2. Assemble the piston as shown in Fig. 9-68.

PA_C1_0007b_01
Fig. 9-68 Clamp piston halves together
1 Eye bolt
2 Piston crown
3 Piston skirt
3. Clamp the assembled piston together by using two vises.

4. Fit the piston onto the piston rod.

2 3 4
PA_C1_0006b_01
Fig. 9-69 Fit piston onto piston rod
1 Vise
2 Piston
3 Piston rod
4 Fixation device
5. Lubricate the thread of the piston rod by using MOLYKOTE® G-N Plus.
6. Fit the support and the seal rings onto the piston nut SUPERBOLT®.

7. Secure, that they are assembled according to Fig. 9-70.
1 2 3 4 5 6
8 7
PB_C1_0052b_01
Fig. 9-70 Piston details (typical view)
1 Piston rod 6 Upper piston crown

2 Oil shield 7 Piston nut SUPERBOLT®
3 Center ring 8 O-ring
4 Lower piston crown 9 Support ring
5 Piston skirt
 This seal protects the inside of the piston against contamination.

8. Screw the piston nut SUPERBOLT® onto the piston rod and tighten it
firmly by hand.
9. Tighten the piston nut SUPERBOLT® according to section “Com-

9.11.5 Piston Rings

Completed activities:
• 9.11 Piston and Piston Rod
• 9.14 External Gas Pipes
Special Tools Micrometer
Procedure 1. Check the gap “Y” by inserting the piston rings into the cylinder.
Fig. 9-71 Piston rings inserted into cylinder

Y Y
Y
1 1 2
PB_C1_0083b_01
Fig. 9-72 Gap “Y” of piston rings
1 Piston ring with scarf joint

2 Guide ring (rider ring)
2. Check the wear of the piston rings by measuring the radial thicknesses
according to section “Compressor” in chapter 13 Appendix.
3. Check the dimension of the running surface at the cylinder liner ac-
4. Check the condition of the running surface at the cylinder liner ac-
5. Check pistons for flawed ring grooves and score marks. Replace pis-
tons if necessary.
Piston Rings
The more the radial thickness of the piston rings are worn, the bigger
is the gap.
Before you will install the new piston rings
 check the gap.
 check the axial clearance of the piston rings in the piston groove ac-
cording to section “Compressor” in chapter 13 Appendix

Conventions of designation for piston ring with scarf joint with left (L)
or right (R) cuts.
Look at the outer (sealing) surface of the piston ring:
• left cut (L): the cut goes from bottom left to top right,
• right cut (R): the cut goes from bottom right to top left.
1. Secure, that you insert the different types of the piston rings in the cor-
rect grooves of the piston.
1st Stage
4 5 6 7 8
1 2 3
10 11 9 10 11
L R
PB_C1_0226b_01
Fig. 9-73 Assembly of Redura® piston rings
1 Piston rod 7 Upper piston crown

2 Oil shield 8 Hydraulic piston nut
3 Center ring 9 Guide ring (rider ring)
4 Lower piston crown 10 Piston ring with scarf joint (left
5 Pretension cut)
6 Piston skirt 11 Piston ring with scarf joint (right
cut)
2. Secure, that the Y gaps are offset with 180° to each other as shown in
Fig. 9-74.

PA_C1_0022a_01
Fig. 9-74 Horizontal arrangement of the joint gaps
3. After installation of piston/piston rod carry out a mechanical test run.
9.11.6 Install Piston and Piston Rod
CAUTION
All components coming into contact with process gas must be clean (oil-
free and free of grease).
When using solvents, observe the safety precautions of the manufacturer.
Presetting Adjusting 1. Measure the diameter X of the crosshead.

Screws

10
12
PB_M3_0001c_01
11
Fig. 9-75 Connection between crosshead and piston rod
X Diameter 7 Crosshead
1 Piston rod 8 Crosshead pin bearing
2 Locking plate 9 Crosshead pin
3 Set collar 10 Circlip
4 Set screw 11 Connecting rod
5 Shim 12 Cylindrical pin
6 Piston rod nut SUPERBOLT®
2. Measure the inner diameter Y of the adjusting ring according to

Fig. 9-76.

Fig. 9-76 Measure diameter Y
Fig. 9-77 Preset set screws
1 Set screw

3. Preset the lateral screw and the bottom screw at the adjusting ring.
 You are able to put the adjusting ring onto the crosshead without
jamming.
4. Put the adjusting ring onto the crosshead.
5. Restrict the adjusting ring by regulating the two remaining screws uni-
formly.
6. If not already done: install the piston rings on the piston. Proceed ac-
cording to section 9.11.5 Piston Rings.
Installation with Assembly 1. Fit the assembly sheet around the piston.
Sheet (1st Stage)
 The piston rings are fixed on the piston by the assembly sheet
during installing.
Fig. 9-78 Piston with assembly steel sheet
2. Check that the sheet is tight enough, so that the piston rings are cor-
rectly fitted in the piston grooves.
3. Fit the protective sleeve on the piston rod (see Fig. 9-79).

PA_T9_0022a_01
Fig. 9-79 Protective sleeve
4. Fit the dismantling and assembling device to the piston.
5. Lift the piston according to Fig. 9-80.
Fig. 9-80 Lift of piston
6. Install the piston in the cylinder.

7. Secure, that the stopper of the assembly sheet at the piston is posi-
tioned at the cylinder liner according to Fig. 9-81.

Fig. 9-81 Assembly steel sheet with stopper
1 Cylinder
2 Assembly steel sheet
3 Stopper
8. Proceed with the installation as described in sub-section “Further In-

stallation Steps for all Stages”.
1. Push the piston into the cylinder until the protective sleeve passes the
piston rod packing according to Fig. 9-82.
Fig. 9-82 Piston rod passes the piston rod packing
1 Protective sleeve
2 Piston rod packing
2. Fit the oil shield on the piston rod (see Fig. 9-83).

Fig. 9-83 Fit the oil shield
1 Protective sleeve
2 Oil shield
3 Distance piece packing
3. Push the piston into the cylinder until the protective sleeve passes the
wiper elements.
4. Remove the protective sleeve.
5. Push the piston rod into the crosshead.
6. Screw the tensioner SUPERBOLT® on piston rod.

Fig. 9-84 Tighten the tensioner SUPERBOLT®
1 Connecting rod
2 Torque wrench
3 Crosshead
4 Tensioner SUPERBOLT®
7. Tighten the pressure screws of the tensioner SUPERBOLT® by ap-

plying the defined value of the tightening torque (see section “Com-
pressor” in chapter 13 Appendix).
Further Steps and Final 8. Check, and if necessary, readjust runout according to section 9.11.7
Checks Adjust Piston Rod Runout.
9. Install proximity sensor for piston rod monitoring (see section 9.11.8
Piston Rod Monitoring).
10. Install the cylinder cover (see section 9.8 Cylinder Cover).
11. Check the cylinder clearance: TDC and BDC (see section 8.7.3 Cyl-
inder Clearance Measurement).
12. Carry out a mechanical test run.

9.11.7 Adjust Piston Rod Runout

The runout of the piston rod must be checked in horizontal and vertical di-
rection.
Check the runout of the piston rod and readjust it, if it is too low or too high
via the adjusting screws.
The runout may be readjusted with one dial gauge only. Measure at the
points indicated in Fig. 9-86 successively.
Fig. 9-85 Check piston rod runout: dial gauge near piston rod packing
1 Piston rod
2 Dial gauge

Readjust the Piston Rod 1. Place dial gauge near piston rod packing in such a way that the dis-
Runout placement can be measured according section A-A in Fig. 9-86.
1 2 3 4 5 6 4
A
A-A
PB_M3_0029b_02
7 7
A
Fig. 9-86 Place dial gauges for vertical runout check
1 Crosshead at BDC 5 Piston

2 Crosshead bore 6 Cylinder
3 Piston rod 7 Dial gauge (X-axis)
4 Dial gauge (Y-axis)
2. Turn crank to bottom dead center (BDC).

3. Set both dial gauges to zero position.
4. Move crank to top dead center (TDC) by means of the barring device
and in one swift movement.
5. Check dial gauges.
6. Adjust the piston rod runout via its adjusting ring.
5
PA_M3_0007b_02
Fig. 9-87 Adjust piston runout
1 Adjusting screw
2 Adjusting ring
3 Set screw
4 Piston rod
5 Crosshead

7. Move crank back to BDC, set dial gauges to zero position and recheck
runout as described above.
8. Repeat these steps until runout is within the tolerances specified in the
runout log sheet in the Quality Documentation.
9. Record measured values (see example sheet in section 8.7.5 Piston
Rod Runout).
10. When the vertical runout is adjusted, repeat these steps with laterally
positioned dial gauges until horizontal runout is also within the toler-
ances specified in the runout log sheet in the Quality Documentation.
11. Record measured values (see example sheet in section 8.7.5 Piston
Rod Runout).
 The axis of the crosshead, the piston rod and the cylinder are posi-
tioned horizontally according to Fig. 9-88.
2 3
PA_M3_0008b_01
5 4
Fig. 9-88 Piston rod axis
1 Runout is not adjusted 4 Piston rod axis

2 Adjusting ring 5 Crosshead axis
3 Partially worn piston ring 6 Runout is adjusted
Further Steps and Final 12. Install proximity sensor for piston rod monitoring (see section 9.11.8
Checks Piston Rod Monitoring).
14. Check the cylinder clearance: TDC and BDC (see section 8.7.3 Cyl-
inder Clearance Measurement).
15. Carry out a mechanical test run.


• 9.11.6 Install Piston and Piston Rod
Special Tools none
Preparation 1. Record value of proximity probes with the piston in BDC on the installed
monitoring system before dismantling.
Dismantle and Assemble For detailed description of dismantling and assembling of proximity
probe(s) and piston rod monitoring refer to the corresponding section in
document “Functional Description” in the Technical Documentation.

Dismantle and assemble the proximity probe according to Fig. 9-89.
1 2 3 4
PB_C1_0067b_02
Fig. 9-89 Location of proximity probe
1 Distance piece
2 Piston rod packing flange
3 Proximity probe
4 Piston rod
X Clearance = 1.25 mm
Required Checks With New Guide Rings (Rider Rings)

• Check installation of proximity probe (3) in accordance to the above il-
lustration and adjust clearance X.
With Used Guide Rings (Rider Rings)

• Check voltage on the installed monitoring system and compare with re-
corded value.
– If necessary adjust with thread on proximity sensor.
The rod is monitored with one vertical proximity probe on each piston rod.
The rod proximity probe detects excessive rod vibration. The guide ring
(rider ring) wear is also evaluated based on the signal of this sensor.

9.11.9 Measure the Cylinder Clearance

• 9.11.6 Install Piston and Piston Rod
Special Tools Barring device, optionally: feeler gauge
Procedure
CAUTION
pressor failure.
clearance.

list of section 8.7.4 Clearance Measurement Log Sheet. Compare them
to the values in section “Compressor” in 13 Appendix.

Internal Pipes (Distance Piece)
9.12 Internal Pipes (Distance Piece)

Special Tools none
9.12.2 Dismantle and Assemble Internal Pipes

Dismantle and assemble the internal pipes according to Fig. 9-90.
1 2
1 2 3
PB_M6_0020b_02
7 6 5 4
8 7 6 5 4
Fig. 9-90 Internal pipes in the distance piece
A Distance piece from top 4 Buffer gas pipe (inlet)

B Distance piece from bottom 5 Coolant pipe (inlet)
1 Coolant pipe (outlet) 6 Gas leakage pipe
2 Screw plugs 7 Oil return
3 Packing flange 8 Buffer gas to the distance piece
packing

Piston Rod Packing
9.13 Piston Rod Packing

• 9.12 Internal Pipes (Distance Piece)
Special Tools none

Piston Rod Packing
9.13.2 Piston Rod Packing Design

1st Stage
1
5 4 3 2.2 1
C B2 B1 A
PB_C5_0081a_02
Fig. 9-91 Piston rod packing 1st stage
A Zone A 1 Markings
B Zone B 2 Gas flow
C Zone C

Piston Rod Packing
9.13.3 Dismantle the Piston Rod Packing

Special Tools none
Dismantle
CAUTION
Observe defective components!
Check also all accessible compressor components, e.g. the wear of the
piston rings, the guide rings (rider rings), the piston, the piston rod, the cyl-
inder liner, etc.
 If necessary replace or repair the worn and the defective components
respectively.
1. Remove the piston according to chapter 9.11 Piston and Piston Rod.
2. Remove the packing flange.
3. Remove the packing cartridge.
Fig. 9-92 Removed piston rod packing
1 Centering pin
4. Disassemble the piston rod packing.
All components coming into contact with process gas must be clean and
free of grease and oil.
When using solvents, observe manufacturer’s safety precautions.

Piston Rod Packing
PB_C5_0001b_01
8 7 6 5 4 3 2 1
Fig. 9-93 Dismantled packing cartridge (typical view)
1 O-ring 5 O-ring
2 Basic bush for packing 6 Support ring and seal element
3 Pressure breaker 7 Packing cups
4 Threaded bolt 8 Nut
Required Checks Piston Rod Packing
5. Remove O-rings from packing cups.

6. Check O-rings and replace them if necessary.
7. Check the cooling channels and drilled holes for fouling/plugging and
clean it if necessary according to chapter 10 Clean and Degrease Plant
and Compressor Components.
CAUTION
Contamination!
Damaged O-rings leads to contamination of the coolant.
 Always replace the complete set of O-rings.
8. Check condition of packing elements (see Fig. 9-91 and Fig. 9-93). Re-
place them if necessary.
9. Measure axial clearance of the packing rings with a feeler gauge (see
Fig. 9-94).
10. Compare measured values:

Piston Rod Packing
Zone C B2 B1 A
[mm] [mm] [mm] [mm]
Axial clearance 0.700–0.902 0.300–0.493 0.300–0.493 0.100–0.230
Tab. 9-9 Axial clearances of packing rings 1st stage
Fig. 9-94 Example: Measure axial clearance
1 O-ring 3 Packing cup

2 Feeler gauge 4 Threaded bolt
11. If necessary replace or re-machine worn components.

 You have removed the piston rod packing and disassembled it.
Piston Rod
12. Check the surface of the piston rod for scratches.

Piston Rod Packing
CAUTION
Scratches on piston rods, which are tungsten carbide coated!
The seal rings wear out fast, if there are scratches on the piston rod.
 replace the piston rod or
 remove damaged coating and coat piston rod newly.
13. Check the piston rod for transfer film.
CAUTION
Increased wear and thermal failure of the sealing rings.
A thick transfer film on the piston rod deteriorates the heat removal from
the contact area (packing rings – piston rod).
 Remove the black transfer film by using emery cloth.
 Never use any solvent or lubricant for removing transfer film.
Typical colors of transfer films:

• Filled PTFE: grey to dark grey
• Polymer blends: light grey, brown
• Modified PEEK: light grey
Fig. 9-95 Transfer film on piston rod
9.13.4 Assemble the Piston Rod Packing

Special Tools none
Redura® Brand Redura® is the brand of Burckhardt Compression AG for piston rings and
packings. With the brand Redura® Burckhardt Compression provides a
comprehensive product line of rings and packings for reciprocating com-
pressors. It stands for reliable, durable and advanced sealing elements. the
product line includes standard rings and packings as well as specifically in-
house developed, designed and patented products. The entire engineering
of piston/piston rod sealing system is done with an in-house developed
sealing system software.

Piston Rod Packing
Configuration of Zone A
(Cylinder Side) A
1 2
PB_C5_0095b_01
3
®
Fig. 9-96 Redura pressure breaker RB110
A Zone A
1 Crankgear side
2 Cylinder side
3 Pressure breaker (throttle ring)
Pressure Breaker RB110

The pressure breaker is installed in the packing bush. The 3 segments of
the pressure breaker are assembled with a radial cover ring and a garter
spring. To prevent gap alignment of cover ring and ring segments, the cover
ring is held in position by a pin. In order to work properly, the 3-piece ring
must face the pressure.
The 3 ring segments have engraved figures:
• on 2 segments the figures are at the end
• on 1 segment the figure is in the middle.
The segments are arranged properly if the 2 segments with their figures en-
graved at their end are positioned in such a way that the figures are located
side by side.

Piston Rod Packing
Configuration of Zone B1
B1
1 2
PB_C5_0093b_02
4 3
Fig. 9-97 Redura® pressure breaker RB210 with support ring RC800
B1 Zone B1
1 Crankgear side
2 Cylinder side
3 Pressure breaker (crown ring)
4 Support ring
Pressure Breaker RB210

The pressure breaker (crown ring) is a 3-piece packing ring. The pressure
breaker is assembled with a garter spring. In order to work properly, the
rings have to be installed with the grooves of the crown ring facing the pres-
sure.
side by side.
Do not, not ever, interchange segments of different pressure breakers.
Support Ring RC800

The support ring is an endless 1-piece ring (without gap) that prevents the
sealing ring from creeping into the gap between ring chamber and piston
rod. In a seal element, the support ring is always furthest away from the
pressure.

Piston Rod Packing
Configuration of Zone B2
B2
1 2
PB_C5_0124b_01
3 4 5
Fig. 9-98 Redura® seal element RS310 with support ring RC800
B2 Zone B2
1 Crankgear side
2 Cylinder side
3 Support ring
4 Packing ring with step bridge cut
5 Packing ring with radial cut
The seal element RS310 consists of a packing ring with step bridge cut and
a packing ring with radial cut.
Support Ring RC800

The support ring is an endless 1-piece ring (without gap) that prevents the
sealing ring from creeping into the gap between ring chamber and piston
rod. In a seal element, the support ring is always furthest away from the
pressure.
Packing Ring with Step Bridge Cut

The packing ring with step bridge cut is a 3-piece sealing ring, assembled
with a garter spring. It may be installed in combination with
• a side-loaded pressure ring (in the packing flange) or
• an support ring and a cover ring (as a seal element)
In a seal element, the step bridge cut ring is installed between the support
ring and the cover ring. The step bridge cut and cover ring are fixed against
each other by a pin.
Packing Ring with Radial Cut

The radial cut ring is a 3-piece ring, assembled with a garter spring. It is
used as cover ring for a sealing ring. The radial cut ring is fixed against the
sealing ring by a pin. In order to ensure proper working of the seal element,
the cover ring must face the pressure.

Piston Rod Packing
Configuration of Zone C
(Crankgear Side) C
1 2
PB_C5_0100b_01
3 4 4 3
Fig. 9-99 Redura® seal elements RS900
C Zone C
1 Crankgear side (low pressure side)
2 Cylinder side (higher pressure side)
4 Packing ring with step bridge cut
3 Pressure ring
A seal element RS900 consists of a pressure ring and two packing rings
with step bridge cut.
Pressure Ring
The side-loaded pressure ring is a 2-piece ring that is assembled with a
garter spring. This pressure ring is equipped with springs and combined
with 2 sealing rings. All three rings together form the seal element RS900.
Depending on the application, the arrangement of the seal element(s) in
the packing flange varies.
In order to work properly the pressure ring(s) must be placed on the side
with the higher pressure. Check all pressures (of process gas, buffer or
purge gas and in the distance piece) and install accordingly.
Packing Ring with Step Bridge Cut

The packing ring with step bridge cut is a 3-piece sealing ring, assembled
with a garter spring. It may be installed in combination with
• a side-loaded pressure ring (in the packing flange) or
• an support ring and a cover ring (as a seal element)
In a seal element, the step bridge cut ring is installed between the support
ring and the cover ring. The step bridge cut and cover ring are fixed against
each other by a pin.

Piston Rod Packing
side by side.
Do not, not ever, interchange segments of different step bridge cut rings!
Assemble New Assemble Cartridge

or Used Parts
1. Assemble the components of the piston rod packing according to the
numbering in Fig. 9-91 and Fig. 9-93.
Install Packing Cartridge in Cylinder Sleeve
2. Install the packing cartridge into the cylinder sleeve.
1 2
PB_C5_0033b_01
4 3
Fig. 9-100 Insert packing cartridge into cylinder sleeve
1 Packing cartridge 3 Support

2 Cylinder sleeve 4 Support

Piston Rod Packing
Install Piston Rod Packing
3. Install the packing cartridge into the cylinder in reversed order as de-
scribed in section 9.13.3 Dismantle the Piston Rod Packing.
4. Fit the packing flange.
5. Tighten the nuts of the packing flange by applying the defined value of
the tightening torque (see section “Compressor” in chapter 13 Ap-
pendix).
Connect Piping
6. Connect the buffer gas pipe.
7. Connect the cooling water pipe.
8. Connect the piping of the leak gas pipe.

External Gas Pipes
9.14 External Gas Pipes

Special Tools none
Dismantle and Assemble For details concerning external gas pipes please see section “General Ar-
rangement” in chapter 13 Appendix.
9.15 Cylinder

Special Tools spirit level

XA_T9_0025a_01
Fig. 9-101 Lifting ring VLBG

Cylinder
XA_T9_0007a_01
Fig. 9-102 Flogging spanner
9.15.2 Dismantle and Assemble Cylinder

Dismantle Take care to avoid any damage; please refer also to section 5.7 Lifting Pro-
cedure.
1. Remove coolant pipes from cylinder.
2. Dismantle connection between cylinder and cylinder support.
3. Remove the SUPERBOLT® nuts from the threaded bolts.
DANGER
Suspended loads!
4. Attach carrying ropes in the safe manner, described and illustrated in

section 5.7 Lifting Procedure.
5. Lift off the cylinder. Be careful that the threaded bolts do not touch the
bores in the frame.
Required Checks 6. Check if the O-ring (between cylinder and distance piece) is in perfect
condition.
7. Replace O-ring, if necessary.

Cylinder
Installation
All components coming into contact with process gas must be clean and
free of grease and oil.
When using solvents, observe manufacturer’s safety precautions.
Fit Cylinder to Distance Piece

Take care to avoid any damage; please refer also to section 5.7 Lifting Pro-
cedure.
DANGER
Suspended loads!
1. Apply MOLYKOTE® G-N Plus to threaded bolts.

2. Fit the bolts to the cylinder.
3. Fit the round cord to the bottom of the cylinder.
4. Lift cylinder with proper attachment gear and attach it to the crane (see
section 5.7 Lifting Procedure).
5. Put a spirit level on top of the cylinder and level the cylinder accurately.
It must be ensured, that the cylinder is kept absolutely horizontal in all
directions.
 The cylinder is absolutely horizontal.
6. Slide cylinder bolts carefully through the bores of the distance piece.
7. Re-check levelling of cylinder with the spirit level.
Tighten Nuts for Cylinder
1. Install and tighten nuts.

Cylinder
Install Cylinder Support
1 2
PB_M6_0053a_02
3
Fig. 9-103 Location of cylinder support (typical view)
1 Crankgear
2 Cylinder
3 Cylinder support
1. Put a spirit level into the cylinder liner and into the crosshead guide.
2. Lift cylinder max. 0.5 mm and fit cylinder support.
3. Re-check leveling, correct height of support until leveling is perfect.
4. Attach cylinder support to cylinder.
5. Re-check leveling.
6. Loosen ropes of attachment gear by moving down the crane hook.
7. Re-check leveling. Correct, if necessary.

Cylinder
9.15.3 Cylinder Liner

Completed activities:
Special Tools Micrometer
Preparations
Hone or ground the running surfaces of the cylinder liner, which fea-
ture excessive wear or score marks.
Cylinder liners, you have also treated may only be honed or grounded to a
limited extend.
 Do not increase 0.2 % of the nominal diameter by honing or grinding
the surfaces of untreated cylinder liners.
 Contact our customer support service, if you need further information.
1. Measure the dimensions of the cylinder liner by using an inside mi-

crometer.
Fig. 9-104 Measure cylinder liner
1 Cylinder
2 Cylinder liner
3 Inside micrometer

Cylinder
Dismantle 1. Remove the cylinder liner (1) by using stud bolts with nuts (2) and a
steel plate (3).
 Stud bolts are installed, so that force can be applied to the steel
plate.
1 2 3
PB_C0_0092a_01
Fig. 9-105 Remove cylinder liner
1 Cylinder liner
2 Stud bolt with nut
3 Steel plate
2. Loosen the cylinder liner by tightening the nuts.

3. Remove the cylinder liner carefully. Use a lifting device.
Assemble Fitting of the Centering Pin and Installation of Cylinder Liner
1. Fit the centering pin before installing the cylinder liner.

2. Install pin and cylinder liner according to the following illustration(s).

Cylinder
1 2 3 4 5 2 1 6 7
PB_C0_0004b_01
X
Fig. 9-106 Cylinder liner
1 Cylinder 5 Groove for centering pin

2 Cylinder liner 6 Centering pin
3 Piston 7 Cylinder cover
4 O-ring X Protrusion = 10mm
The protrusion of the centering pin (distance X, see Fig. 9-106) must cor-
respond to the set value. Fit the centering pin from the valve chamber side,
for example before installating the valves.

Distance Piece
9.16 Distance Piece

• 9.15 Cylinder
Special Tools none
9.16.2 Dismantle and Install Distance Piece

Dismantle and Assemble The distance piece is built as shown in Fig. 9-107.
1 2 3 4 5 1
PB_M6_0001b_01
10 9 8 7 6
Fig. 9-107 Double compartment distance piece
1 Attachment gear (eye bolt) 6 SUPERBOLT® connection dis-

2 Breather tance piece –cylinder
3 SUPERBOLT® connection 7 Chamber at cylinder side
crankgear–distance piece 8 Distance piece packing
4 Buffer gas to the distance piece 9 Chamber at crankgear side
packing 10 Oil scraper
5 Distance piece cover

Distance Piece Packing
Dismantle and assemble the distance piece according to the above illustra-
tion. For tightening and loosening of the tensioner SUPERBOLT®, please
refer to section 8.7.8 Tensioner SUPERBOLT®.
9.17 Distance Piece Packing

Special Tools none
9.17.2 Dismantle and Assemble Distance Piece Packing

Dismantle The distance piece packing is installed in the separating plate of the two
distance piece chambers.
The description in section 9.13 Piston Rod Packing concerning the as-
sembly of the piston rod packing of the zone “C” also applies to the distance
piece packing.
1. Remove the cover (4) from the housing (1).

2. Remove the packing rings (6/7) from its housing.
The packing rings of the distance piece packing may also be dismantled/
replaced, without removing the piston rod.
Assemble 1. Mount the packing rings of the distance piece packing.
There is a position pin at one of the seal rings and at the other one, there
is a pinole. The seal elements are positioned accurately, if the position pin
and the pinole match on each other.
The serial number on the seal rings may not positioned onto the face.
 Turn the seal elements, that the stamped serial numbers do not contact
the face.
2. Install the packing rings (6/7) to its housing.

3. Install the cover (4) to the housing (1).

Distance Piece Packing
PB_M6_0002b_03
9 8 7 6
1 Housing 6 Seal element (step bridge cut)

2 Cylindrical pin 7 Pressure ring
3 O-ring 8 Spring
4 Cover 9 Material code
5 Garter spring

Oil Scraping
9.18 Oil Scraping
For dismantling and assembling of the 3-piece wiper elements it is not nec-
essary to remove the piston rod from the cylinder.

Special Tools none
9.18.2 Dismantle the Wiper Elements
CAUTION
Damage to wiper elements!
The operation of the compressor depends on the condition of the wiper el-
ements and on the way, how they are assembled.
 Handle the wiper elements with great care.
 Handle the surface of the piston rod in the area of the wiper elements
with great care.
1 2 3 4
11
PB_M5_0008b_01
10
9 8 7 6 5
Fig. 9-109 Oil scraping
1 O-ring 7 Cylindrical pin

2 Spring plate 8 Oil scraper plate
3 Cover 9 Allen screw
4 Screw 10 Prewiper element
5 Seal element 11 Pre oil scraper cover
6 Wiper element

Oil Scraping
1. Remove the cover (3) from the oil scraper plate (8).
2. Remove the spring plate (2) from the oil scraper plate.
3. Remove the garter springs from the 3-piece wiper elements.
4. Remove the wiper elements (6) and seal element (5) from the oil
scraper plate.
9.18.3 Assemble the Wiper Elements

Final Checks • Check the piston rod for any surface defects.
CAUTION
Damaged wiper elements!
The wiper elements shall not show any sign of damage and must lie snug
against the piston rod along their entire circumference.
 The scraping edges must be as sharp as possible.
 The wiper elements must have a slight pretension when pushed onto
the piston rod.

Oil Scraping
1 2 3 4 1
PB_M5_0007c_01
7 6 5
9 8
Fig. 9-110 Oil scraper
1 Rollpin 6 Wiper element

2 Garter spring 7 Support ring
3 Scraping edge 8 Cylinder side
4 Contact area 9 Crankgear side
5 Seal element
1. Check all items to be fitted for damage.

2. Check if the piston rod surface is in perfect condition. Should a piston
rod be damaged, contact our Technical Service Support.
3. Assemble the 3-piece wiper elements with garter springs onto the
piston rod.
4. Install the wiper elements, support rings and seal elements into the oil
scraper plate.
• Check the correct sequence of the oil scraper according to
Fig. 9-110.
5. Fit the spring plate and the cover to the oil scraper plate.

9.19 Connecting Rod Bearing

Special Tools plastic hammer
PA_T9_0006a_01
Fig. 9-111 T97460 dismantling and assembling device

PA_T9_0024a_01
9.19.2 Dismantle the Connecting Rod Bearing

Special Tools plastic hammer, T97460 dismantling and assembling device, stop for
T97460
Dismantle 1. Measure the clearance of the connecting rod bearing.

2. Write the values of the measured clearances in a log sheet.
3. Turn the crank to the upper vertical position.
4. Attach the dismantling and assembling device to the connecting rod ac-
cording to Fig. 9-113.

Fig. 9-113 Dismantling and assembling device for connecting rod
1 Crankshaft
2 Connecting rod
3 Dismantling and assembling device for connecting rod
5. Remove the SUPERBOLT® nuts of the connecting rod.

6. Remove the bearing cover of the connecting rod according to
Fig. 9-114.

Fig. 9-114 Bearing cover removal

2 Connecting rod
3 Connecting rod bearing cover
4 Crankshaft
7. Remove the bearing cover carefully and ensure that the crankshaft and
bearing shell will not get damaged.
8. Knock carefully against the bearing shell of the bearing cover by using
a plastic hammer.
 The bearing shell of the bearing cover loosens.
9. Turn the crankshaft away from the connecting rod.

Fig. 9-115 Removed connecting rod

2 Connecting rod
3 Connecting rod bearing
4 Crankshaft
10. Knock carefully against the bearing shell of the connecting rod by using
a plastic hammer.
 The bearing shell of the connecting rod loosens.
Required Checks • Clean all contact surfaces of the connecting rod and its bearing.
• Check the diameter of the bearing journal.
9.19.3 Assemble the Connecting Rod Bearing

Special Tools plastic hammer, T97460 dismantling and assembling device, stop for
T97460
Assemble 1. Secure that the crank is still turned to the upper vertical position.
2. Install the new bearing shells carefully to the connecting rod.
3. Move the crankshaft until it fits to the connecting rod bearing.
4. Install the bolts to the connecting rod.
5. Assemble the bearing cover of the connecting rod with the bearing
shells.
6. Grease by using MOLYKOTE® G-N Plus

• the thread
Fig. 9-116 Thread lubrication
• the contact surface of the tensioner SUPERBOLT®.
Fig. 9-117 Contact surface lubrication

7. Fit the tensioner SUPERBOLT® of the bearing covers according to

Fig. 9-118.
Fig. 9-118 Mount tensioner SUPERBOLT®
1 Tensioner SUPERBOLT®
8. Tighten the tensioner SUPERBOLT® by applying the defined value of

the tightening torque (see section “Compressor” in chapter 13 Ap-
pendix).
Required Checks Measure the clearances of the connecting rod bearing.

1. Move the connecting rod in horizontal position by turning the crank-
shaft.
2. Measure the vertical clearance
• by using a feeler gauge:
Measure the clearance outside the chamfer, at least 20 mm from
center line (see Fig. 9-119).
• by using a dial gauge:
Measure the clearance by lifting up the connecting rod (see
Fig. 9-119).
3. Compare the measured values with the set values in the table of clear-
ances (see section “Compressor” in chapter 13 Appendix).
 You have assembled the connecting rod bearing correctly, if the values
of the measured clearances correspond with the set values in the table
of clearances.

Crosshead and Connecting Rod
PA_M4_0014b_02
20 20
Fig. 9-119 Measure vertical clearance (two methods)
1 Dial gauge
9.20 Crosshead and Connecting Rod

• 9.19 Connecting Rod Bearing
Special Tools feeler gauge, micrometer gauge
9.20.2 Check the Clearance of Crosshead

Check Clearance 1. Move the connecting rod/crosshead to the top dead center (TDC) by
turning the crankshaft with the barring gear.
2. Check the clearance between the crosshead and its bore by using the
feeler gauge.
3. Move the connecting rod/crosshead to the bottom dead center (BDC)
by turning the crankshaft with the barring gear.
4. Check the clearance between the crosshead and its bore by using the
feeler gauge.


7. If necessary (e.g. for new crosshead), rework crosshead (see section

9.20.6 Rework of a New Crosshead) or exchange crosshead or cross-
head shoes.
9.20.3 Dismantle Connecting Rod and Crosshead
CAUTION
Compressor failures!
Damages to compressor components caused by careless handling can
lead to major compressor failure.
 Always handle all compressor components with great care.
Dismantle 1. Turn the crank to the lowest vertical position according to Fig. 9-120.
Fig. 9-120 Crank on lowest position
2. Pull the connecting rod and the crosshead out of the crosshead bore
according to Fig. 9-121.

Fig. 9-121 Pull-out conneting rod
3. Lift the connecting rod and the crosshead out of the crankgear ac-
cording to Fig. 9-122.
Fig. 9-122 Lift the connecting rod
Required Checks 4. Check the clearances of the connecting rod bearing on the dismantled
connecting rod (see section 9.20.4 Clearance of Connecting Rod
Bearing).

9.20.4 Clearance of Connecting Rod Bearing

Check Clearance 1. Measure the bearing diameter at the positions 1, 2 and 3. See
Fig. 9-123.
3
20mm
2
20mm
PA_M4_0002b_01
Fig. 9-123 Measure the bearing diameter
1 Measure position 1

2. Measure the diameter of the crank beside the coupling and beside the
oil pump.
XA_T9_0031b_01
1 2
Fig. 9-124 Measure the diameter
1 Micrometer gauge
2 Crank
3. Calculate the clearances of the bearing:
• radial clearances = diameter (Pos. 3, Fig. 9-123) – diameter of the

crankshaft journal
• axial clearances = diameter (Pos. 2, Fig. 9-123) – diameter of the
crankshaft journal or axial clearance = diameter (Pos. 1, Fig. 9-123) –
diameter of the crankshaft journal
 The axial clearance is larger than the radial clearance.
The values of the measured clearances correspond with the set values
in the table of clearances.
9.20.5 Parallelism of Connecting Rod Bores

The parallelism of the big and small connecting rod bores (with both bear-
ings installed) has to be checked if one or more of the following compo-
nents was replaced:
• connecting rod bearing (connecting rod dismantled),
• crosshead pin bearing,
• connecting rod.
Procedure 1. Disassemble connecting rod and crosshead by dismantling the cross-

head pin (see section 9.21.2 Dismantle the Crosshead Pin Bearing).
2. Check the bores of the connecting rod for parallelism.

CAUTION
Differences of the bores in the connecting rod.
The measured parallelism must correspond with the set value.
 Measure the parallelism of the bores.
 Compare the measured value with the set value.
 Replace the connecting rod if necessary.
1 2 3
PA_M4_0003b_01
A–A
Fig. 9-125 Parallelism of connecting rod bores (typical view)
1 Connecting rod
2 Set value B-B (// 0.02mm)
3 Connecting rod cover

9.20.6 Rework of a New Crosshead

Scrape the running surface of the crosshead according to Fig. 9-126.
Fig. 9-126 Scraped surface of crosshead

9.20.7 Assemble Connecting Rod and Crosshead

Special Tools plastic hammer
PA_T9_0006a_01
Fig. 9-127 T97460 dismantling and assembling device

PA_T9_0024a_01

Procedure 1. Lift the connecting rod and the crosshead into the crankgear according
to Fig. 9-122.
2. Oil the running surface of the crosshead with the oil, which is defined
for the compressor according to Fig. 9-129.
Fig. 9-129 Oil crosshead
3. Insert the connecting rod and the crosshead into the crosshead bore.

4. Oil the crank and the bearing shell by turning the crankshaft. Use the
oil, which is defined for the compressor.
Fig. 9-130 Oil crankshaft
5. Install the bearing cover according to chapter 9.19 Connecting Rod

Bearing.
Further Steps and Checks 6. Install piston rod and piston (see 9.11 Piston and Piston Rod).
7. Adjust the piston rod runout (see section 9.11.7 Adjust Piston Rod
Runout).


9.21 Crosshead Pin Bearing

• 9.19 Connecting Rod Bearing
• 9.20 Crosshead and Connecting Rod
Special Tools Press, feeler gauge, jackscrew, circlip pliers, combination spanner, pulling
eye bolt
PA_T9_0026a_01
Fig. 9-131 Pull-off device for removing crosshead pin

9.21.2 Dismantle the Crosshead Pin Bearing
1 2
PA_M3_0029b_02
5 4 3
Fig. 9-132 Dismantle the crosshead pin bearing
1 Connecting rod
2 Crosshead
4 Crosshead pin
5 Circlip
1. Put the crosshead and the connecting rod onto a suitable table.
2. Dismount the crosshead pin.
3. Push the worn crosshead pin bearing out of the bore of the connecting
rod with a press.
Required Checks 1. Clean the bore of the connecting rod and the crosshead pin.
2. Check the diameter of the crosshead pin and of its bearing.
3. Compare the values of these diameters with the set values in the table
of clearance (see section “Compressor” in chapter 13 Appendix).

9.21.3 Assemble the Crosshead Pin Bearing
CAUTION
Deformation!
The connecting rod could deform caused by irregular heating-up. A burner
or a blower would only heat-up certain positions on the connecting rod.
 Always heat-up the connecting rod in hot oil.
1. Heat-up the connecting rod in hot oil with 60°C until 80°C.
2. Put the connecting rod on a level surface (see Fig. 9-133).
1 2 3
PA_M4_0004b _02
Fig. 9-133 Connecting rod on shims
1 Connecting rod
3 Marking
4 Shims
X Protrusion of crosshead pin bearing
3. Check the protrusion of the crosshead pin bearing (4).

It must be X = 5mm.
4. Insert the new crosshead pin bearing by respecting its markings (3) into
the bore of the connecting rod.

CAUTION
Jammed bearing!
You cannot correct the position of the crosshead pin bearing after a few
seconds due to thermal expansion and due to thermal shrinkage of the con-
necting rod.
 The crosshead pin bearing must be inserted in a one-step procedure.
5. Secure that the crosshead pin bearing inside the bore rests on the sur-
face below.
6. Secure that the markings (3) are correctly positioned.
7. Wait until the crosshead pin bearing and the connecting rod will have
reached ambient temperature.
8. Check the diameter of the crosshead pin bearing.
9. Check the parallelism of the two bores of the connecting rod (see sec-
tion 9.20.5 Parallelism of Connecting Rod Bores).
10. Check the diameter of the crosshead pin.
11. Measure the inner diameter of its bearing.
12. Calculate the clearances of the bearing.
 radial clearance = diameter of the pin bearing - diameter of the pin
13. Install the circlip on the lower side of the crosshead.
Fig. 9-134 Connecting rod - crosshead assembling
14. Put the crosshead and the connecting rod onto a suitable table (see
Fig. 9-134).

PA_M3_0022a_01
Fig. 9-135 Lift crosshead pin
15. Lift the crosshead pin (see Fig. 9-135).

16. Oil the crosshead pin with an oil, which is defined for the compressor.
17. Heat-up the crosshead with a burner to about 80°C (see Fig. 9-136).

Fig. 9-136 Heat-up crosshead (typical view)
1 Connecting rod
2 Crosshead
3 Burner
18. Align the bore of the crosshead to the bore of the connecting rod (see
Fig. 9-137).
19. Insert the crosshead pin into the bores of the crosshead and the con-
necting rod (see Fig. 9-137).

Fig. 9-137 Insert crosshead pin (typical view)
1 Crosshead
2 Crosshead pin
20. Wait until the crosshead and the connecting rod will have reached am-
bient temperature.
21. Fit the second circlip.
22. Measure the clearances of the crosshead pin bearing with a feeler
gauge.
Final Checks 25. Check the clearance of the crosshead pin bearing, which you have in-
stalled (see section 9.21.4 Check Clearance of Crosshead Pin
Bearing).
9.21.4 Check Clearance of Crosshead Pin Bearing

Special Tools dial gauge, jackscrew
Clearance Check The crosshead pin bearing clearance can only be checked in running direc-
tion of the piston (). The piston/piston rod must be removed.

PA_M3_0009e_01
1 2 3
Fig. 9-138 Crosshead pin bearing
1 Jackscrew
2 Dial gauge
3 Dial gauge
7. Move connecting rod/crosshead in Top Dead Center (TDC) by turning

the crankshaft.
8. Secure connecting rod in this position, for example, with a jackscrew
(1).
9. Place dial gauge according to position (2) against connecting rod-
bearing cover.
10. Place dial gauge according to position (3) against crosshead.
11. Move crosshead forward and backward to its running direction.
12. Read the horizontal clearance of the crosshead pin bearing on dial-
gauge (3). The hand of the dial gauge (2) must remain at zero position.

13 Appendix.

Gear Oil Pump
9.22 Gear Oil Pump

• 9.10 Drain Lubricating Oil
Special Tools none
9.22.2 Dismantle Gear Oil Pump

1. Remove external oil pipes.
2. Dismantle the gear oil pump according to Fig. 9-139.
9.22.3 Assemble Gear Oil Pump
1. Assemble the gear oil pump according to Fig. 9-139.

2. Install external oil pipes.
1 2 3 4
PA_M2_0008b_02
7 6 5
Fig. 9-139 Crankshaft-driven gear oil pump (typical view)
1 Housing for gear oil pump coupling 5 Hexagonal screw

2 Coupling halves 6 Spider
3 Intermediate flange 7 Allen screw
4 Gear oil pump

Electric Motor
9.23 Electric Motor

Special Tools none
9.23.2 Dismantle Electric Motor
1. Remove flywheel guard.

2. Release electric motor from coupling.
9.23.3 Assemble Electric Motor

For detailed assembly instructions see chapter 5.11 Install Electric Motor
and Coupling.
9.24 Flywheel

Special Tools fine file or scraper
9.24.2 Transport and Lifting of the Flywheel

For transport and lifting of flywheel, take care to avoid any damage; please
see section 5.2.1 Safety of Transport.
DANGER
Suspended loads!
 Lift flywheel only in the correct manner as described and illustrated in

Flywheel
PA_L1_0002a_01
Fig. 9-140 Transport and lifting of flywheel
9.24.3 Dismantle the Flywheel
PB_L1_0004b_02
1 2 3
Fig. 9-141 Flywheel
1 Allen screw
2 Flywheel
3 Crankshaft flange
Dismantle 1. Attach carrying ropes in the safe manner as illustrated in this Instruction
Manual.

Flywheel
2. Remove Allen screws (1).

3. Lift flywheel (2) away from crankshaft flange (3).
9.24.4 Assemble the Flywheel
DANGER
Falling machine components!
Serious crushes of body and death.
 Protect carrying ropes against sharp edges.
 Store flywheel securely - this means, prevent it from overturning, for ex-
ample when it is pushed by crane load, cart, etc.
 Notice the corresponding weights according to chapter 5.3 Dimen-
sions, Weights, Space Requirement.
Assemble New For detailed assembly instructions see chapter 5.10.3 Flywheel.
or Used Parts
Required Checks 1. Check radial and face runout as illustrated in Fig. 9-142.
1 2 3 4
PA_L1_0001b_01
Fig. 9-142 Radial and face runout
1 Flywheel
2 Crankshaft
3 Dial gauge
4 Measuring head

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

• 9.24 Flywheel
Special Tools none
9.25.2 Dismantle and Assemble the Crankshaft Seal

Dismantle or assemble the crankshaft seal according to Fig. 9-143.
For applicable tightening torques see section “Compressor” in chapter 13
Appendix.

Crankshaft Seal
PB_M1_0003b_01
1 2 3 4
Fig. 9-143 Components of crankshaft seal
1 Gasket
2 2-piece oil trap cover
3 Seal ring (2 pieces)
4 2-piece cover

Crankshaft Seal
9.25.3 Trigger Sensor

Special Tools none
Dismantle and Assemble Dismantle and assemble the trigger sensor/Keyphasor® according to
Fig. 9-144.
7
PB_M1_0007b_01
Fig. 9-144 Location of probe
1 2-piece oil trap cover 5 Crankshaft

2 Probe 6 Trigger sensor/Keyphasor® con-
3 Cylindrical pin nection
4 Crankshaft seal 7 Plug

Bearings
9.26 Bearings

Special Tools none
9.26.2 General Checks for Fitting New Bearings
1. Check the bearing clearances with a feeler gauge:

• We provide this method by considering deviations due to the
problem of inserting the gauge in the limited space and also be-
cause of the round surfaces, which are to be checked.
2. Measure the bearing clearances with a dial indicator:
• This is a method, which do not require any disassembly. Depending
on the compressor design, it could be difficult to position the dial in-
dicator optimally. Measure the relative movement -this is the
bearing clearance- between the bearing and journal with an indi-
cator.
3. Check the bearing bore and the bearing journal:
• Check the shaft surface on wearing.
• Compare the diameter with the defined value of the clearances.
• Check the bores of the frame and the shells for damages and burrs.
• Position the bearing shells correctly.
4. Check the gap of the bearing:
• The bearing shells must be positioned firmly with a certain preten-
sion at the bore of the frame, The pretension avoids the bearing
shells to be lifted from the bore of the frame and it avoids the
bearing to follow the turning movement.
• The bearings are jammed or do not have enough clearance.
PA_M4_0005a_01
Fig. 9-145 Check gap of bearing
5. Check the contact of the bearing:

Bearings
• Check the contact during installation of the bearing shell by using a

feeler gauge. Protruding burrs or bearing shells, which jam, prevent
the contact of the bearing shell with the bore of the frame. The bore
of the bearing may be reduced and become eccentric. This causes
too small bearing clearances or even marks.
• Rework the burrs slightly: max. 0.1 mm x 45°.
PA_M4_0006a_01
Fig. 9-146 Check contact of the bearing
6. Check the edges:

• Rework sharp edges slightly.
PA_M4_0007a_01
Fig. 9-147 Check edges
7. Check the position of the shells:

• The upper bearing shell must fit to the lower one.
PA_M4_0008a_01
Fig. 9-148 Check position

Crankshaft Bearing
9.27 Crankshaft Bearing

Special Tools Dial indicator, hydraulic jack
9.27.2 Dismantle Crankshaft Bearing

Special Tools dial indicator, hydraulic jack
You can change the crankshaft bearing without dismantling the crankshaft.
If you have to replace all bearings
 dismantle the crankshaft and
 install the bearings according to this instruction.
Required Checks 1. Check the clearance of the crankshaft bearing according to section
9.27.4 Measuring the Clearance.
2. Record measured values in the log sheet.
1 7
4
PA_M1_0012c_01
Fig. 9-149 Crankshaft bearing
1 Threaded bolt for crankshaft bearing cover

2 Hexagonal nut
3 Crankshaft bearing cover drive end
4 Crankshaft bearing shell drive end
5 Tie rod for crankshaft bearing cover
6 Frame
7 Crankshaft bearing covers center and non-drive end

Crankshaft Bearing
Important Note First dismantle the tie rods (horizontal bearing cover bolts), and only after-
wards dismantle the vertical bearing cover bolts.
Dismantle Horizontal 1. Remove the tensioners SUPERBOLT® from the tie rods for the covers
Bearing Cover Bolts of the crankshaft bearings. For loosening procedure, see section 8.7.8
(Tie Rods) Tensioner SUPERBOLT®.
Dismantle Vertical Bearing 2. Dismantle hexagonal nuts from the vertical bearing cover bolts.
Cover Bolts
Remove Bearing Cover 3. Lift the cover of the crankshaft bearing (see Fig. 9-150).
Fig. 9-150 Lift bearing cover
1 Sling
2 Shackle
3 Eye bolt
4 Bearing cover
Remove the Drive End Lift Crankshaft

Crankshaft Bearing
4. Position the dial indicator (1) according to Fig. 9-151.
5. Lift the crankshaft (3) or the flywheel (2) with a hydraulic jack (4) for
max. 0.5 mm

Crankshaft Bearing
1 2
PA_L1_0005b_02
Fig. 9-151 Jack-up crankshaft
1 Dial indicator
2 Flywheel
3 Crankshaft
4 Hydraulic jack
Remove Bearing Shells
6. Rotate the bearing shells to 90°.
7. Lift the now upper bearing shell out off the crankshaft.
8. Rotate the lower bearing shell at the drive end 180°.
9. Lift the lower bearing shell out off the crankshaft.
Required Checks 10. Check the surface of the crankshaft for any damage.
11. If necessary, rework the surface of the crankshaft.
12. Check the new bearing shell for any damage.
Install New Bearing Shells 13. Proceed with installing the new bearing shells on the drive end side ac-
cording to section 9.27.3 Assemble Crankshaft Bearing.

Crankshaft Bearing
Always replace old with new bearing shells in one step. Before you replace
the center and non-drive end bearings proceed according section 9.27.3
Assemble Crankshaft Bearing, “Assemble Drive End Crankshaft Bearing”.
Remove the Non-Drive End 14. Install the hydraulic jack inside of the frame.
Crankshaft Bearings
15. Lift the crankshaft approximately 0.20 mm by using a hydraulic jack.
16. Rotate the bearing shells to 90°.
17. Lift the now upper bearing shell out off the crankshaft.
18. Rotate the lower bearing shell at the drive end 180°.
19. Lift the lower bearing shell out off the crankshaft.
Required Checks 20. Check the surface of the crankshaft for any damage.
21. If necessary, rework the surface of the crankshaft.
22. Check the new bearing shell for any damage.
Install New Bearing Shells 23. Proceed with installing the new bearing shells according to section
9.27.3 Assemble Crankshaft Bearing.
Always replace old with new bearing shells in one step. Before you replace
the other crankshaft bearings proceed according section 9.27.3 Assemble
Crankshaft Bearing, “Assemble Center Crankshaft Bearing”.

Crankshaft Bearing
9.27.3 Assemble Crankshaft Bearing

Special Tools dial indicator, hydraulic jack
General Remarks The crankshaft bearings are installed as illustrated in the following illustra-
tion:
1 7
PA_M1_0012c_01
5
Fig. 9-152 Crankshaft bearing
1 Threaded bolt for crankshaft bearing cover

2 Hexagonal nut
3 Crankshaft bearing cover drive end
4 Crankshaft bearing shell drive end
5 Tie rod for crankshaft bearing cover
6 Frame
7 Crankshaft bearing covers center and non-drive end
Assemble Drive End 1. Check the new bearing shells for any damage.
Crankshaft Bearing
3. Oil the inner side of the bearing shell by using compressor oil.
4. Position the new bearing shell onto the crankshaft.
5. Rotate the bearing shell to 180°.
6. Place the second bearing shell onto the crankshaft.
7. Rotate the bearing shells by 90°.
8. Lower the crankshaft with the hydraulic jack.

Crankshaft Bearing
Assemble Non-Drive End 1. Check the new bearing shells for any damage.
Crankshaft Bearings
2. Install the hydraulic jack inside of the frame.
4. Oil the inner side of the bearing shell by using compressor oil.
5. Position the new bearing shell onto the crankshaft.
6. Rotate the bearing shell to 180°.
7. Place the second bearing shell onto the crankshaft.
8. Rotate the bearing shells by 90°.
9. Lower the crankshaft with the hydraulic jack.
PB_M1_0006b_02
3 2 1
Fig. 9-153 Correctly installed bearing non-drive end
1 Crankshaft
2 Main bearing non-drive end
3 Threaded bolt for bearing cover
Install Bearing Covers 1. Install the bearing covers.

Crankshaft Bearing
Fig. 9-154 Lift bearing cover
1 Sling
2 Shackle
3 Eye bolt
4 Bearing cover
Install Nuts for Vertical 2. Fit the hexagonal nuts to the vertical bolts for the cover of the crank-
Bearing Cover Bolts shaft bearing.
3. Tighten the hexagonal nuts with the mandatory tightening torque (see
section “Compressor” in chapter 13 Appendix).
Install Nuts for Horizontal 4. Fit the tensioners SUPERBOLT® to the horizontal bolts (tie rods) for the
Bearing Cover Bolts cover of the crankshaft bearing.
(Tie Rods)
5. Tighten the tensioners SUPERBOLT® according to section 8.7.8 Ten-
sioner SUPERBOLT®. Apply the mandatory tightening torque (see
section “Compressor” in chapter 13 Appendix).

Crankshaft Bearing
9.27.4 Measuring the Clearance

• 9.27.2 Dismantle Crankshaft Bearing
Special tools Feeler gauge
CAUTION
Always measure the clearance of the crankshaft bearing at both
sides!
 For example, measure the clearance at the oil pump side and at the
coupling side.
1. Secure, that the W, Y and Z measuring points are accessible by turning

the crankshaft.

Crankshaft Bearing
Y
X
PA_M1_0009a_01
Fig. 9-155 Measuring points
W Measuring points for axial clearance

X Clearance (chamfer)
Y Measuring point for radial clearance
Z Measuring point for radial clearance
1. Measure the radial clearance between the crankshaft and the crank-
shaft bearing at the W, Y and Z measuring points by using a feeler
gauge.
2. Measure the radial clearance of the Y measuring point outside the
chamfer, at least 20 mm from the center line.

Axial Bearing
3. Measure the axial clearance of the W measuring point between the

axial bearing and the crankshaft.
9.28 Axial Bearing

• 9.27 Crankshaft Bearing
Special Tools none

Axial Bearing
1 2
PA_M1_0005b_02
Fig. 9-156 Axial bearing
1 Frame 4 Axial bearing half

2 Axial bearing 5 Axial bearing half
3 Crankshaft 6 Crankshaft main bearing
The axial bearing (2) at the drive end side is equipped with two axial
bearing halves (4/5).
The axial bearing limits the axial movement of the shaft system – crank-
shaft and motorshaft.
9.28.2 Dismantle Axial Bearing
1. Lift the bearing cover.

2. Turn crankshaft and axial bearing halves simultaneously about 180°.
3. Take the bearing halves out.

Dismantle Crankshaft
9.28.3 Assemble Axial Bearing
1. Install the axial bearing halves.

2. Install the bearing cover.
9.29 Dismantle Crankshaft

We strongly recommend that crankshaft dismantling is carried out by our
specialists at site. We assume no liability for damage caused by inexpert
crankshaft dismantling.
Please contact our Technical Support Service (TSS), address see section

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

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

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


Cleaning Specification
10.1 Cleaning Specification
10.1.1 Scope and Purpose

This chapter deals with the cleaning of plant components and compressor
parts to assure that all parts and surfaces exposed to process gas are
cleaned to the required level of cleanliness.
Care must be taken that all parts and surfaces of the plant components ex-
posed to process gas are compatible with the process gas and free from
contaminants.
Applicability The cleaning specification is applicable during manufacturing, installation

of the compressor plant on site as well as during preventive maintenance
or repair. It also applies to gas pipes made and/or adapted on site.
For acid pickling and passivation of gas pipes – with the exception of stain-
less steel pipes welded with inert gas – see section 5.13.4 Pickle and Pas-
sivate Piping.
cleanliness.
CAUTION
Existing company-internal cleaning instructions must be taken into account

too.
10.1.2 Terms
Significant Surface Any surface which is exposed to process gas.
10.1.3 Required Level of Cleanliness

It is the superior authority’s responsibility to ensure safe working condi-
tions.

Cleaning Specification
Significant surfaces must be dry and free of contaminants including:

• hydrocarbon oils or greases,
• conventional paints, varnishes, fluxes or organic rust preventatives,
• loose or potentially loose parts such as slug, rust, welding residual
matter, abrasive particles (e.g shot peening remains).
10.1.4 Principles
Adapt cleaning process to type and extent of contaminant present.
• Accomplish adequate cleaning whilst manufacturing, installation and

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

Personnel who use cleansing agents must take safety precautions ac-
cording to the Material Safety Data Sheets (MSDS) when working with
such materials. For general information refer to section 2.4.9 Handling
Chemicals.
DANGER
Health hazard and fire hazard!
Chemicals can be toxic, caustic, flammable and explosive.
 Do not eat, drink or smoke in the proximity of chemicals!
 Before handling any chemicals,
• pay attention to the warning symbols, peril indications and safety
advice on the label of the storage container,
• familiarize yourself with procedures in the event of contamination,
poisoning, corrosion, spilling, leakage of unknown substance.
10.1.6 Responsibility
Hazards The superior authority is obliged to inform the personnel handling chemi-
cals about possible dangers to humans and the environment.

Working Environment

• flash point,
• toxicity,
The superior authority is obliged to instruct personnel using cleansing

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

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

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

– assembled,
– disassembled.
• Complexity:
– big or elongated (pipes) parts,
– complicated/dead ends, gaps.

Select Cleansing Agent
10.2.1 Workplace
The workplace for cleaning and installation has to be clean and as far from
heavy manufacturing and machine tools as possible. Its arrangement shall
make an inadvertent mix-up of cleaned and uncleaned components as well
as the utilization of non-approved material for assembly impossible. The
cleanliness of the workplace must correspond to the commonly accepted
work place for light assembly and testing.
Harmless cleaning agents should preferably be applied. The use of harmful
cleaning agents must be limited to a minimum. Components cleaning must
be carried out in closed facilities.
DANGER
Health hazard!
Cleansing agents may impair your health.
 Avoid concentrations higher than the MAC-value (Maximum Allowable
Concentration for working area).
 Provide adequate ventilation in areas where cleaning operations are
performed.
DANGER
Fire hazard!
Flammable organic solvents, acids or lyes.
 Provide adequate ventilation in areas where cleaning operations are
performed.
 No open fire.
 No smoking.
10.2.2 Tools and Facility

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

Special care shall be given to the properties of the cleansing agent re-
garding compatibility with process gas, flammability, toxicity, corrosion ef-
fect, and environmental impact.
Personnel who use cleansing agents must take safety precautions ac-
cording to the Material Safety Data Sheets (MSDS) when working with
such materials. For general information refer to section 2.4.9 Handling
Chemicals.

Health Aspects The ideal agent is non-toxic or at least has a low toxicity. The main factors
to take into consideration are inhalation effects, skin effects and eye ef-
fects.
Environmental Aspects There are four main issues concerning the environment: emission to water,
waste disposal, emission to air and energy.
Emission to Water
Contamination of water arises from improper waste disposal, inadequate
waste water treatment or in case of solvents, accidental spillage caused by
improper handling or storage.
Waste Disposal
Degreasing with solvents gives rise to a residue containing oils and
greases. The solvent content can easily be reduced by distillation either in
house or by licensed recycler, thus recovering useful quantities of solvent.
The residue – a highly concentrated final waste – should be disposed by a
licensed contractor, meeting local regulations.
Cleaning in an aqueous system generates effluent containing chemical
products necessary for the cleaning process and may be contaminated
with oils and greases. This residue must be treated in a waste water treat-
ment plant.
Emission to Air
The limit values of emissions to air due to organic solvents are given in na-
tional regulations.
Energy
When a drying procedure is required, aqueous cleaning processes can be
more energy intensive than those using solvents.
Organic Solvents The increasingly stringent environment regulations of the last years, regu-
lations including the phasing out of most chlorofluorocarbons (CFC), re-
strictions in the use and banning of some volatile organic compounds
(VOC) led to the necessity to develop alternatives.
CFCs contribute to the depletion of the ozone layer, VOCs are a major
source of photochemical smog and ground level ozone that have harmful
effects on human health and the environment.
Potential users should determine whether the solvent has been declared
acceptable by national authorities.

Acetone
For the cleaning of significant surfaces, we recommend the use of acetone.
• Clean parts with a paint brush or a clean, lint-free cleaning tissue
soaked in acetone.
• Completely remove liquid and vapors after cleaning.
• Purge cleaned spaces with oil-free compressed air till no trace of the
solvent can be detected.
WARNING
Fire and health hazard!
Acetone is flammable. Vapor may cause flash fire. Harmful if swallowed or
inhaled. Causes irritation to skin, eyes and respiratory tract. Affects central
nervous system.
 Restrict the use of acetone to a minimum.
 No open fire.
 No smoking.
Cleansing Agent BLG05

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

Cleaning Methods
10.4 Cleaning Methods

cleanliness.
CAUTION
Principles • Each – or a combination – of the cleaning methods listed below can be

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

cleanliness.
10.4.1 Mechanical Cleaning

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

Cleaning Methods
10.4.2 Chemical Cleaning

Normally a preliminary cleaning operation for piping and vessels. This in-
cludes acid pickling (descaling), passivation, derusting, bright dipping, al-
kaline cleaning, etc. Conventional chemical solutions are acceptable
providing they do not leave a residue or are followed by final cleaning.
The manufacturer’s specification for application of the cleansing agent and
necessary safety precautions must be strictly observed.
For detailed instruction of acid pickling and passivation of piping – with the
exception of stainless steel pipes welded with inert gas – see section 5.13.4
Pickle and Passivate Piping.
Since oil and grease generally cannot be removed by acids, these contam-
inants – if present – must be removed with an organic solvent or alkaline
solution prior to acid pickling.
10.4.3 Flushing
With this method, the equipment to be cleaned is filled with a flowing sol-
vent or heated cleansing agent which is agitated if possible. Thorough
rinsing with clean water and subsequent drying with oil-free dry air or ni-
trogen is required if a detergent is used. If a solvent is used, the vessel
must be thoroughly purged with oil-free, dry air or nitrogen.
10.4.4 Immersion
With this method, the equipment to be cleaned is submerged in a solvent
or cleansing agent and scrubbed, if possible. When many parts are to be
cleaned, use two baths, the first to remove most of the contaminants and
the second to remove the remaining contaminants. When the first bath be-
comes dirty, it is discarded and the second becomes the first and a new,
clean, final bath is provided. Briefly immerse non-metallic parts or wipe with
a tissue as described below.
10.4.5 Wiping
Components with readily accessible surfaces may be cleaned with this
method using a solvent or cleansing agent. Typical examples are vessels
that can be entered (using only cleansing agents and observing all appli-
cable safety procedures). Non-metallic parts that cannot be immersed be-
cause the solvent causes them to swell, may be cleaned by wiping with a
clean tissue moistened with solvent or cleansing agent.
10.4.6 Spraying
The cleansing agent – solvent or detergent – is discharged at high velocity
through nozzles specially chosen for particular applications. This method is
frequently used on large equipment or piping.

Preserve Cleanliness
10.4.7 Degreasing with Solvent Vapor

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

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

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

Preserve Cleanliness

Decommissioning and Waste Disposal
11 Decommissioning and Waste Disposal
11.1 Preserve Compressor Plant . . . . . . . . . . . . . . . . . . . . . . . . 11 - 3

11.2 Maintain Plant during Decommissioning. . . . . . . . . . . . . . . 11 - 5
11.3 Recommission Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 5
11.4 Dispose Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 6


Preserve Compressor Plant
11.1 Preserve Compressor Plant

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

A special corrosion protecting oil from a reputable supplier may be
used during the standstill period.
3. Oil the piston rods well by hand up to the oil shield. Turn the flywheel
min. 1 rotation by means of the barring device in running direction.
Generally, the gas conducting compressor and plant components should

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

continuously through with nitrogen, or kept under a slight overpressure of
0.05 bar g/0.005 MPa g/0.05 kg/cm2 g.
DANGER
Plant/compressor under nitrogen pressure.
system.

Preserve Compressor Plant
DANGER
Health hazard!
symptoms.
5. Alternative solution:
To prevent corrosion in the vicinity of the cylinder insert moisture absor-
bent agent – e.g. VCI mats (Volatile Corrosion Inhibitor) – in the cyl-
inder, valve spaces and distance piece.
Experience has shown that in the area of the lubricated crankgear, ab-
sorbent agents are not necessary.
CAUTION
Forgotten absorbent agent mats can damage the compressor!
 Record number and location of absorbent agent packs/mats in the
compressor.
 Make sure the flywheel can still be turned manually.

Maintain Plant during Decommissioning
11.2 Maintain Plant during Decommissioning

1. Check condition of moisture absorbent agent every six months and re-
place if necessary.

1 rotation).
3. Large differences between day and night temperatures can lead to

condensation in the electric motor. Due attention should be given to this
occurrence during the standstill period and before putting into opera-
tion again (dry out, heat, ventilate, check insulation resistance, etc.).
motor manufacturer.
4. Annually conduct a condition check of the complete compressor

system.
11.3 Recommission Plant

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

when this work is carried out.
motor manufacturer.

Commissioning.

Waste Disposal
11.4 Waste Disposal

Compressor Components At the end of their lifetime, the compressor components must be disposed
of according to all applicable regulations. We recommend contacting a
company specializing in recycling and waste disposal.
Lubricants • Oils must be recycled, return them to the supplier.

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

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

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

12.1.1 Burckhardt e-ShopTM . . . . . . . . . . . . . . . . . . . . . . 12 - 4
12.1.2 Original Spare Parts Only! . . . . . . . . . . . . . . . . . . 12 - 4
12.1.3 Importance of Spares Inventory . . . . . . . . . . . . . . 12 - 5
12.1.4 Spare Parts Recommendation . . . . . . . . . . . . . . . 12 - 6
12.2 Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 8
12.3 Spare Parts Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 15

Spare Parts

Spare Parts
Order Spare Parts
12.1 Order Spare Parts

Required Data When ordering spare parts, always provide the following data:
• Compressor serial no.: 200322
• Compressor type: 2B1XC2.64_1
• Spare part designation
• Code no.
Stage Dependent Code When ordering stage dependent spare parts, consider the following ex-
Numbers ample:
C4*330
C4*310
C4*360
C4*350
C4*400
C4*390
C4*380
XA_CX_0044b_02
C4*320
C4*430 C4*370
Fig. 12-1 Example for stage dependent code numbers
* = placeholder for stage.

Example: code no. for a 1st stage discharge valve is C41200
1st stage: C41200

nd
2 stage: C42200
rd
3 stage: C43200
and so on
A 0 (zero) in the third position of a code no. (on spare parts drawings and/
or in spare parts lists) signifies that this spare part is identical for all stages.
A code no. in brackets ( ) indicates spare parts, which are not always im-
plemented and may not be applicable for your plant.
Approach 1. Find the demanded spare part on respective spare parts drawing in
section 12.3 Spare Parts Drawings and note the corresponding code
no.

Spare Parts
Order Spare Parts
Bold printed code no. on spare parts drawings refer to detail drawing of the
respective spare part.
2. Consult the spare parts list in section 12.2 Spare Parts List and look up
the related spare part designation.
3. Order spare parts (address see section 1.6 Contact Address) providing
compressor type and serial no.
12.1.1 Burckhardt e-ShopTM

In the Burckhardt e-ShopTM, you can access an on-line catalog for informa-
tion or to order spare parts. You can find in it all drawings, spare parts and
spare part recommendations related to your compressor. In this way, you
can not only simplify your maintenance planning and speed up your orders,
the system also contains various features to help you with the identification
and selection of the parts needed. Last but not least, you will have the latest
drawings available at any time. For more details or to register to the Burck-
hardt e-ShopTM, please contact e-shop@burckhardtcompression.com.
12.1.2 Original Spare Parts Only!

We only assume liability for original spare parts which have been supplied
by Burckhardt Compression. Spare parts and plant accessories which have
not been delivered by us may not correspond to the original or modified de-
sign.
CAUTION
Increased risk!
components and/or their operational safety may be impaired.
 Do not modify parts/spare parts.
 Only use original spare parts.
 Never use unsuitable material.
Please note that specific fabrication and supply specifications often exist
for parts supplied by Burckhardt Compression as well as by sub-suppliers.
We can always offer you spare parts which correspond to the latest tech-
nical standards and comply with the newest legal regulations.

Spare Parts
Order Spare Parts
12.1.3 Importance of Spares Inventory

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

reflects the number of recommended wear/capital spare parts for 1 com-
pressor as described in this manual. For some parts a quantity of “0” may
appear, because such parts are:
• Non built-in options to the specific compressor described in this
manual.
• Assemblies containing wear/capital spare parts quantified elsewhere in
the column.
For specific details see the respective spare parts drawing(s) in section
12.3 Spare Parts Drawings.
Our Spare Part division of Customer Support Service will be glad to provide
you with a corresponding tender for wear parts and/or capital spare parts.
Contact address see section 1.6 Contact Address.

Spare Parts
Order Spare Parts
12.1.4 Spare Parts Recommendation

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

C01400 Cylinder liner 1st stage X 1
C01415 O-ring for cylinder liner 1st stage X 4
C01620 O-ring for cylinder cover 1st stage X 2
C11110 Piston skirt 1st stage X 1
C11261 Piston ring, scarf joint, right 1st stage X 4
C11262 Piston ring, scarf joint, left 1st stage X 4
C11280 Rider ring for piston (guide ring) 1st stage X 8
C11500 Piston rod 1st stage X 1
C11700 Oil shield for piston rod, complete 1st stage X 2
C21016 O-ring for suction valve cover 1st stage X 8
C21330 Center bolt to suction valve 1st stage X 4
C21350 Locking disc for suction valve 1st stage X 8
C21370 Lift washer no. 1 for suction valve 1st stage X 24
C21380 Valve plate for suction valve 1st stage X 8
C21390 Damper plate for suction valve 1st stage X 4
C21400 Valve spring for suction valve 1st stage X 192
C31001 Controlled suction valve, complete 1st stage X 4
C31030 Special nut 1st stage X 4
C31040 Spring dowel pin 1st stage X 16
C41016 O-ring for discharge valve cover 1st stage X 8
C41200 Discharge valve, complete 1st stage X 4
C41330 Center bolt for discharge valve 1st stage X 4
C41350 Locking disc for discharge valve 1st stage X 8
C41370 Lift washer no. 1 for discharge valve 1st stage X 24
C41380 Valve plate for discharge valve 1st stage X 8
C41390 Damper plate for discharge valve 1st stage X 4
C41400 Valve spring for discharge valve 1st stage X 192
C51400 Packing cartridge, complete, per piston rod 1st X 1
stage
C51499 Pressure breaker (crown ring) for packing 1st X 2
stage
C51517 Seal element (Pair of seal rings) 1st stage X 6
C51519 Pressure breaker, no. 1(throttle ring) 1st stage X 2
C51521 Support ring for piston rod packing 1st stage X 8
C51528 Seal element, complete 1st stage X 4
C51529 O-ring No. 1 for packing cup 1st stage X 86

Spare Parts
Order Spare Parts
Code No Designation W C Qty

C51534 O-ring No. 4 for basic bush 1st stage X 2
M10200 Crankshaft bearing X 1
M10401 Axial guide ring X 2
M10735 V-seal ring X 2
M30015 Crosshead shoe X 2
M30600 Crosshead pin X 1
M40300 Connecting rod bearing X 1
M40410 Crosshead pin bearing X 1
M50526 Wiper element, multisegmented X 4
M50530 Seal element in 2-pieces X 2
M50535 Supporting ring for wiper element X 2
M50545 Spring plate X 2
M60005 O-ring for distance piece/crankgear X 2
M60205 Gasket for distance piece cover X 4
M60206 Gasket for distance piece cover X 4
M60350 Seal element, complete for M60300 X 4

Spare Parts
Spare Parts List
12.2 Spare Parts List
Code No Designation W C
A10000 Internal piping
A10025 Gasket to Oil pipe
A10030 O-ring No.1 to oil pipe
A10035 O-ring No.2 to oil pipe
A20490 Socket ball valve
A40301 Gasket for oil pipe no. 1
A40302 Gasket for oil pipe no. 2
C0*001 Cylinder
C0*061 Cylinder base
C0*065 O-ring for cylinder base
C0*070 Cylinder sleeve for packing
C0*130 O-ring for cylinder/distance piece
C0*200 Threaded bolts for cylinder/frame, dis-
tance piece
C0*210 Threaded bolts for cylinder cover
C0*212 Threaded bolts for cylinder base
C0*215 Hexagonal nut for cylinder cover
C0*219 Hexagonal nut for cylinder base
C0*220 Threaded bolt for suction valve cover
C0*225 Threaded bolts for discharge valve cover
C0*230 Hexagonal nut for valve cover
C0*250 Threaded bolts for piston rod packing
C0*255 Hexagonal nut for packing
C0*270 Threaded bolts for connection suct. &
disch. line
C0*275 Hexagonal nut for pipe connection suc./
dis. line
C0*400 Cylinder liner X
C0*405 Cylinder liner, complete
C0*415 O-ring for cylinder liner X
C0*519 Gasket for suction-/discharge pipe
C0*605 Cylinder cover, complete
C0*620 O-ring for cylinder cover X
C00206 SUPERBOLT® nut for cylinder/frame
C01001 Cylinder 1st stage
C01140 Cleaning cover, large no. 1, for cylinder
1st stage
C01145 Gasket for large cylinder cleaning cover
no. 1, 1st stage

Spare Parts
Spare Parts List
C01155 Cleaning cover, small no. 1, for cylinder
1st stage
C01156 Cleaning cover, small no. 2, for cylinder
1st stage
C01160 Gasket for small cylinder cleaning cover
no. 1 1st stage
C01166 O-Ring for small cylinder cleaning cover
no.2 1st stage
C01180 Screw plug, small 1st stage
C01185 Gasket for small screw plug 1st stage
C1*000 Piston & piston rod
C1*010 Piston complete incl. piston rod &piston
rings
C1*110 Piston skirt X
C1*120 Upper piston crown
C1*130 Lower piston crown
C1*230 Piston back-up ring
C1*261 Piston ring, scarf joint, right X
C1*262 Piston ring, scarf joint, left X
C1*280 Rider ring for piston (guide ring) X
C1*500 Piston rod X
C1*550 SUPERBOLT® nut for piston
C1*610 O-ring for SUPERBOLT® nut
C1*700 Oil shield for piston rod, complete X
C2*010 Valve cover, suction valve with actuator
C2*016 O-ring for suction valve cover X
C2*020 Valve lantern for suction valve
C2*025 Pressure screw, suction side
C2*045 Cap nut for pressure screw, suction side
C2*050 Gasket for cap nut, suction side
C2*320 Suction valve seat
C2*330 Center bolt to suction valve X
C2*350 Locking disc for suction valve X
C2*360 Suction valve guard
C2*370 Lift washer no. 1 for suction valve X
C2*380 Valve plate for suction valve X
C2*390 Damper plate for suction valve X
C2*400 Valve spring for suction valve X
C2*430 Cylindrical pin for suction valve
C3*000 Controlled suction valve with actuator
C3*001 Controlled suction valve, complete X

Spare Parts
Spare Parts List
C3*020 Pressure sleeve
C3*030 Special nut X
C3*040 Spring dowel pin X
C3*060 Compression spring
C3*070 Finger unloader, complete
C3*409 Washer to TURCITE®
C3*410 Actuator, complete
C3*412 O-ring for actuator housing
C3*413 Nipple
C3*414 Gasket for nipple
C3*415 STEPSEAL® TURCITE®
C3*416 Circlip
C3*417 Guiding band for actuator
C3*418 Screw plug, complete
C3*419 Pipe union for actuator, complete
C3*420 Gasket for pipe union, actuator
C3*421 Pressure pin, actuator
C3*422 Strain washer USIT / flat gasket
C3*423 Washer
C3*424 Self locking hexagonal nut
C3*426 O-ring for actuator
C3*427 Cylindrical head screw, short
C3*430 Screw plug, complete
C3*431 Venting valve for actuator, complete
C3*435 Position indicator, complete for actuator
C3*436 Indicator bolt
C3*437 Screw plug
C3*438 O-ring for position indicator
C3*440 Actuator piston incl. GLYD- and O-ring
C3*445 Spring no. 3, medium, for actuator piston
C3*446 Circlip for actuator
C3*447 Scraper for actuator
C3*475 Cylindrical head screw, long
C3*480 Actuator housing, compl.
C4*000 Installation of discharge valve
C4*005 Valve cover, discharge valve
C4*016 O-ring for discharge valve cover X
C4*020 Valve lantern for discharge valve
C4*025 Pressure screw, discharge side

Spare Parts
Spare Parts List
C4*045 Cap nut for pressure screw, discharge
side
C4*050 Gasket for cap nut, discharge side
C4*096 Screw plug for valve cover, discharge
valve
C4*097 Gasket for screw plug, discharge valve
C4*200 Discharge valve, complete X
C4*310 Hexagonal nut for discharge valve
C4*320 Discharge valve seat
C4*330 Center bolt for discharge valve X
C4*350 Locking disc for discharge valve X
C4*360 Discharge valve guard
C4*370 Lift washer no. 1 for discharge valve X
C4*380 Valve plate for discharge valve X
C4*390 Damper plate for discharge valve X
C4*400 Valve spring for discharge valve X
C4*430 Cylindrical pin for discharge valve
C5*002 Packing, complete, per piston rod
C5*400 Packing cartridge, complete, per piston X
rod
C5*499 Pressure breaker (crown ring) for packing X
C5*500 Packing flange
C5*502 Basic bush for packing
C5*503 Basic ring/Packing cup No. 1
C5*504 Packing cup No. 2
C5*517 Seal element (Pair of seal rings) X
C5*519 Pressure breaker, no. 1(throttle ring) X
C5*521 Support ring for piston rod packing X
C5*528 Seal element, complete X
C5*529 O-ring No. 1 for packing cup X
C5*534 O-ring No. 4 for basic bush X
C5*545 Cover for flange
C5*546 Stud bolt complete for packing
L00100 Anchor bolts for compressor
L00110 Nut for anchor bolt
L00117 Protecting sleeve to nut
L10000 Drive
L10010 Flywheel

Spare Parts
Spare Parts List
L10120 Coupling bolt
L10130 Hexagonal nut
L10140 Split pin for L10120
M00000 Crankgear
M00015 Crankcase
M00045 Threaded bolt for bearing cover
M00060 Tie rod for crankshaft bearing cover
M00065 Nut for crankshaft bearing
M00068 Protecting sleeve to nut
M00070 SUPERBOLT® nut for frame
M00100 Threaded bolt for distance piece
M00105 SUPERBOLT® nut for distance piece
M00110 O-ring for frame/distance piece
M00215 Cover for bearing bracket, non-drive end
M00220 Gasket for cover of bearing bracket, non-
drive end
M00410 Frame cover, large
M00415 Gasket for large frame cover
M00440 Frame cover, small-sized
M00445 Gasket for small-sized frame cover
M00900 Breather for crankgear/distance piece
M00910 Spare cartridge for breather
M10005 Crankshaft
M10200 Crankshaft bearing X
M10401 Axial guide ring X
M10600 Oil trap & crankshaft seal
M10615 Gasket for oil trap
M10630 Oil trap cover in 2-pieces
M10660 Trigger sensor
M10661 Reduction for keyphasor
M10662 Gasket for keyphasor
M10730 Cover in 2 pieces for crankshaft seal
M10735 V-seal ring X
M20000 Gear oil pump complete
M20001 Gear oil pump Typ R, complete
M20015 Housing for oiler drive
M20016 Gasket for housing of oiler drive
M20030 O-ring No. 1 for oil pump
M20060 Driving gearwheel
M20090 Driven gearwheel

Spare Parts
Spare Parts List
M20150 Crankshaft seal for oil pump
M20155 Circlip for crankshaft seal
M20160 Intermediate piece for oil pump
M20165 Intermediate flange for oil pump
M20170 Coupling for pump drive
M30000 Crosshead-piston rod connection
M30006 Crosshead body
M30015 Crosshead shoe X
M30115 Hydraulic nut for crosshead
M30195 Washer for crosshead
M30206 Locking plate for screw
M30207 Washer for screw
M30210 Set collar for crosshead
M30215 SUPERBOLT® nut for crosshead/piston
rod
M30220 Set screw, complete for set collar
M30225 Allen srew for crosshead shoe
M30230 Strain washer for allen screw
M30600 Crosshead pin X
M30620 Circlip for crosshead pin
M4*000 Connecting rod, complete with bearings
M4*410 Crosshead pin bearing X
M40000 Connecting rod, complete with bearings
M40010 Connecting rod, without bearings
M40020 Connecting rod bolt
M40050 SUPERBOLT® nut for M40000/10
M40300 Connecting rod bearing X
M50001 Oil scraping
M50400 Oil scraper plate
M50410 O-ring for oil scraper plate
M50420 Cover for oil scraper plate
M50425 Cover for oil scraper plate
M50501 Set of wiper elements, complete (set per
piston rod)
M50526 Wiper element, multisegmented X
M50530 Seal element in 2-pieces X
M50535 Supporting ring for wiper element X
M50545 Spring plate X

Spare Parts
Spare Parts List
M50555 Prewiper element
M60001 Distance piece
M60005 O-ring for distance piece/crankgear X
M60075 Gasket for nipple
M60200 Cover for distance piece
M60205 Gasket for distance piece cover X
M60206 Gasket for distance piece cover X
M60300 Distance piece packing
M60320 Housing
M60330 O-ring for distance piece packing
M60340 Cover for distance piece packing
M60350 Seal element, complete for M60300 X

Spare Parts
Spare Parts Drawings
12.3 Spare Parts Drawings
Bold printed code no. on spare parts drawings refer to detail drawing of the
respective spare part.
Overview
Title Drawing No.

Compressor layout 126003420
Drive System
Title Drawing No.

Drive 126000935
Lubricating System
Title Drawing No.

Gear oil pump, type R 126000285
Gear oil pump, type R 126000286
Oil pipe in the carter 126001232
Crankgear
Title Drawing No.

Crankgear 126001128
Oiltrap and crankshaft seal 126000707
Connecting rod 126001108
Crosshead-piston rod connection 126000361
Distance Piece
Title Drawing No.

Distance piece 126001188
Oil scraping 126001196
Distance piece packing 126000702

Spare Parts
Spare Parts Drawings
Cylinder
Title Drawing No.

Cylinder 126001428
Piston 126003421
Piston rod packing 126002287
Controlled suction valve with actuator 126000937
Controlled suction valve 126000088
Actuator for controlled suction valve 126000517
Installation of discharge valve 126000765
Assembly of discharge valve 126000089

M00900 M00215 M00900
C01001 M60001 M00910 M00220 M00910 M60001 C01001
C01156
C01166
C01140 A20490 M60200 M60202 A40301 A40302 M00000 A20490 C01140 A20490
C01145 M60205 M60206 C01145
C01156
C01155
L10000 M60075 C01155 C01166
C01160 M60075
C01160
Compressor layout
C01180 M60200 M60201 M00440 M00410 M20000 M20015
C01185 M60205 M60206 M00445 M00415 M20016
Kompressor Ansicht
2B1XC2.64_1
SA55/ae Original 123 606 130 200 22.04.2016 Rev. 0 126 003 420
Drive
Antrieb L10000
L10010
L10120
Center 1st crank

Mitte 1. Kurbel
L10130
L10140
CO20/bk Original 122 856 649 200 12.05.2009 Rev. 0 126 000 935
Gear oil pump, type R
Zahnradölpumpe, Typ R M20000
M20000
M20160 M20170 M20120 M20165 M20030 M20001
CO20/kw Original 122 853 333 200 17.06.2010 Rev. 1 126 000 285
Gear oil pump, type R
Zahnradölpumpe, Typ R M20001
M20180 M20060 M20150 M20155
M20090 M20200
CO20/gw Original 122F65109 07.01.2013 Rev. 4 126 000 286

Oil pipe in the carter
Ölleitung im Kurbeltrog A10000
A10025
A10035 A10030
CO20/ekn Original 122 855 758 200 08.07.2010 Rev.0 126 001 232
Crankgear
Kurbeltrieb M00000
M00045
M00065
M00015
M10200
M00068 M00060 M00015 M30000 M00100

M00070 M00110
A10000 M40000 L00110

L00100
L00117
M10200
M00015
M00045
M10401
M10005
M10600
Oil trap & shaft seal
Ölfang & Wellendichtung M10600
Option:
M10660
M10661
M10662
M10735 M10730
M10615 M10630
Connecting rod
Schubstange M4*000
Stage*
Stufe Code No. * * select stage as applicable,
e.g.: Connecting rod, complete with bearings 2nd stage M42000
entsprechende Stufe auswählen,

1 M41000 z. B. Schubstange, komplett, inkl. Lager 2. Stufe M42000
2 M42000
3 M43000
4 M44000
5 M45000
6 M46000
M4*410
M40010
M40300
M40020
M40050
CO20/ekn Original 122 863 074 200 25.03.2010 Rev. 0 126 001 108
Crosshead-Piston rod connection
Kreuzkopf-Kolbenstangenverbindung M30000
M30015
M30225
M30230
M30006
M30210
M30195
M30207
M30220
M30215
Option M30115
M30620
M30206
M30600 M30620 M30006
122 852 908 200
Distance piece
Distanzstück M60001
M60005 M60300
M50001
C00206
M00105
CO20/SaM Original 122 861 514 200 31.05.2010 Rev. 1 126 001 188
Oil scraping
Ölabstreifung M50001
M50425 M50555 M50400
M50410
M50545 M50420
M50501
M50535 M50526 M50530
Distance piece packing
Distanzstückpackung M60300
M60320
M60330
M60340
M60350
M60350 M60350
CO20/SaM Original 122 852 849 200 19.06.2009 Rev. 1 126 000 702
Cylinder
Zylinder C0*001
C3*000 C1*000 C0*270

stage * C0*275
Stufe Code No. * C0*519
1 C01001
2 C02001
3 C03001
4 C04001
5 C05001
6 C06001
* entsprechende Stufe auswählen,

z. B. Zylinder 2. Stufe C02001
select stage as applicable,

e.g.: Cylinder 2nd stage C02001
C0*620
C0*219
C0*212
C0*130 C0*605
C0*070
C5*002
C0*210
C0*215
C0*250
C0*255
C0*200
C0*061
C0*065
C4*000 C0*415 C0*400
C0*405
CO20/gw Original 122 871 336 200 07.08.2014 Rev. 3 126 001 428
Piston
Kolben C1*000
Stage *
e.g.: Piston complete incl. piston rod & piston rings
1st stage C11010
1 C11010
2 C12010 z. B. Kolben komplett, inkl. Kolbenstange & Kolbenringe
3 C13010 1. Stufe C11010
4 C14010
5 C15010
6 C16010
C1*010
C1*130
C1*500 C1*700 C1*230

C1*610
C1*550
C1*120
C1*110
C1*261 C1*262 C1*280 C1*261 C1*262
SA55/ae Oiriginal 123 606 451 200 20.04.2016 Rev. 0 126 003 421
Piston rod packing
Kolbenstangenpackung C5*002
Stage *
Stufe Code No. *
1 C51500
C5*500 2 C52500
3 C53500
4 C54500
C5*506 C5*504 C5*502
C5*534
5 C55500
C5*507 C5*505 C5*503
C0*255 6 C56500
(C0*250)
C5*002
* select stage as applicable,
e.g.: Packing flange 2nd stage C52500
C5*545 entsprechende Stufe auswählen,

z. B. Packungsflansch 2. Stufe C52500
C5*529
C5*400
C5*400
C5*529
C5*546 C5*529
C5*528 C5*521 C5*517 C5*521 C5*499 C5*519
CO20/rmi Original 122 877 511 200 14.04.2016 Rev. 1 126 002 287
Controlled suction valve with actuator
Gesteuertes Saugventil mit Stellzylinder C3*000
Stage *
e.g.: Actuator for controlled suction valve 1st stage C31410

1 C31410 z. B Stellzylinder zu gesteuertem Saugventil 1. Stufe C31410
2 C32410
3 C33410
4 C34410
5 C35410
6 C36410
C3*410
C2*045
C0*220
C0*230
C2*010
C2*050
C2*025
C2*016
Variant
C2*020 Variante
C3*001
C2*016
CO20/SaM 122 855 926 200 mod. 18.01.2010 Rev. 2 126 000 937
Controlled suction valve
Gesteuertes Saugventil C3*001
Stage *
e.g.: Controlled suction valve, complete,
2nd stage C32001
1 C31001
2 C32001 z.B. Gesteuertes Saugventil, komplett ,
3 C33001 2. Stufe C32001
4 C34001 C3*001
5 C35001
6 C36001
C3*020
C3*040
C3*030
C2*330
C3*070
C3*060
C2*320
C2*380
C2*390
C2*360
C2*430 C2*350 C2*370 C2*400
CO20/ae 08.04.2010 Rev. 13 126 000 088

Actuator for controlled suction valve
Stellzylinder zu gesteuertem Saugventil C3*410
Stage * C3*430 C3*435

Option
Stufe Code No. *
1 C31410
2 C32410 C3*437
3 C33410 C3*427
4 C34410 C3*438
5 C35410
6 C36410 C3*436
C3*475
C3*410
* select stage as applicable,
e.g.: Actuator, complete 1st stage C31410 C3*426
z. B. Stellzylinder, komplett 1. Stufe C31410 C3*424
C3*423 C3*422
C3*440 C3*431
C3*445
C3*421
C3*416
C3*409
(C3*418)
C3*415
(C3*419)
C3*412
(C3*420)
C3*417
C3*413
C3*480
C3*414
C3*415
Option
C3*447
C3*446
CO20/kw Original 122 854 926 200 03.06.2010 Rev. 4 126 000 517
Installation of discharge valve
Druckventil, Einbau C4*000
Stage*
e.g.: Discharge valve 2nd stage C42200

1 C41200 z. B. Druckventil 2. Stufe C42200
2 C42200
3 C43200
4 C44200
5 C45200
6 C46200 Variant
Variante
C4*016
C4*200
C4*020
C4*025
C4*016
C4*005
C0*230
C0*225
Option C4*045 C4*050
C4*097
C4*096
CO20/ekn Original 122 856 872 200 22.02.2011 Rev. 3 126 000 765
Assembly of discharge valve
Druckventil, Zusammenbau C4*200
Stage *
e.g.: Discharge valve 2nd stage C42200

1 C41200
z.B. Druckventil 2. Stufe C42200
2 C42200
3 C43200
4 C44200
5 C45200
6 C46200
C4*200
C4*330
C4*310
C4*360
C4*350
C4*400
C4*390
C4*380
C4*320
C4*430 C4*370
CO20/ae 28.03.2010 Rev. 8 126 000 089

Appendix
13 Appendix
P & I Diagram
Title Drawing No. Sheet No.

P & I DIAGRAM GAS SYSTEM 125608116 E01
P & I DIAGRAM PURGE SYSTEM 125608124 E01
P & I DIAGRAM CAPACITY CONTROL 125608127 E01
P & I DIAGRAM COMPRESSOR MONI- 125608126 E01
TORING
Technical Data

2001754 Performance Summary 2047744 S10
Utility Consumption List 2048026 E01
General Arrangement

GEN. ARRANGEMENT OVERALL 125608129 E01
Control Description

In Process
Foundation

In Process
Drive System

Motor Dimension Drawing 122F80116 E01
Motor Sole Plate Drawing 122F80014 E01

Appendix
Lubricating System

Lubrication of BCA Piston Compressors VBCA546005
(VSB)
Lubricating Oils ISO VG 150 Categories 1001135 (VSB)
C/CL
Cooling System

Cooling Water Quality Requirements VBCA200050
Compressor

COMPRESSOR OUTLINE 123606130200 D01
COMPRESSOR OUTLINE 123606130200 D02
Bearing Clearance Table 2051650 000
Maintenance of Compressor 2051647 000
Tightening Torques Cylinder (Drawing)
Tightening torques crankgear 2B1X
(Drawing)
Tightening Torques 2001754 2051648 000

RecipCalc™
Compressor Performance Summary
Customer Tecnicas Reunidas

Project PRPC PENGERANG-09
Job Site JOHOR, MALAYSIA
Item No. 1510-K-151
Compressor Type 2B1XC2.64_1
Units 1
Customer Reference 02260
Burckhardt Compression Ref. No. 2001754
Table of Contents
1.1 Summary operation data 2

1.2 Gas properties 4
1.3 Summary loading data 4
1.4 Compressor design data 5
1.5 Summary coolant data 5
1.6 Summary auxiliary data 5
1.7 Compressor sketch 6
1.8 Torque diagrams 7
1.9 Starting torque 9
1.10 Unbalanced forces and moments 9
1.11 Sound pressure level 10
REV.INDEX: 03 DOK.NR.:
PREPARED 04.09.2015 KELLER_J (TDO) 2047744-S10
APPROVED 09.11.2015 HATT_M PAGE 1
2001754/PRPC PENGERANG-09[03]&ORDER RecipCalc V 04.00.00 OF 10
This document contains inf ormation which is conf idential and shall not be giv en to any third party without the written consent of Burckhardt Compression
RecipCalc™
Customer: Tecnicas Reunidas BCA Tender No.: Q-003595-A-00-SZ00

Project: PRPC PENGERANG-09 BCA Contract No.: 2001754
Application: REF BCA Equipment No.: 200322
Compressor type: 2B1XC2.64_1 Customer Reference: 02260
1.1 Summary operation data
Start-up Start-up Pre-refor MT shift MT shift

Operating conditions at battery limit Long Loop Long Loop mer heatup heatup
(Design) (50% VU) heatup (100% N2) (30% H2)
MT shift MT shift
Pre-reform
Design Design heatup heatup
er heatup
(100% N2) (30% H2)
Suction Suction Suction Suction
Type of control valve valve valve valve
unloaders unloaders unloaders unloaders
Suction pressure at battery limit bar a 8.00 8.00 8.00 8.00 8.00
Suction temperature °C 50 50 50 50 50
Rel. humidity (inlet H2O) % 0.00 0.00 0.00 0.00 0.00
Discharge pressure at battery limit bar a 15.00 15.00 11.70 11.90 12.39
Discharge temperature °C 120 121 95 96 98
Capacity wet kg/h 49630 24180 26212 26101 27800
Capacity dry kg/h 49630 24180 26212 26101 27800
Standard volume flow (0°C/1.013bar a) Nm3/h 39691 19337 20963 20874 30825
Inlet volume flow m3/h 5948 2898 3142 3128 4627
Specified capacity wet kg/h 48503 24251 15666 24000 24740
Shaft power (coupling) kW 1102 613 436 449 632
Recommended motor power kW 1300 1300 1300 1300 1300
Speed rpm 370 370 370 370 370
Operating conditions at cylinder flange 1 1 1 1 1

Active compression chambers/stage % 100 50 50 50 75
Clearance pockets active (yes/no/-) - - - - -
Mole weight kg/kmol 28.0 28.0 28.0 28.0 20.2
Suction pressure at cylinder flange bar a 7.92 7.92 7.92 7.92 7.92
Suction temperature °C 50 50 50 50 50
Discharge pressure at cylinder flange bar a 15.15 15.15 11.82 12.02 12.52
Adiabatic discharge temperature °C 115 115 88 90 94
Predicted discharge temperature °C 120 121 95 96 98
Capacity wet (inlet) kg/h 49630 24180 26212 26101 27800
Capacity dry (inlet) kg/h 49630 24180 26212 26101 27800
Standard volume flow (0°C/1.013bar a) Nm3/h 39691 19337 20963 20874 30825
Inlet volume flow m3/h 6008 2927 3173 3160 4673
Volumetric efficiency % 84.7 83.7 90.6 90.3 88.2
Condensate flow upstream stage kg/h 0 0 0 0 0
Delta temp. to dew point °C 223 223 223 223 228
Bypass flow across stage kg/h
Side stream kg/h
Shaft power kW 1102 613 436 449 632
Manufacturer capacity including API618 requirements with tolerances as follows: specified capacity +3/-0 %
shaft power +3/-3 %
RecipCalc™
RecipCalc™
Gas-Library: PPDS2 Model: 10 (LKP/LKP)
1.2 Gas properties
Start-up Start-up MT shift MT shift

Pre-reform
Operating conditions Chem. Long Loop Long Loop heatup heatup
er heatup
(Design) (50% VU) (100% N2) (30% H2)
MT shift MT shift
Pre-reform
formula Design Design heatup heatup
er heatup
(100% N2) (30% H2)
Stage 1 1 1 1 1
Gas comp. at cyl. inlet flange [mole %]:
Nitrogen N2 100.00 100.00 100.00 100.00 70.00
Hydrogen (normal) H2 30.00
1.3 Summary loading data
Start-up Start-up MT shift MT shift

Pre-reform
Operating conditions Long Loop Long Loop heatup heatup
er heatup
(Design) (50% VU) (100% N2) (30% H2)
MT shift MT shift
Pre-reform
Design Design heatup heatup
er heatup
(100% N2) (30% H2)
Stage (cylinder flange) 1 1 1 1 1
Max. allowable gas rod load kN 350 350 350 350 350
Max. allowable combined rod load (C/T) kN 350 350 350 350 350
Gas rod load compression kN 266 26 26 26 171
Gas rod load tension kN 256 254 146 153 162
Combined rod load compression kN 276 87 100 96 201
Combined rod load tension kN 254 247 176 179 184
Combined rod load at relief valve set C kN 312 85 92 92 302
Combined rod load at relief valve set T kN 289 282 289 289 276
Rod reversal at normal op. condition deg 175 80 95 95 90
Rod reversal at safety valve setting deg 175 75 75 75 75
RecipCalc™
1.4 Compressor design data
Running Dry
Stage 1
No. of cylinders per stage 2
Acting (single=s/double=d) d
Piston diameter mm 640
Piston rod diameter mm 75
Stroke mm 250
Average piston speed m/s 3.08
Piston displacement m3/h 7093
Spacer ring height mm -/-
Clearance volume (average) % 22.0
Valve type plate
No. of suction valves per cylinder - 4
Suction valve size BCAG-308
Suction valve pressure class 16/32
Suction valve lift mm 2.10
Suction valve gas velocity (average) m/s 21.56
No. of discharge valves per cylinder - 4
Discharge valve size BCAG-308
Discharge valve pressure class 16/32
Discharge valve lift mm 2.10
Discharge valve gas velocity (average) m/s 21.56
Unloader type finger
No. of clearance pockets per stage - n.a.
1.5 Summary coolant data
Serial Tin Tout Capacity Power

Name/Coolant Operating Case / max. cooling power Element
no. [°C] [°C] [m3/h] [kW]
Cylinder (Water) Start-up Long Loop (Design) 34 40 10.2 70.7
Start-up Long Loop (50% VU) VR1.1 2.46 17.1
Start-up Long Loop (Design) VR1.2 2.37 16.5
Start-up Long Loop (50% VU) VR2.1 2.46 17.1
Start-up Long Loop (Design) VR2.2 2.37 16.5
Start-up Long Loop (Design) PF1 0.33 2.3
Start-up Long Loop (Design) PF2 0.33 2.3
Oil (Water) Start-up Long Loop (Design) 34 39 1.46 8.5
Start-up Long Loop (Design) oil cooler 1.46 8.5
Remarks:
VR: compression chamber
PF: piston friction
KL: gas cooler
1.6 Summary auxiliary data
Relief valve setting
Suction side 1st stage bar g

Discharge side 1st stage bar g 15.5
Cooling water system bar g
RecipCalc™
1.7 Compressor sketch
Crank C1 C2
Stage 1/1 1/1
Stroke [mm] 250 250
Piston diameter [mm] 640 640
Number of suction valves 2/2 2/2
Number of discharge valves 2/2 2/2
Valve size 308 308
Valve manufacturer BC BC
Clearance volume [%] 21.8/22.2 21.8/22.2
Stage 1
Piston displacement m3/h 7131
RecipCalc™
1.8 Torque diagrams
Maximum torque
Start-up
Operating conditions Long Loop
(Design)
Design
Torque diagram (compressor excitation torque before flywheel)
Mt0 [kNm] 28.432 Fourier-Analysis

Mtmax [kNm] 69.815 Mt=Mt0+SUM[Mt(j)*COS[j*ABS(w)*t-phi(j)]]
Mtmin [kNm] -3.143 ord. j amp. Mt(j) [kNm] phi(j) [deg]
Delta A/A [-] 0.18441 1 3.414 332.5
Inertia compr. [kgm2] 13 2 30.276 188.3
Inert. flywheel [kgm2] 2256 3 3.771 162.0
Inert. motor [kgm2] 874 4 2.897 325.2
Irregularity* [1/...] 142 5 0.795 359.8
Pad [kW] 971.9 6 2.461 230.3
Shaft power
[kW] 1101.9 7 0.892 200.3
(coupling)
Speed [rpm] 370 8 1.952 343.8
9 0.805 336.0
10 0.639 116.6
11 0.375 129.8
12 0.149 320.0
*Considering compressor, motor and flywheel (if available). The whole train is assumed fully rigid.
RecipCalc™
Maximum irregularity
Start-up
Operating conditions Long Loop
(50% VU)
Design
Torque diagram (compressor excitation torque before flywheel)
Mt0 [kNm] 15.824 Fourier-Analysis

Mtmax [kNm] 62.582 Mt=Mt0+SUM[Mt(j)*COS[j*ABS(w)*t-phi(j)]]
Mtmin [kNm] -13.346 ord. j amp. Mt(j) [kNm] phi(j) [deg]
Delta A/A [-] 0.50448 1 21.567 99.0
Inertia compr. [kgm2] 13 2 18.296 157.2
Inert. flywheel [kgm2] 2256 3 3.423 354.0
Inert. motor [kgm2] 874 4 2.453 325.0
Irregularity* [1/...] 93 5 2.790 74.4
Pad [kW] 483.2 6 0.653 206.2
Shaft power
[kW] 613.1 7 0.904 196.1
(coupling)
Speed [rpm] 370 8 0.849 330.6
9 0.173 26.7
10 0.472 99.9
11 0.227 219.4
12 0.235 253.5
*Considering compressor, motor and flywheel (if available). The whole train is assumed fully rigid.
RecipCalc™
1.9 Starting torque
1.10 Unbalanced forces and moments

Related to point Z = 396 mm from 1st bearing
Q = time * angular velocity
Q = t(sec) * (360/60 * 370) (deg/sec)
Speed = 370 rpm
Mt = Motor torque
Resulting forces
Horizontal FH [kN] = 0.000 1st order
+ 0.000 2nd order
Vertical FV [kN] = 0.000 1st order
+ 0.000 2nd order
Resulting moments
Horizontal MH [kNm] = 44.553 * cos(Q - 180.0) 1st order
+ 4.612 * cos(2 * Q - 180.0) 2nd order
Vertical MV [kNm] = 11.138 * cos(Q - 90.0) 1st order
+ 0.000 2nd order
Max. amplitudes 1st order 2nd order Rotating (*) Resultants

Forces
Horizontal, FH [kN] 0.000 0.000 0.000 0.000
Vertical, FV [kN] 0.000 0.000 0.000 0.000
Moments
Horizontal, MH [kNm] 44.553 4.612 11.138 49.143
Vertical, MV [kNm] 11.138 0.000 11.138 11.138
(*) for information only, included in 1st order
RecipCalc™
1.11 Sound pressure level
Valid for free field sound radiation at 1 m distance from compressor

and low basic noise at n = 370.0 rpm
According ISO 2151
Lp = 86.5 dB(A)
Octave spectrum of sound pressure level
f [Hz] 63 125 250 500 1000 2000 4000 8000

Lp [dB] 84.5 86.5 84.5 82.5 81.5 79.5 75.5 70.5
f: frequency, Lp: sound pressure level
RAPID PROJECT PACKAGE 3
TR PROJECT NO. EQUIPMENT (ITEM AND DESCRIPTION)

02260 1510-K-151 - N2 Compressor
PURCHASE ORDER NUMBER SUB SUPPLIER IDENTIFICATION
0226005040
REVIEW RESPONSE BY PURCHASER:
Purchaser review and comments do not indicate either responsibility or liability for accuracy and completeness of this document or alter any
contractual terms and conditions:
Rejected Reviewed With Comments Reviewed Without Comments
Comment As Noted Reviewed As built For Information
VOID DATE:
DOCUMENT DATA VENDOR IDENTIFICATION: Burckhardt Compression AG
DOCUMENT TITLE: Utility Consumption List
VENDOR DOCUMENT NO.: TSP 2048026 REV: A CODE: LIS-0007
PURCHASER DOCUMENT NO.: V-02260-1510-K-151-0001 REV: A CLASS: O
OWNER DOCUMENT NO.: RAPID-P0003-3004-MEC-LST-1510-0009 REV: A

DOCUMENT NUMBER V-02260-1510-K-151-0001_A Rev Page
Project Package Originator Discipline Doc. Type Unit nº Serial nº
A 1/2
RAPID P0003 3004 MEC LST 1510 0009
PETRONAS RAPID PROJECT

(PACKAGE 3)
Utility Consumption List
OWNER approval:
Name:
Date (DD-MMM-YY):
Signature:
Document Class: 0
Pages modified under this revision:
1 26.01.2016 IFA - Issued for Approval FEUSI_M MUELLER_H FEUSI_M

0 22.05.2015 First Issue GERBER_M GERBER_M MUELLER_A
A 27.01.2016 IFR ‐ Issued for Review GERBER_M MUELLER_H FEUSI_M
DATE WRITTEN BY CHECKED BY APPROVED BY
REV. STATUS-REVISION MEMO
DD-MMM-YY (name & signature) (name & signature) (name & signature)
Sections changed in last revision are identified by a vertical line in the right margin.
Electronic Filename: RAPID-P0003-TRSA-MEC-LST-1510-0009_A.xls

UTILITY CONSUMPTION LIST
PRELIMINARY to be finalized according to design
CLIENT PRPC REFINERY AND CRACKER SDN BHD PLANT CAPACITY

Burckhardt Compression Project: 2001754
LOCATION Johor, Malaysia UNIT No./ CODE 1510-K-151 CHANGE REV. A SHEET
PROJECT No. 2260 CASE DATE 16.07.2015 1
UNIT TYPE OFF GAS COMPRESSOR ORIG. BY GERBER_M OF
DOCUMENT No. TSP 2048026 APP. BY FEUSI_M 3
UNIT/ ELECTRIC POWER kW STEAM CONDENSATE BFW DEMIN
EQUIP. DESCRIPTION MOTOR/ MECH. ELEC. kg/hr kg/hr WATER REMARKS Rev.
No. LOAD RUNNING OPER HHP HP MP LP MP LP COLD/VAC kg/hr
RATING LOAD LOAD STM STM STM STM COND COND COND LOSSES kg/hr
1510-KM-161 OFF GAS COMPRESSOR DRIVE MOTOR 1300 1104 A
MH-01 MOTOR SPACE HEATER 0.7 (1) A
1510-PM-161B AUX LUBE OIL PUMP MOTOR 3.0 A
1510-K-151-PM03 MAIN MOTOR HYDROJACKING PUMP MOTOR ~1 A
1510-K-151 SOLENOID VALVES (VALVE UNLOADERS) 3x 20W (2) A
1510-K-151 LOCAL OPERATING PANEL ~0.5 A
TOTAL ~1304 ~1.3 A

NOTES: Solenoids are not reported in this document MOTOR/LOAD RATING: NAMEPLATE RATING OF MOTOR OR LOAD
(1) INTERMITTENT PRODUCER/CONSUMER MECH. RUNNING LOAD: MOTOR SHAFT POWER
(2) INTERMITTENT PRODUCER/CONSUMER (10 times per hour) ELECT. OPERATING LOAD: POWER ABSORBED BY MOTOR (MECH. LOAD/ EFFY AT DESIGN CONDITION)

UNIT/ ELECTRIC POWER kW STEAM CONDENSATE BFW DEMIN
EQUIP. DESCRIPTION MOTOR/ MECH. ELEC. kg/hr kg/hr WATER REMARKS Rev.
No. LOAD RUNNING OPER HHP HP MP LP MP LP COLD/VAC kg/hr
RATING LOAD LOAD STM STM STM STM COND COND COND LOSSES kg/hr
NO COOLING WATER SKID A
TOTAL
NOTES: MOTOR/LOAD RATING: NAMEPLATE RATING OF MOTOR OR LOAD
MECH. RUNNING LOAD: MOTOR SHAFT POWER
(1) INTERMITTENT PRODUCER/CONSUMER ELECT. OPERATING LOAD: POWER ABSORBED BY MOTOR (MECH. LOAD/ EFFY AT DESIGN CONDITION)

UNIT/ COOLING WATER UTILITY DESAL INST. PLANT AIR NITROGEN MINERAL FUEL
3
EQUIP. DESCRIPTION TEMP. FLOW TEMP. FLOW WATER WATER AIR Nm /hr Nm3/hr OIL FIRED REMARKS Rev.
No. RISE m³/hr RISE kg/hr m3/h m3/h Nm3/hr CONT. INTER CONT. INTER Kg/h NOTE 1
°C °C M'ENT M'ENT
1510-E-151A LUBE OIL COOLER A 2 5.00 A
1510-E-151B LUBE OIL COOLER B 2 5.00 A
1510-KM-151 MAIN MOTOR, PURGE 151 HOLD A
1510-K-151 COMPRESSOR, PURGING + BUFFERING N2 17.0 A
1510-K-151 CAPACITY CONTROL 0.6 0.2 (2)
1510-X-151 PNEUMATIC BARRING DEVICE 0.8 for 1 Crankshaft Revolution A
1510-K-151 CYLINDER COOLING WATER FLOW 6 ~11 Common A
TOTAL ~21 151 0.8 17.6 0.2 A

NOTES: (2) Continuous=> Nm3/h running at 50% load, 5 actuations per hour; Intermitt.=>Nm@startup to run 0%load
(1) INTERMITTENT PRODUCER/CONSUMER

Diego Freitas
Luiz Dal Bo Luiz Dal Bo
2016.03.04 2016.03.04 2016.03.04
16:35:26 17:47:28 17:47:47
-03'00' -03'00' -03'00'
Diego Freitas Luiz Dal Bo Luiz Dal Bo
2016.03.04 2016.03.04 2016.03.04
15:13:02 17:47:03 17:47:14
-03'00' -03'00'
-03'00'
Gilt für / Valid for BCAG
Verteiler / Distribution Intranet: Qualitaet / VBCA
Lubricating Oil Specifications
Lubrication of BCAG Piston Compressors
Scope of Application
This specification applies to the lubrication of BCAG secondary compressors (hyper compressors), process gas compressors
®
and open/closed (pressure resistant) labyrinth piston compressors (Laby ).
General
The cylinder lubricating oil of the process gas compressors with lubricated cylinders comes into contact with the compressed
gas and is partially carried over to the process downstream.
®
In closed (pressure resistant) labyrinth piston compressors (Laby ) the process gas generally comes in contact with the
lubricating oil in the crankgear. This has to be considered for the choice of the lubricating oil.
a) Crankgear Lubrication
a1) For the lubrication of the crankgear, mineral oil according to the Lubricating Oil Specification (VSB) 1001132 is used.
Exception: labyrinth piston compressors (pressure resistant).
a2) For the lubrication of the crankgear of closed (pressure resistant) labyrinth piston compressors, oil according the
“Allocation Table Crankgear Lubrication” (VSB) 1001300 must be used
®
a3) For LNGM (Laby -GI) applications see paragraph d).
b) Cylinder Lubrication
b1) In most cases, mineral oil according to the Lubricating Oil Specification (VSB) 1001133 is used for cylinder lubrication
of BCAG process gas compressors.
Exceptions:
• Primary compressors for LDPE production:
Applicable lubricants:
- Same cylinder lubricating oil as in the secondary compressor.
See Lubricating Oil Specification (VSB) 1001134
- Same cylinder lubricating oil (ISO VG 100) as for cooling and flushing of secondary compressor (model year 2007
and onwards).
See cooling and flushing oil secondary compressor Specification (VSB) 1006423.
• Compressors for NH3, corrosive gases etc.: Check with Burckhardt Compression.
b2) For the cylinder lubrication of BCAG secondary compressors, white oils and polyalkylene glycols (PAG) according to
the Lubricating Oil Specification (VSB) 1001134 are used.
®
b3) For LNGM (Laby -GI) applications see paragraph d).
c) Cooling and Flushing Oil

For “Cooling and Flushing Oil” of secondary compressors the following qualities are admissible:
c1) ISO VG 68 for compressor model 2006 and before
Technical or pharmaceutical white oil
Mineral oil categories C and CL according to Lubricating Oil Specification (VSB) 1001303
c2) ISO VG 100 for compressor model 2007 and after
Technical or pharmaceutical white oil
Mineral oil categories C and CL according to Lubricating Oil Specification (VSB) 1006423
Rev. Index F Dat. Sig. (VSB) VBCA546005

ausgestellt von / issued by 03.07.2015 KAUFMANN_W ersetzt / replaces VBCA546005
Seite / Page 1
überprüft / reviewed 03.07.2015 CRUZ_R Revision E
Freigabe DVS 03.07.2015 ARZTMANN_R vom / from 02.04.2015 von / of 2
Gilt für / Valid for BCAG
Verteiler / Distribution Intranet: Qualitaet / VBCA
Lubricating Oil Specifications

®
d) For LNGM (Laby -GI) applications
General lubrication
VBCA 546005 – Lubrication of BCAG Piston Compressors
information
Crankgear lubrication VBCA 1001132 – Crankgear Lubrication Mineral Oil
Fuel Gas Supply System (FGS) with regular Fuel Gas Supply System (FGS) with regular
low pressure re-liquefaction systems high pressure re-liquefaction systems
(side stream < 30bar a) (side stream > 200bar a)
VBCA 1001133 VBCA 1001301

Cylinder lubrication ®
Cylinder Lubrication Mineral Oil Laby Polyalkylene Glycol Lubricants (PAG)
Rev. Index F Dat. Sig. (VSB) VBCA546005

ausgestellt von / issued by 03.07.2015 KAUFMANN_W ersetzt / replaces VBCA546005
Seite / Page 2
überprüft / reviewed 03.07.2015 CRUZ_R Revision E
Freigabe DVS 03.07.2015 ARZTMANN_R vom / from 02.04.2015 von / of 2
Revision
(VSB)
Lubricating Oils ISO VG 150 Categories C/CL 1001135
General
This list contains a selection of lubricating oils of the viscosity class ISO VG 150 in the categories C (DIN 51 517 Part 1) and CL
(DIN 51 517 Part 2). The listing is in alphabetical order according to manufacturer’s and/or brand names. It is intended for the
use with “Lubricating Oil Specifications” (VSB) 1001132 and (VSB) 1001133.
Lubricating Oil Categories

Lubricating oil category C (according to DIN 51 517 Part 1): Ageing-resistant mineral oils without additives
Lubricating oil category CL (according to DIN 51 517 Part 2): Mineral oils with additives to increase corrosion
protection and ageing resistance.
This list contains only lubricating oils without zinc dialkyl dithiophosphate (ZDDP, ZDTP, ZDP) additive.
Category
Brand Name Name VG Remarks ISO
(DIN 51 517)
AGIP Radula 150 150 C

AGIP Acer 150 150 CL
BP Amoco Energol CS 150 150 C
Castrol Magna 150 150 C
Chevron (Texaco) Regal R&O 150 150 CL
ExxonMobil Mobil DTE 10 Excel 150 150 CL
ExxonMobil Mobil Vacuoline 128 150 CL
Shell Morlina S1 B 150 150 C
Shell Morlina S2 B 150 150 CL
Total Cirkan RO 150 150 CL
Total Dacnis 150 150 CL
Strub Vulcobase P 150 C
Burckhardt Compression AG does not assume any responsibility for the quality and properties of the sub-
supplied lubricating oils.
Further relevant BCAG specifications etc.:
MI-76en Safe Handling of Lubricants
Rev. Dat. Sig. Ersatz für 1001135

Erstellt / Prepared 07.01.2015 KAUFMANN_W Replacement for Seite 1 von 1
Überprüft / Reviewed E 07.01.2015 CRUZ_R Revision 2 Page 1 of 1
Freigabe / Approval DVS 08.01.2015 ARZTMANN_R vom / date 07.05.2004
Revision
(VSB)
1. Scope of Document
This standard covers the minimum set of parameters for cooling water to be defined in order to
protect compressors and their accessories from following effects:
 Corrosion on metallic materials and/or
 Formation of fouling in piping systems, cylinder water jackets, heat exchangers, etc.
Cooling water which deviates from the values and limitations indicated in below table (ref. to
table 1), might have negative influence on compressor performance and lifetime of components
in direct contact with the coolant.
In order to guarantee the product performance and expected lifetime, the selection of suitable
materials and/or type of cooling water system is essential.
The values given in the below table shall be understood as a general guideline for cooling water
circuits connected to BCAG compressor systems. Reference is made to the engineering
standard published by “The Association of German Engineers (VDI)”, standard no. VDI 3803.
2. Responsibilities
1. Purchaser shall inform BCAG concerning project related cooling water quality during
bidding stage by submitting detailed cooling water analysis.
Grade of cooling water quality might have influence on project costs.
Purchaser by minimum to inform about the values of the cooling water parameters as listed
in the table below (ref. to table 1). In special cases, BCAG can provide specific detailed
questionnaire “Evaluation criteria for cooling water quality and water treatment methods”
(ref. to VSB VBCA200050 E02).
2. BCAG will review provided cooling water analysis and inform purchaser whether the given
values are acceptable or special care has to be taken with respect of material selection
and/or type of cooling water system.
3. In case of conflicting deviations to the defined standard cooling water quality, the following
procedures might apply:
a. Material selection for components in contact with cooling water will be reviewed by
BCAG internal material specialists. Alternative material selection might be required.
b. Alternative type of cooling water system will be evaluated together with the purchaser.
c. Cooling water treatment to improve coolant quality.
4. In case of no cooling water analysis is provided by purchaser, design and selection of

materials for compressor and accessories (heat exchangers, piping system, etc.) is based
on below water quality parameters (ref. to table 1).
It is in the responsibility of the purchaser to inform BCAG concerning any changes to the cooling
water analysis during the complete bidding and project phase. Deviating actual cooling water
quality from information available during bidding stage might be related to design changes
during project phase and cost adders for changes might apply resp. delivery delay might occur.
Rev. Dat. Sig. Ersatz für

Erstellt / Prepared 26.01.2016 REGEZ_R Replacement for Seite 1 von 3
Überprüft / Reviewed 26.01.2016 BOSSHARD_K Revision Page 1 of 3
Freigabe / Approval DVS 26.01.2016 TUERKMEN_N vom / date
Revision
(VSB)
3. Limitation of Liabilities
Compliance to the BCAG standard cooling water quality guideline (refer to table 1) is a basic
requirement for the trouble-free operation of the compressor plant.
All deficiencies caused by non-conformance of the cooling water quality to the standard
parameters listed in table below resp. non-conformance to the deviations which have been
explicitly agreed by BCAG are excluded from BCAG’s guarantee and liability.
Recommended Guide Values for Cooling Water for Compressor Systems
Parameter Abbr. Unit Range Remarks

Conductivity - [μS/cm] < 2’200 @ reference temp. of 20°C
pH-value - [-] 7.5 – 9.0
m-alkalinity - [meq/l] < 4.0
2+
Calcium Ca [mg/l] >20
-
Chloride Cl [mg/l] < 150 For coolant T ≥ 50°C, < 100
Sulphate SO4 [mg/l] < 325
Carbonate hardness - [°dH] < 4.0
KMnO4-consumption - [mg/l] < 100
Microbial count - [CFU/ml] < 10’000
Total Organic Carbon TOC [mg/l] < 30
Suspended solids - [mg/l] < 10
2 -4
Fouling factor - [m K/W] 1.8 x 10
Table 1 – minimum parameters for cooling water quality
Periodic, monthly sampling of cooling water is recommended in order to ensure proper quality
4. Coolant Temperature Requirements

General reference is made to API 618 5th edition, chpt. 6.1.7 table 1 – Cooling Systems
Conditions.
In case of process gas might form condensation, coolant inlet temperature shall be maintained
at a minimum of 6K above the gas inlet temperature (refer to API 618, para 2.6.3.3).
In order to minimize fouling effects, BCAG defines the coolant flow and velocity over the heat
exchanger surfaces. Coolant flow and related velocities are selected to prevent solids,
suspended in the coolant, from depositing and causing increased fouling.
For compressors equipped with water jackets on cross head and guide bearings (Laby®
design), a minimum supply temperature of 15°C shall be guaranteed all-the-year.

Revision
(VSB)
5. Cooling Water Treatment

In order to prevent freezing in closed cooling water circuits, antifreeze additives are normally
added. In the same way anticorrosion agents, biocidal products and similar products may need
to be added to the cooling water.
Please contact a specialized company for detailed information and services concerning water
treatment. BCAG is not able to provide detailed information concerning water treatment. The
responsibility of cooling water treatment remains with the compressor operator. Local
environmental regulations shall be respected.
In case demineralized water is used as make-up water in closed circuits, a special selection of
materials is required and/or additives are to be added. BCAG must be explicitly informed about
the additives used. Additives can have a chemical aggressiveness and a galvanic effect in the
cooling water circuit.

LAGERSPIELTABELLE
BEARING CLEARANCE TABLE
TABLEAU DES JEUX DE PALIER
Kunde Maschinen Nr. Typ
Client / Client Machine n°. / No. de la machine Type / Type
Técnicas Reunidas, S.A. 200322 2B1XC2.64_1
Kunden ref. Auftrags-Nr.
Client ref. / Client réf. Job n° / Commission no.
PRPC PENGERANG-09 2001754
B D A C
Hersteller Nennmass 1)
Gegenstand Normales Lagerspiel [mm] Max. zul. Spiel [mm] Kontrollpunkte
[mm]
Object Manifactured dimension Bearing clearance normal Max. allowed clearance Checkpoint
Objet Cote nominale d'usinage Jeu normal de palier Jeu maximum admissible Point de contrôle
Führungs- und Hauptlager

Radialspiel [A]
0.24 - 0.348 1.
Main + Guide bearing 2.
lateral clearance 225 Trennfuge 0.398 3.
Kurbelwelle Parting joint
Palier de guidage et principal 4.
Joint médian
jeu radial
Crankshaft
Führungslager
Axialspiel [A]
Vilebrequin Axial clearance of
guide bearing 144 0.200 - 0.600 0.8 2.
3.
Palier de guidage
jeu axial
Kurbelzapfenlager
Radialspiel [B]
0.24 - 0.348 1.
Crank pin bearing 2.
lateral clearance 225 Trennfuge 0.398 3.
Parting joint
Palier de maneton 4.
Joint médian
jeu radial
Schubstange Kreuzkopfzapfenlager
Radialspiel [C]
Connecting rod 1.
Crosshead pin bearing
lateral clearance 135 0.092 - 0.172 0.22 3.
Bielle de poussée 4.
Coussinet de tourillon de cross
jeu radial
Axialspiel [C]
1.
Axial clearance 250 0.30 - 0.40 0.45 3.
Dégagement axial
4.
Kreuzkopf Radialspiel [D]

1.
Crosshead Lateral clearance 340 0.23 - 0.337 0.5 3.
4.
Crosse Jeu radial
1) Lagerspiele nach Zeichnungsmassen. Wenn Spiele mit Fühlerlehre 1) Clearances acc.to dimensions on drawing. If clearances measured
gemessen werden, können obige Spiele wie folgt kleiner sein: by feeler gauges, the above values can be less as follows:
min. ≤0.1mm = 0.01mm und min. >0.1mm = 0.015mm min. ≤0.1mm = 0.01mm und min. >0.1mm = 0.015mm
Kontrolle des Wellen- und Lagerdurchmessers. Kontrolle des Lagerspieles.
1. Check of bearing gap. 3. Check of bearing clearance.
Contrôle du diamètre d'arbre et du coussinet. Contrôle du jeu de palier.
Kontrolle der Lagerauflage in der Grundbohrung. Spezielle Kontrolle je nach Maschinenteil.
2. Check of bearing application in basic bore. 4. Special check depending on part of machine.
Contrôle de l'assise du coussinet dans l'alésage. Contrôle spécial selon la partie de la machine.
REV. INDEX DOK.-NR.:
2051650
ERSTELLT / PREPARED 23.11.2015 BONADIO_M (TDO)
UEBERPRUEFT / REVIEWED 27.11.2015 FEJZULI_B SEITE / PAGE 1
GENEHMIGT / APPROVED 27.11.2015 FEJZULI_B SW / 15-02-00 / rev. 0 VON / OF 1
WARTUNG DES KOMPRESSORS
MAINTENANCE OF COMPRESSOR
Kunde Maschinen Nr. Typ
Client Serial no. Type
Técnicas Reunidas, S.A. 200322 2B1XC2.64_1
Projektdefinition Auftrags-Nr. Kurbel Nr. Stufe
Job name Job no. Crank no. Stage
PRPC PENGERANG-09 2001754 1/2 1
Kolbendurchmesser Kolbenspiel Hub
[mm] [mm] [mm]
Piston diameter Piston clearance Stroke
UTP OTP
640 BDC
1.5 - 2.5 TDC
3.5 - 4.5 250
Kolbendurchmesser
Piston diameter
Ø 640 mm
Zulässiges Mass infolge Abnutzung

Benennung Menge Werkstoff Nennmass [mm] Rauheit [µm]
[mm]
Description Quantity Material Nominal dimension Roughness
Service limit dimension
A Ø640 Ø641 Ra 0.2 - 0.4

Zylinderbüchse EN-GJLP
1 B Ø690
Cylinder liner EN-GJLP
C 70
Kolbenstange WC-beschichtet Ra 0.15 - 0.25 ***

1 D Ø75 Ø74.9
Piston rod TC-coated Ra 0.1 - 0.2 ****
E 55
0.4
N5
16
F 0.66 - 0.895
G Ø615
0.2
N4
8
Führungsringe
4 PTFE H
Guide rings
PTFE 1.0 - 1.415
I
0.1
N3
K 12 10.8
L 11.8 +0 / +1.3
µm
µ in
M 15
Classes of roughness
Rauheitsklassen
Ra
Kolbenringe 4* PTFE N 0.186 - 0.332

Piston rings PTFE O 25 18.7
Max. roughness
Max. Rauheit
P 7.7 +0 / +0.7*
Q Ø634
Kolben Sphäroguss
1 R 55
Piston Nodular cast iron
S 15
Bemerkungen
* Schrägschnitt zur Berechnung:
/ Diagonal cut
** Überlappt / Bemerkungen
Overlapped zur Berechnung:
*** Packungsbereich / Packing area
**** Ölabstreiferbereich / Oilscraper area
REV. INDEX DOK.-NR.:
2051647
ERSTELLT / PREPARED 23.11.2015 BONADIO_M (TDO)
GEPRUEFT / REVIEWED SEITE / PAGE 1
FREIGABE DVS / RELEASE DVS KT / 02.02.10 / Rev.3 VON / OF 1
Anzugsdrehmomente
Tightening torques Process Cylinder
002 004-1 004-11 003-1 001-1
006-1 004-12 005-1
CO20/SaM 27.09.2011 TIM-ID 28821 Rev. 001

Anzugsdrehmomente
Tightening torques Crankgear 2BX
009
011
012
014 013
008 007 010
CO20/rmi 14.03.2016 TIM-ID 54941 Rev. 001

TIGHTENING TORQUES BX 2001754
Pos Bolt / Location Dimension Material Method Torque Angle Rev.

001 Cylinder cover
-1 1st Stage M30 x 158 A193 B16 II 650 Nm
002 Cylinder bottom

003 Pipe connection gas piping

-1 Recycle M30 x 168 A193 B16 II 250 Nm A
004 Valve cover

-11 Pressing bolt ss1) G1/2” x 95 34CrMo4 II 100 Nm
-12 Pressing bolt ds2) G1/2” x 95 34CrMo4 II 60 Nm
005 Piston nut

-1 1st Stage SB M56x4 1.7225-B7M V 49 Nm
006 Packing
007 Frame – Distance Piece SB M42x3 1.7225 V 51 Nm
008 Distance Piece – Cylinder SB M42x3 1.7225 V 51 Nm
009 Connecting rod SB M42x3 1.7225 V 58 Nm
010 Piston rod – Crosshead SB M56x4 1.7225 V 65 Nm
011 Main bearing cover vertical M30x2 A193 B16 III *) 65°
*) after the gap is closed
012 Main bearing cover horizontal SB M42x3 1.7225 V 40 Nm
013 Foundation bolt SB M48x5 1.7225 V 74 Nm
014 Coupling bolts M52x3 x 345 34CrNiMo6 III 35 – 45°

1)
ss = Suction Side
2)
ds = Discharge Side
Lubricate all bolt connections.

Lubricate all the other bolt connections according to the instructions, stated in data sheet MBN707
DOK.-NR.:
REV. INDEX
(TDO)
2051648
ERSTELLT / PREPARED 26.04.2016 BONADIO_M
UEBERPRUEFT / REVIEWED SEITE / PAGE 1

GENEHMIGT / APPROVED SW / 11-04-00 / rev. 0 VON / OF 1
Index
14 Index
A ultrasonic cleaning 10-11

Absorbent agent 5-99, 11-4 wiping 10-10
Acids 2-9 Cleaning methods 10-9
Actuator 4-6, 4-35, 4-36, 6-12 Cleaning of compressor plant 2-12
Address 1-5 Cleaning specification 10-3
Algae 8-25 Cleansing agent 10-6
Align electric motor 5-47 Clearance measurement 8-39, 8-34, 8-39
API 618 4-32 Clearance of crosshead pin bearing 9-136
API standard 1-6 Clearance pocket control 4-36
Assemble compressor 5-36 Commissioning 6-4
Assemble compressor components 9-1 Commissioning after maintenance 2-13
Assemble electric motor 9-139 Compressor
Assemble gear oil pump 9-138 design data 6-3
Assess vibrations 5-94 overview 4-3
Axial bearing 9-156 Compressor designation 1-5
assemble 9-158 Compressor maintenance 2-13
dismantle 9-157 Compressor operation 2-12
Connecting rod 4-15, 9-120
B
parallelism of bores 9-124
Barring device 3-4, 5-43
Connecting rod bearing 4-16, 8-50, 8-52, 9-113
proximity probe 3-14
Control elements 3-10
Bearing
Controlled suction valve 6-12, 9-15
axial 4-14
Controlled suction valves 4-36, 8-70
center 4-14
Cooling system 3-7, 8-24
main 4-10, 4-12, 4-14
Copyright 1-3
Bearings 9-145
Crankcase 4-7, 4-7
Brands 1-10
Crankgear 4-7, 8-49
Breather 3-13
Crankgear lubricating system 5-89
Buffer gas 3-6, 6-6
Crankshaft 4-13
Burckhardt Plate Valve™ 4-31, 4-32, 9-33
Crankshaft bearing 9-147
Burckhardt Poppet Valve™ 4-31, 4-33
assemble 9-151
Bypass control 4-36
dismantle 9-147
C Crankshaft deflection 5-35
Calcium carbonate deposits 8-25 Crankshaft main bearing 8-50
Capacity control 4-35, 6-11 Crankshaft seal 4-10, 8-50, 9-142
CE conformity 2-3 Crosshead 4-15, 4-16, 8-55, 9-120
Check crankshaft deflection 5-50, 8-49 lubrication 4-16
Check fabrication 5-62 reciprocating movement 4-7, 4-13
Chemical handling 2-8 Crosshead coupling 4-26
Clean compressor plant 8-6 Crosshead pin bearing 4-16, 8-56, 9-130
Cleaning Crosshead-piston rod connection 4-16
tools and facility 10-6 Cylinder 4-21, 8-59, 9-100
working environment 10-5 water cooled 4-21
workplace 10-6 Cylinder clearance 4-27, 9-86
Cleaning method measurement 8-31
chemical cleaning 10-10 Cylinder cover 9-56
degreasing with solvent vapor 10-11 dismantle 9-56
flushing 10-10 install 9-58
immersion 10-10 Cylinder liner 9-104
mechanical cleaning 10-9 Cylinder support 5-36
spraying 10-10

Index
D Grout sole plates 5-51

Damper 5-52 Grout supporting surface 5-32
Definitions for this document 1-1 Grouting Material 5-13
Deposits 3-8
H
Deposits of sand 8-25 Hazard identification diamond 2-14
Depressurize plant 8-6 Hazard seriousness 1-7
Dimensions 5-10, 8-31
caution 3-5
Discharge pressure 6-3 danger 1-7
Discharge valves 4-31, 8-69, 9-20 warning 1-7
Disclaimer 1-3
Hydraulic pressure test 5-85, 8-30
Dismantle compressor components 9-1 Hydraulically tightened piston nut 4-28
Dismantle crankshaft 9-158
Dismantle electric motor 9-139 I
Dismantle gear oil pump 9-138 Importance of cleanliness 5-3
Disposal 11-6 Important notes 5-3
Dispose components 11-6 Inspect compressor plant 5-98
Distance piece 4-17, 9-107 Install compressor 5-28
internal pipes 9-87 Install coupling 5-45
Distance piece packing 8-56, 9-108 Install electric motor 5-45
Drain lubricating oil 9-60 Install pipe work 5-58
Drive end 4-9 Install plant components 5-52
Drive system 3-3 Installation 5-1
Duplex oil filter 3-9, 8-27 Instruction Manual
applicability 1-4
E
document structure 1-6
Electric motor 5-45, 9-139 revision sheets 1-3
Electric motor rating 6-3 symbols 1-7
Electrical hazard 2-6
target group 1-4
Electrical installation 5-85 warnings 1-7
Electrical motor and coupling 8-23 Intended use 2-11
Emergency stop 3-12
Emergency stop during pre-commissioning 5-88 J
Explosion protection 2-11 Jackscrews 5-15
Explosion risk 2-11 L
External gas pipes 9-100 Lantern 4-31
F Legal regulation 2-3
Fabricate piping 5-59 Level compressor 5-28
Flange connections 8-23 Level indicator 3-14
Flywheel 5-40, 9-139 Level monitoring 3-14
Flywheel guard 3-14 LIB 3-11
Foundation 5-12 Lift compressor 5-19
Frame Alignment 8-40 Lift crankgear 5-20
Frame covers 9-59 Lift crankgear with distance piece 5-21
dismantle and assemble 9-59 Lift cylinder 5-24
Lift cylinder with distance piece 5-22
G Lift distance piece 5-23
Gas specification 2-14
Lift plant components 5-25
Gas system 3-5, 8-23 Lifting procedure 5-18
check cleanliness 5-90 Local instrument board LIB 3-11, 5-56
Gear oil pump 4-11, 9-138
Local operator panel LOP 3-11
General design and function of compressors 4-1 LOCTITE® 8-46
Grounding wire 5-85 Log sheet 6-8
Grout foundation bolts 5-30
LOP 3-11
Grout Foundation Bolts 5-49 Lubricant handling 2-7

Index
Lubricating oil Oil sight glass 3-10

drain and refill 9-60 Oil skid 3-8, 5-56
Lubricating system 3-8, 8-26 Oil specifications 8-29
instrumentation 8-28 Oil strainer 3-10, 8-27
non-return valve 8-26 Operating elements 3-10
Lubrication Operation 6-1
crosshead 4-16 monitoring 6-8
external oil pump 4-8, 4-11 prepare 6-4
gear oil pump 4-8, 4-11 safety precaution 6-5, 8-3
prelubrication pump 4-8 Operation with process gas 6-5
Lyes 2-9 Organic solvents 2-10
Orifice plates 3-7
M
Maintain plant during decommissioning 5-100, 11- P
5 Passivate piping 5-64
Maintenance Pickle piping 5-64
compressor in general 8-31 Pipe fastenings 8-23
control valve 8-26 Pipe support 5-68
plant 8-21 Pipe work
prerequisites 8-3 blowing out 5-92
relief valve 8-26 fabrication 5-58
shut-off valve 8-26 sandblast 5-68
Maintenance practices 2-12 Piping
Maintenance schedule 8-17 final assembly 5-83
compressor 8-19 Piston 4-26, 8-61, 9-61
plant 8-18, 8-23 assemble the 3-piece piston 9-65
Mandatory tightening torques 5-3 dismantle 9-65
Manley® valve 4-31, 4-34 Piston and piston rod
Marking of compressor components 8-31 install 9-73
Marking of packages 5-6 dismantle 9-62
Mass flow 6-3 Piston nut 4-28
Mechanical hazard 2-6 Piston nut SUPERBOLT® 4-28, 4-28
Mechanical test run 5-91 Piston rings 9-70
Monitor Operation 6-8 Piston rod 4-26, 8-59, 9-61
runout 4-29, 8-39
N
Piston rod monitoring 9-84
Name plate 1-5
Piston rod packing 8-59, 9-88
NFPA-Rating 2-14
design 9-89
Nitrogen 2-16
dismantle 9-90
Nitrogen test run 5-94
Piston rod runout
Non-drive end 4-11
adjust 9-81
Non-return valve 3-13, 5-85, 9-6
Place compressor 5-28
NORD-LOCK® Securing System 8-47
Plant
O overview 3-3
Obligations 2-3 Plant configuration and function 3-1
Oil change 8-28 Pneumatic barring device 3-4
Oil cooler 8-27 Pre-commissioning 5-1
Oil drain 3-10 cooling system 5-88
Oil level switch 3-10 of compressor plant 5-88
Oil quality 8-29 prerequisite 5-88
Oil quantity 8-28 Prelubrication pump 8-26
Oil scraper 9-110, 8-58 Prepare assembly 5-36
Oil scraping 9-110 Prepare installation 5-15, 5-52
Oil shield 4-27 Preserve cleanliness 10-11

Index
Preserve compressor plant 11-3 Suction temperature 6-3

Preserve compressor plant after installation 5-98 Suction valve actuator 9-6
Pressure monitoring 3-13 Suction valves 4-31, 8-69, 9-20
Pressure screw 4-31 Suction volume 6-3
Preventive maintenance 8-1 SUPERBOLT® 8-64
Process gas 2-14 loosening procedure 8-43
Protection against loud noise 2-7 preventive maintenance 8-43
Proximity probe 3-14 tightening procedure 8-44
Pulsation damper 3-7 SWAGELOK® 5-79
Purge gas 2-14 Switch off compressor 9-5
Purge plant 8-6 Switch off cooling system 9-6
Purge system 3-5 T
Purging during normal operation 3-5, 6-7
Target groups 1-4
Purging prior to maintenance 3-6 Technical Documentation 1-4
Purging prior to normal operation 3-6 Technical support 5-3
R Temperature monitoring 3-12
Recommission plant 5-100, 11-5 Tensioner SUPERBOLT® 8-42
Reference documents 1-4 Term cross reference to API standard 1-6
Refill lubricating oil 8-29, 9-60 Thermal hazard 2-6
Registered trademarks 1-10 Tighten foundation bolts 5-33
Relief valve 3-13, 8-29 Tightening methods 8-41
Revisions 1-3 Tightening torques and method 8-21
Rotation speed 6-3 Tightening torques for attachment gear 5-18
Rotation speed control 4-36 Tools 8-6
Runout special 8-10
adjust 9-81 standard 8-6
Transport 5-1, 5-5
S
Trigger Sensor 4-10, 9-144
Safety
Trouble shooting 7-1
preventive measures 2-5
compressor noise 7-15
Safety advice 2-1
compressor shutdown 7-21
Safety devices 2-6, 3-11, 8-29
compressor start-up interlock 7-23
Safety measures 2-5
compressor vibrations 7-19
Safety of transport 5-5
cooling system 7-7
Safety valve 3-13, 8-29
lubricating system 7-10
Scope of supply 5-8
prerequisites 7-3
Serial number 1-5
process gas system 7-4
Shaft power (coupling) 6-3
SUPERBOLT® 8-45
Shipping condition 5-7
Trouble shooting list 7-3
Shipping Package 5-5
Tube fittings 5-71
Single-compartment distance piece 4-17
Turn flywheel 5-43, 5-90
Space requirement 5-10, 8-31
Two-compartment distance piece 4-18
Spare parts 12-1
ordering 12-3 U
original 12-4 Unload compressor 5-7
Spare parts drawings 12-15 V
Spare parts list 12-8
Valve
Spare parts recommendation 12-6 assembly 9-15, 9-37
Spares inventory 12-5 disassembly 9-33
Standard volume 6-3
disassembly and repair 9-33
Standstill 5-98, 6-13, 11-3 dismantling 9-15, 9-24
Store components 5-8 installation 9-41
Suction pressure 6-3
Valve failures 8-69
Suction strainer 3-5

Index
Valve maintenance 8-69

Valve service 8-69
Valve types 4-31
Valves 4-31, 8-69
diameter 4-32
fixation 4-31
location 4-31
VCI mat 5-99, 11-4
Vibration measurement 5-97
Vibration monitoring 3-13
W
Warning signs at compressor site 2-5
Warning symbols 1-8
Warranty 1-3
Weights 5-10, 8-31
Y
Year of manufacture 6-3

Index

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RAPID PROJECT PACKAGE 3

Rejected Reviewed With Comments Reviewed Without Comments

Comment As Noted Reviewed As built For Information

VENDOR DOCUMENT NO.: IM200322_2001754 REV: 0 CODE: MAN‐0001

PETRONAS RAPID PROJECT

Instruction Manual Compressor Type

Process Gas Nitrogene (N2)

Compressor Project No.

1 Definitions for this Document

2 Elementary Safety Advice

3 Plant Configuration and Function

4 General Design and Function of

5 Transport, Installation and Pre-Commis-

9 Dismantle and Assemble Compressor Com-

10 Clean and Degrease Plant and Compressor

11 Decommissioning or Dispose Plant

17.05.2016 Rev. 001/kalajdzisa_a 2B1XC2.64_1 IM 200322en

IM 200322en 2B1XC2.64_1 Rev. 001/kalajdzisa_a 17.05.2016

1 Definitions for this Document

1.1 Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

18.05.2016 Rev. 001/kalajdzisa_a 2B1XC2.64_1 IM 200322en 1–1

1–2 IM 200322en 2B1XC2.64_1 Rev. 001/kalajdzisa_a 18.05.2016

Book Chapter Page Technical Date Description

If there have been necessary technical modifications, the present Instruc-

without our authorization.

1.3 Legal Disclaimer

18.05.2016 Rev. 001/kalajdzisa_a 2B1XC2.64_1 IM 200322en 1–3

1.4 Purpose of this Manual

The Instruction Manual must be read carefully before commissioning, as

1.4.2 Target Groups and Assumed Knowledge

Target group Description Tasks and responsibilities Chapter

1–4 IM 200322en 2B1XC2.64_1 Rev. 001/kalajdzisa_a 18.05.2016

1.5 Compressor Designation

Fig. 1-1 Example for compressor designation

1 Number of cranks 5 Cylinder lubrication:

1.6 Contact Address

Contact in Switzerland: Burckhardt Compression AG

18.05.2016 Rev. 001/kalajdzisa_a 2B1XC2.64_1 IM 200322en 1–5

1.7 Structure and Layout

1.7.1 Document Structure

1.7.2 Visual Elements

1.8 Term Cross Reference to API Standard

Designation according to API Designation according to

1–6 IM 200322en 2B1XC2.64_1 Rev. 001/kalajdzisa_a 18.05.2016

Designation according to API Designation according to

1.9 Warnings and Symbols

1.9.1 Level of Hazard Seriousness

1.9.2 Useful Information

18.05.2016 Rev. 001/kalajdzisa_a 2B1XC2.64_1 IM 200322en 1–7

1.9.3 Warning Symbols Used in this Instruction Manual

Common safety sign. Generally, the triangular warning

Whenever possible, the symbol indicates the hazard a person is exposed

Automatic start-up possible

Electrical danger or hazard

Machine under maintenance or overhaul

Flammable material or risk of fire

Potentially explosive atmosphere

Hot surface, don’t touch!

Pressurized vessel or pipe – depressurize plant before

Slip hazard – watch your step!

1–8 IM 200322en 2B1XC2.64_1 Rev. 001/kalajdzisa_a 18.05.2016

Corrosion hazard, avoid contact with caustic substances!

Risk of frost or low temperature