Ro-Flo Packaging Guidelines ENG

PACKAGING GUIDELINES FOR
RO-FLO® COMPRESSORS AND VACUUM PUMPS
MAY 2018
Ro-Flo Compressors, LLC

2540 West Everett St.
Appleton, WI 54914
United States of America
16-620-107-000 REV 02
TABLE OF CONTENTS
SAFETY INFORMATION 6
GENERAL INTENT 7
PACKAGER DESIGN REVIEW - GRATUITOUS ADVICE 7
PACKAGER RESPONSIBILITIES 8
UNDERSTAND THE COMPRESSOR DESIGN LIMITATIONS 8
UNDERSTAND THE CUSTOMER SPECIFICATIONS 8
PACKAGING QUALITY 8
PROVIDING THE CUSTOMER WITH NECESSARY INFORMATION 8
PROVIDE PROPER STORAGE 8
ITEMS PROVIDED BY RO-FLO COMPRESSORS 9
SKID DESIGN AND COMPRESSOR MOUNTING 10

COMPRESSOR WEIGHTS AND CENTER OF MASS 10
SKID MOUNTING 10
COMPRESSOR MOUNTING 10
COMPRESSOR OPERATING LIMITS 10
COMPRESSOR SYSTEM SOUND CONTROL 10
COMPRESSOR DRIVE 11
DRIVE SELECTION 11
Engine Drives 11
Electric Motor Drives 11
DRIVE ARRANGEMENTS 12
Direct Drive 12
Belt Drive 12
Belt Drive With Jackshaft 12
Two (2) Stage Compressor Train 12
Tandem Drive 13
GUARDS 13
COUPLINGS 13
COMPRESSOR ALIGNMENT 14
PIPING SYSTEMS AND VESSELS 15
Ro-Flo Compressors, LLC -3- 16-620-107-000 REV 02 (May 2018)

EQUIPMENT GROUNDING 15
INLET FILTERS 15
SEPARATOR VESSELS / DRIP LEGS 15
PROCESS PIPING 15
DISCHARGE CHECK VALVE 16
PRESSURE SAFETY RELIEF VALVE 16
GAS COOLERS 16
GAS RECYCLE (BYPASS) LOOP 16
LUBRICATION 18
LUBRICATION SETUP 18
COMPRESSOR LUBE RATE CALCULATION 20
Normal Lube Rate 20
Break-in Lube Rate 20
Compressor Lube Rate Calculation Example 20
OIL SYSTEM FOR DOUBLE BELLOWS TYPE & CARTRIDGE SHAFT SEALS 21
COMPRESSOR COOLING SYSTEM 22

OPEN LOOP COOLING 22
CLOSED LOOP COOLING 22
COOLANT FLOW REQUIREMENT 23
COOLING WATER CONTAMINANTS 23
COOLING WATER PRESSURE DROP 23
COOLING OF TWO STAGE SYSTEMS 23
INSTRUMENTATION AND CONTROL SYSTEM 24

SHUTDOWNS - MINIMUM RECOMMENDATIONS 24
ALARMS 24
LOCAL INDICATORS / GAUGES - MINIMUM RECOMMENDATIONS 24
INSTALLATION OF LOCAL INDICATORS / GAUGES 24
DRIVERS 24
LUBRICATION 24
COMPRESSOR COOLING JACKET 24
SEPARATORS (SCRUBBERS) 25
Ro-Flo Compressors, LLC - 4- 16-620-107-000 REV 02 (May 2018)

HEAT EXCHANGERS 25
AIR QUALITY MONITORING/GAS DETECTOR 25
OXYGEN (O2) SENSOR 25
DRY-OUT CYCLE 25
CONTROL STRATEGY 25
ASSEMBLY AND SHOP TESTING 26

START-UP, SERVICE, AND PARTS 27
APPENDIX I - EXPECTED SOUND PRESSURE LEVELS 28

APPENDIX II - EXAMPLE SINGLE STAGE BASIC P&ID 30
APPENDIX III - EXAMPLE SINGLE STAGE P&ID 32
APPENDIX IV - EXAMPLE SINGLE STAGE DOUBLE BELLOWS & DOUBLE OPPOSED CARTRIDGE
SEAL SUPPORT SYSTEM P&ID 34
APPENDIX VI - EXAMPLE TWO STAGE BASIC P&ID 36
APPENDIX VI - EXAMPLE TWO STAGE P&ID 38
APPENDIX VII - EXAMPLE TWO STAGE DOUBLE BELLOWS &
DOUBLE OPPOSED CARTRIDGE SUPPORT SYSTEM P&ID 40
CONTACT RO-FLO COMPRESSORS 42

GENERAL INQUIRIES 42
NEW COMPRESSOR AND VACUUM PUMP SALES 42
PARTS INQUIRIES 42
SERVICE AND SUPPORT 42

SAFETY INFORMATION
SAFETY INFORMATION
CAUTION
RO-FLO COMPRESSORS AND VACUUM PUMPS MUST BE OPERATED BY PROFESSIONALS TRAINED IN THE USE OF GAS
COMPRESSION EQUIPMENT.
PLEASE CONTACT YOUR SYSTEM INTEGRATOR / PACKAGER FOR TRAINING IN THE USE AND MAINTENANCE OF RO-FLO
COMPRESSORS AND VACUUM PUMPS AS APPLIED IN YOUR SYSTEM.
CAUTION
READ AND UNDERSTAND THE OPERATOR’S MANUAL BEFORE USING THIS COMPRESSOR. IT IS ESSENTIAL TO REFER TO THE
PACKAGER'S OPERATING MANUAL FOR COMPLETE OPERATING INSTRUCTIONS.
FAILURE TO FOLLOW OPERATING INSTRUCTIONS MAY RESULT IN SERIOUS INJURY OR DEATH.
Read this document carefully before installing and starting your compressor.
The following instructions have been prepared to assist in installation, operation, and maintenance of your Ro-Flo® sliding vane compressor. Fol-
lowing these instructions and those provided for the compressor package will ensure a long operational life for your equipment.
The entire manual should be reviewed before attempting to install, operate, service, or repair the compressor.
Ro-Flo® sliding vane compressors are positive displacement style compressors, which are designed to compress gas. The compressor must not be
subjected to liquids in the inlet gas stream. Ro-Flo Compressors, LLC is not responsible for the system design to prevent liquid in the gas stream,
and as such Ro-Flo Compressors, LLC cannot warrant equipment damaged by improperly protected or operated equipment.
CAUTION
PERSONAL PROTECTIVE EQUIPMENT (PPE) SHOULD BE USED TO AVOID HEALTH HAZARDS (EXCESSIVE SOUND LEVEL
EXPOSURE) DUE TO HIGH NOISE LEVEL DURING NORMAL OPERATION.
IT IS RECOMMENDED THAT THE CUSTOMER ESTABLISH AN EHS PLAN TO AVOID AN EXPOSURE RISK IN EXCESS OF
PERMISSIBLE EXPOSURE LIMIT (PEL) AS DEFINED BY THE OCCUPATIONAL SAFETY & HEALTH ADMINISTRATION (OSHA) OR
OTHER REGULATING BODY.
CAUTION
THE INFORMATION CONTAINED WITHIN IS INTENDED TO ASSIST OPERATING PERSONNEL BY PROVIDING INFORMATION ON
THE GENERAL CHARACTERISTICS OF EQUIPMENT OF THIS TYPE. IT DOES NOT RELIEVE THE USER OF RESPONSIBILITY TO USE
SOUND ENGINEERING PRACTICES IN THE INSTALLATION, APPLICATION, AND MAINTENANCE OF PARTICULAR EQUIPMENT
PURCHASES.

GENERAL INTENT
GENERAL INTENT
These standards are presented as our guidelines and recommendations
to PACKAGERS for use when designing and installing Ro-Flo® com-
pressors on a packaged unit.
Ro-Flo® sliding vane compressors are normally installed on a structural

steel skid with major components, accessories, on-skid piping, controls,
and alignment completed by a PACKAGER. Skid mounting is by far the
most common arrangement used. The unit is shipped to the site as a com-
plete package ready for installation per the PACKAGER's instructions.
Proper installation is important to the successful operation of the unit.
A PACKAGER is defined as any Ro-Flo Compressors authorized party

incorporating a Ro-Flo® compressor into the manufacture or assembly
for an END USE CUSTOMER.
This STANDARD is not intended to be an engineering data book. It is a

guide and does not supersede customer specifications that meet or
exceed its intent. Ro-Flo Compressors, LLC recognizes that there are
many technically acceptable ways to package compressors.
This STANDARD has been devised as a unit and is not intended to be split
up and distributed in sections. All departments in the PACKAGER's organ-
ization need to be aware of the entire contents.
The wide range of possible uses of Ro-Flo® compressors will periodically

make certain deviations from these STANDARDS necessary. It is the
PACKAGER’s responsibility to insure these deviations are acceptable to
Ro-Flo Compressors, LLC.
PACKAGER DESIGN REVIEW - GRATUITOUS ADVICE

On the occasion of a new PACKAGER relationship, or a new design of a
compressor skid, or in the normal course of business, it is the practice of
Ro-Flo Compressors to offer to review the PACKAGER's design at no
charge to the PACKAGER, and offer advice on overall package design.
On these occasions, this advice is given as Gratuitous Advice.
Gratuitous Advice: If Ro-Flo Compressors furnishes the

PACKAGER with advice or assistance concerning the products,
systems, or work which is not required pursuant to the pur-
chase agreement, the furnishing of such advice or assistance
will not subject Ro-Flo Compressors to any liability, whether in
contract, tort, warranty, indemnity, negligence, strict liability, or
otherwise.

PACKAGER RESPONSIBILITIES
should work with the END USE CUSTOMER to define present and
PACKAGER RESPONSIBILITIES future conditions with regard to:
The PACKAGER must maintain engineering, sales, and service per-
sonnel properly trained by Ro-Flo Compressors to effectively sell, design, A. Design point conditions and any possible alternate conditions.
B. Gas composition, so any special gas components may be iden-
manufacture, maintain, and repair Ro-Flo® compressors.
tified and addressed properly. Special attention should be given to
In addition to the above items, it is the PACKAGER's responsibility to: corrosive characteristics and gas dew point.
C. Site conditions, including site elevation, ambient temperatures,
UNDERSTAND THE COMPRESSOR DESIGN dust, humidity, rainfall, wind velocity, soil conditions, and seismic
LIMITATIONS conditions, seasonal changes in all conditions, and the impact of
these conditions on the package design.
It is the PACKAGER's responsibility to ensure that free liquids in the gas
D. Duty cycle of the compressor operation and its impact on selection
stream are removed to prevent damage to the compressor and ensure
and design of the compressor package and its components.
long operational life. E. Available sources for cooling medium.
PACKAGING QUALITY
WARNING A compressor package's reputation is shared by the PACKAGER, Ro-
Free liquids are the #1 cause of compressor problems & failure. Flo Compressors, and the driver manufacturer, but not always in equal
proportions. A successful package blends precision component selec-
System pressures and temperatures should not exceed maximum allow- tion, design, fabrication, sales, and service. It is Ro-Flo Compressors
able compressor limits. Drivers should be selected so the delivered power intent to lead the industry in performance and reputation. Ro-Flo Com-
does not exceed the compressor shaft horsepower limitations. Design con- pressors and PACKAGER's must work together to meet this expect-
ditions must be provided with the compressor purchase order. ation. This document is intended as a minimum requirement for
The PACKAGER should maintain and use the most current version of the packaging quality. However, the PACKAGER is encouraged to exceed
Ro-Flo Performance software and/or seek assistance from Ro-Flo Com- this standard in providing only the finest packages for the END
pressors for selecting compressors and compressor options or evaluating USE CUSTOMER.
field operating conditions.
PROVIDING THE CUSTOMER WITH NECESSARY
Note: Although the Ro-Flo Performance software is a com- INFORMATION
prehensive tool for Ro-Flo® compressors, the PACKAGER is Provide the END USE CUSTOMER with performance data sheets for
encouraged to use more advanced thermodynamic gas property the intended operating conditions from the Ro-Flo Performance soft-
analysis programs for flash analysis and thermodynamic prop- ware, the Ro-Flo Installation, Operation, and Maintenance Manual, and
erty calculation. adequate instructions so the compressor system can be operated prop-
erly and safely.
When reconfiguring older components or legacy equipment, be aware
that they may have different design limits than equipment of today's cur-
PROVIDE PROPER STORAGE
rent design. Always get serial numbers and check with Ro-Flo Com-
pressors for correct operating limits. The PACKAGER must provide clean, dry storage for all compressors
and parts held in inventory.
UNDERSTAND THE CUSTOMER SPECIFICATIONS
New Ro-Flo® compressors are shipped with a vapor-phase corrosion
The PACKAGER is responsible for ensuring that the package meets all inhibitor (VpCI). This is suitable for storage of equipment for 1 year if all
laws and statutes of where the equipment will be manufactured, installed, shipping covers are left intact. If the shipping covers are removed, new
and operated. VpCI or other means of preservation need to be applied.
The compressor must be selected for the specific operating char- During compressor package construction it is common to remove the
acteristics of the process. Actual gas flows, pressures, and temperatures compressor shipping covers for installation of piping, etc. Care must be
are required so that the optimum operating speed, drive power, and lub- taken to prevent debris from entering the system. In addition, the com-
rication characteristics can be selected. The PACKAGER must provide or pressor package must be suitably preserved to prevent compressor cor-
verify that Ro-Flo Compressors, LLC has the correct design conditions. rosion.
Ro-Flo Compressors, LLC rating plates are stamped with rated per-
formance information. Failure to provide correct design conditions could When applicable, the factory recommended procedures for long-term
void the compressor warranty. storage must be followed. Long term storage procedures are available
in the Ro-Flo Installation, Operation, and Maintenance Manual.
The PACKAGER should understand the END USE CUSTOMER's spe-
cifications and make exceptions where necessary. The PACKAGER

PACKAGER RESPONSIBILITIES
ITEMS PROVIDED BY RO-FLO COMPRESSORS

The following information is available from Ro-Flo Compressors:
1. Ro-Flo Packaging Guidelines

2. Ro-Flo Installation, Operation, and Maintenance Manual
3. Ro-Flo Parts Book
4. Ro-Flo® General Arrangement Drawings
5. Compressor Performance Data Sheet(s), either generated by the
PACKAGER or Ro-Flo Compressors. The Performance Data
Sheet includes the following information:
a. Required operating power and speed
b. Recommended coolant flow rate
c. Recommended lubrication rate and viscosity
The following services are also available from Ro-Flo Compressors.
l Witnessed Hydrostatic Test

l Witnessed Pneumatic Leak Test
l Helium Leak Test
l Material Certificates
l Certificate of Conformance
l Rotor Balancing
l Mechanical and Performance Tests
Please contact your sales representative for more information.

SKID DESIGN AND COMPRESSOR MOUNTING
SKID DESIGN AND COMPRESSOR COMPRESSOR OPERATING LIMITS

The maximum allowable working temperature (MAWT) for all Ro-Flo®
MOUNTING compressor models is 350 °F (176 °C).
Package design is the responsibility of the PACKAGER.
The maximum allowable working pressure (MAWP) for Ro-Flo® com-
Package design and fabrication should be conducted within the following pressors are listed in TABLE 1. The user should refer to doc-
guidelines. This guideline does not replace good engineering practice, umentation provided by the PACKAGER as the compressor may not be
other engineering specifications (such as ASME, API, etc.), or local reg- the lowest MAWP component in the system. Application conditions may
ulations or standards. If a conflict does arise this should be reviewed with limit the discharge pressure to a value less than the MAWP.
Ro-Flo Compressors to provide guidance.
TABLE 1 - Compressor Maximum Allowable Working Pressure
Equipment should be arranged on the skid to provide easy access to the (MAWP)
compressor and other components for maintenance and inspection. The
PACKAGER is referred to the compressor General Arrangement draw- 80 PSIG DISCHARGE 150 PSIG DISCHARGE
ings for recommended service access for Ro-Flo® compressors. The skid MODEL MAWP (psig) MODEL MAWP (psig)
should also be arranged to provide proper access for lifting devices for ser- 2CC 80 206 150
vicing compressor components or other components of the compressor 4CC 80 207 150
system. 5CC 80 208B 150
7D 80 210M 150
COMPRESSOR WEIGHTS AND CENTER OF MASS
8D, SD8D 80 211M 150
Please refer to the general arrangement drawings for your specific com-
8DE, SD8DE 80 212M 150
pressor model for weight and center of mass information. The general
10G 80 217M 150
arrangement drawings and 3D CAD models are available from Ro-Flo
Compressors, LLC upon request. 11S 80 219M 150
11L 80
SKID MOUNTING 12S 80 200 PSIG DISCHARGE
The skid should be rigid enough to prevent twisting due to the torque 12L 80 HP6, HP7, HP8 200
between the driver and the compressor. The skid should be stiff enough to 17S 80 HP10 200
assure reasonable retention of alignment between the driver and the com- 17L 80 HP11 200
pressor when the package is being moved. Final alignment of the com- 19S, SD19S 80 HP12 200
pressor and driver is required upon package installation. The suggested
19L, SD19L 80
procedures for alignment are described in the Ro-Flo Installation, Oper-
19LE, SD19LE 80
ation, and Maintenance Manual.
The skid should provide sufficient mass to absorb vibration transmitted by

the compressor and motor. Ro-Flo® rotary sliding vane compressors pro- COMPRESSOR SYSTEM SOUND CONTROL
duce relatively low vibration levels (as compared to other compressors). The compressor PACKAGER should consider sound control in the
design of the compression system. Ro-Flo® compressor and vacuum
It is recommended that the compressor skid be grouted in location to
pump expected sound characteristics are available in "Appendix I -
absorb vibration and transmit compressor forces.
Expected Sound Pressure Levels".
COMPRESSOR MOUNTING
The PACKAGER is responsible for designing compressor hold down bolt-
ing. Properly designed bolting should consider the following aspects of the
design:
l Bolt length
l Bolt grade
l Skid construction
l All loads acting on the compressor (including gas forces)
In general, it is recommended that AISI 4140 studs be used to secure the

compressor to the skid. These typically extend through full frame mem-
bers.

COMPRESSOR DRIVE
TABLE 2 - Compressor Operating Speed Range.

COMPRESSOR DRIVE
Ro-Flo® compressors are suitable for use with electric motor or engine MINIMUM MAXIMUM
MODEL
drives. Ro-Flo® compressors may be either direct coupled or belt driven. SPEED (RPM) SPEED (RPM)
An application review is required to determine if it is possible to use a belt 2CC, 4CC, 5CC 865 2200
drive (due to belt pull loads on the compressor). 7D 690 1465
8D, 8DE 600 1465
DRIVE SELECTION
SD8D, SD8DE 600 1465
The compressor drive should be selected taking into consideration any 10G 450 1300
losses associated with power transmission (belt drive systems, gear
11S, 11L 400 1000
boxes, etc.).
12S, 12L 380 920
The PACKAGER is responsible for ensuring the driver is capable of devel- 17S, 17L 310 760
oping sufficient torque to overcome compressor starting requirements. It 19S, 19L, 19LE 275 640
is recommended that the drive produce a minimum torque of 108% of the SD19S, SD19L,
required operating torque of the compressor, when started against full dis- 275 640
SD19LE
charge pressure. 206, 207, 208B 600 1465
A variable speed driver will allow for utilization of the Ro-Flo® com- HP6, HP7, HP8 600 1465
pressors turn down capability to control flow rate. Compressor operating 210M, HP10 450 1300
speed ranges are shown in TABLE 2. It should be noted that these are 211M, HP11 400 1000
minimum and maximum operating speeds, however, the compressor 212M HP12 380 920
speed may be further limited by the application conditions. 217M 310 760
219M 275 640
Variable speed controllers should be equipped with stops to prevent oper-
ation above or below the corresponding maximum and minimum oper-
ating speeds of the compressor.
Ro-Flo® compressors are constant torque machines throughout their

operating speed range for a given set of operating conditions.
Engine Drives
For direct-coupled engine drive arrangements, a torsional vibration ana-
lysis is required for selection of flywheel and coupling. Please contact Ro-
Flo Engineering for rotor mass moment of inertia and stiffness inform-
ation.
Electric Motor Drives

It is generally recommended that if single speed electric motors are used,
that a "soft start" system be used. For variable speed drives, it is recom-
mended that the motor be an inverter duty motor, as these typically are
capable of providing constant torque throughout a specified speed range.
If the compressor will have start/stop operation (typically controlled by a

pressure switch), the PACKAGER must review the application with the
motor vendor to determine the acceptable number of start/stops per hour.
Ro-Flo Compressors, LLC - 11 - 16-620-107-000 REV 02 (May 2018)

COMPRESSOR DRIVE
DRIVE ARRANGEMENTS and jackshaft is checked in the same manner as with direct drive units.
There are numerous methods to provide power to Ro-Flo® compressors.
This section will cover some of the more common drive arrangements.
Direct Drive
The most common configuration is to have the driver directly coupled to
the compressor.
FIGURE 3 - Typical arrangement for belt drives with pedestal bear-

ings and a jackshaft.
Two (2) Stage Compressor Train

FIGURE 4 shows a typical 2 stage compressor train driven by one elec-
FIGURE 1 - Compressor directly coupled to electric motor. tric motor.
Belt Drive
Belt drive design must be determined by the compressor operating con-
ditions and belt manufacturer. The belt manufacturer will define tension
levels and belt operating limits. The loads predicted by the belt drive man-
ufacturer should be reviewed with the Ro-Flo Performance software to
determine if a jackshaft arrangement is required.
Cog (toothed) drive belts typically generate lower belt pull forces, which
reduce the side loads on compressor bearings and rotor.
FIGURE 4 - Typical 2 stage compressor train drive arrangement.
FIGURE 2 - V-belt drive with sheave mounted directly on compressor

shaft.
Belt Drive with Jackshaft

FIGURE 3 illustrates a typical jackshaft arrangement, which eliminates
excessive belt load on the compressor. Alignment between compressor

COMPRESSOR DRIVE
Tandem Drive COUPLINGS

Tandem units (2 compressors driven by a double shaft extension motor) All direct coupled units (engine or electric motor) should use a tor-
should have torque controlling couplings (dry powder, friction disc., etc) to sionally rigid coupling. Spacer couplings should be used to allow easy
avoid excessive starting torque on the compressor shaft when one com- access to the compressor for maintenance. For recommended allow-
pressor is uncoupled. ance for maintenance, please refer to the compressor General
Arrangement drawings available on the Ro-Flo Compressors web-
site:
www.roflocompressors.com.
All Ro-Flo® compressors have a straight shaft with a keyway. Com-

pressor shaft dimensions can be found in TABLE 3.
TABLE 3 - Compressor shaft dimensions.
NOMINAL
SHAFT DIAMETER @ SQUARE
MODEL COUPLING KEYWAY
DIMENSION
inch inch
FIGURE 5 - Tandem drive arrangement, with an electric motor between 2CC, 4CC, 5CC +0.000
1.250 0.25
two Low Pressure model compressors. −0.001
+0.000
7D 1.625 0.375
GUARDS −0.001
The PACKAGER shall provide adequate coupling / belt guards that are in +0.000
8D, 8DE 1.625 0.375
compliance with local regulations. −0.001
+0.000
SD8D, SD8DE 1.875 0.500
−0.001
+0.000
10G 2.625 0.625
−0.001
+0.000
11S, 11L 3.000 0.750
−0.001
+0.000
12S, 12L 3.000 0.750
−0.001
+0.000
17S, 17L 3.500 0.875
−0.001
+0.000
19S, 19L, 19LE 3.500 0.875
−0.001
SD19S, SD19L, +0.000
4.000 1.000
SD19LE −0.001
+0.000
206, 207, 208B 1.625 0.375
−0.001
+0.000
HP6, HP7, HP8 1.875 0.500
−0.001
+0.000
210M, HP10 2.625 0.625
−0.001
211M, 212M, +0.000
3.000 0.750
HP11, HP12 −0.001
+0.000
217M, 219M 3.500 0.875
−0.001

COMPRESSOR DRIVE
COMPRESSOR ALIGNMENT
For direct-coupled drive arrangements, angular, parallel, and axial align-
ment between the compressor and driver must be maintained. The pack-
age design should allow for ease of alignment adjustment in the field. This
is normally accomplished with shims and jackscrews on the mounting feet
of the driver. Refer to "Compressor Alignment" on page 14 for alignment
tolerances.
Realignment should be completed upon compressor package installation

and following compressor package transportation. Failure to assure
proper shaft alignment on coupling drive units will result in excessive noise,
coupling wear, and/or bearing damage. Improper shaft alignment for belt
driven units may result in belt slippage and/or unequal belt wear, which
may result in shortened belt life.
Refer to FIGURE 6, FIGURE 7, and FIGURE 8 illustrating angular and FIGURE 8 - Checking angular alignment with dial indicator on coupling
parallel misalignment and the dial indicator method for checking these. It is face.
important to rotate both shafts simultaneously to avoid errors due to sur-
face imperfections of the coupling hubs. Note that each shaft revolution
the coupling will flex for the combined parallel and angular misalignment.
The sum of these may be considered as the overall shaft misalignment.
Parallel and angular alignment of the compressor and driver should be

within 0.006 inch or the coupling limits, whichever is less.
FIGURE 6 - Angular misalignment, parallel misalignment, and axial

capacity illustrated.
FIGURE 7 - Checking parallel alignment with dial indicator on coupling

flange.

PIPING SYSTEMS AND VESSELS
PIPING SYSTEMS AND VESSELS PROCESS PIPING

Extreme care must be taken during piping and fabrication to insure
A properly designed piping system is critical to successful compressor
that contaminants such as grinding dust, weld slag, and rain do not
operation. The following features described in this section have been suc-
get into the compressor or process control valves. Suction pipe intern-
cessfully employed in Ro-Flo® compressor system designs. The following
als must be cleaned. A 16-mesh start-up screen (witch's hat) should
items are illustrated in FIGURE 10, "Appendix III - Example Single Stage
be installed near the compressor suction flange. The screen can be
P&ID" on page 32, and "Appendix VI - Example Two Stage P&ID" on
removed when debris stops accumulating.
page 38.
All mating flanges on compressor inlet and discharge must be flat-
It is the PACKAGER’s responsibility to insure compliance with all state and
faced design with full-face gaskets. RAISED FACE OR RING JOINT
local codes applicable to the particular installation.
FLANGES SHOULD NEVER BE USED ON THESE
CONNECTIONS.
EQUIPMENT GROUNDING
All equipment and the piping system should be grounded to prevent elec- The process piping should be straightforward in its arrangement and
trostatic charge accumulation. when possible sized equal to or larger than the flange connection
sizes on the compressor.
INLET FILTERS
When possible piping should be designed / fabricated with a slight
Inlet filters are required where gas streams contain particulate matter or
slope to drain liquids away from the compressor (especially during
debris. The filter should be designed to remove at least 90% of all dirt
shutdown). Provision must be made to drain accumulated liquids from
particles (10 microns or larger) from the inlet gas stream. Pressure drop
any possible collection points prior to start-up. Drains and drip legs for
through a filter will increase due to contamination and should be accoun-
oil and liquid accumulation are recommended as shown in FIGURE
ted for during equipment selection.
9, on both the suction and discharge piping.
SEPARATOR VESSELS / DRIP LEGS For applications with low gas flow rates, consideration should be
Properly sized separators (scrubbers) must be installed prior to each given to placement of drains, drip legs, & separator vessels, as the
stage of compression. It is the responsibility of the PACKAGER to size and gas velocity may be insufficient to carry liquids away from the com-
select these items. pressor.
WARNING CAUTION
Liquid ingestion in the compressor can result in catastrophic failure. Consideration for liquid drains from the piping should take into
account not only during operation, but also shut down conditions
where process piping has an opportunity to cool, thereby, allowing
Ro-Flo® compressors can tolerate mist or small droplets of liquid, how- additional condensate to form.
ever, the best operating life will occur if all free liquids are removed from
the gas stream. Large quantities of liquid (commonly referred to as a liquid
slug) may result in catastrophic failure. Piping connected to the compressor should be adequately supported
and aligned such that minimal stress is transmitted to the com-
Inlet separators should be located as close to the compressor inlet as feas- pressor/piping connection. Piping stress analysis shall consider
ible to minimize potential liquid formation between the separator vessel thermal loads, gas loading forces, and piping system weight. See
and compressor. TABLE 4 for allowable flange loading for Ro-Flo® com-
pressors/vacuum pumps. Additionally, the piping must have an
Depending on the discharge piping configuration it may be desirable to
adequate number of elbows, tee’s and spool pieces to permit their
have a separator vessel near the compressor discharge to remove liquids
removal for accessibility to the compressor for service. Stud lengths
that may form in the discharge piping due to the cooling of the process
should be selected so that a minimum of one full thread is exposed on
gas. Depending on piping configuration and gas velocities, these free
the stud when the nut is properly torqued.
liquids may flow back into the compressor.
The locations for gas temperature and pressure instrumentation con-
The separator vessels and drip legs should be equipped with automatic
nections, both inlet and discharge, should be as close as possible to
drain valves . It may be necessary to have drain pumps to remove accu-
the compressor flanges. The discharge temperature indicator
mulated liquid depending on the pressure differentials between the pro-
gauges and switches will be most effective if they are placed either in
cess and drain system. It is also necessary to have level switches for high
the compressor inspection openings or in the piping immediately
level alarm and high-high shutdown.
downstream of the compressor.

For installations in cold climates it may be necessary to insulate piping to allowable working pressure of the compressor. Normal engineering
maintain proper process gas temperatures to ensure the process gas practice (ASME Code) requires the valve to be set at 7 PSI or 10%
remains in vapor phase until liquids can be properly managed. above the operating pressure, whichever is greater. The safety relief
valve should NOT be used as a process control device and is meant for
TABLE 4 - Loading Limits on Ro-Flo® Suction and Discharge Flanges emergency situations only.
SUCTION SUCTION DISCHARGE
FLANGE
DISCHARGE
FLANGE FLANGE
GAS COOLERS
MODEL DIA.
FLANGE DIA.
Fx,y,z Mx,y,z Fx,y,z Mx,y,z There are many acceptable styles of gas coolers (vertical or horizontal,
(in) (in) (lbs) (ft-lbs) (lbs) (ft-lbs) gas-to-air, gas-to-water, etc.) for compression applications, however,
2CC 2 1.5 100 1190 75 970 all designs should allow for drainage of liquids formed in the cooler.
4CC 2 1.5 100 1190 75 970
Two-stage Ro-Flo® systems generally require intercooling (between
5CC 2 1.5 100 1190 75 970
the first and second stage) to insure a second-stage gas discharge tem-
7D 3 3 150 1500 150 1500 perature of 350 ºF or less.
8D, SD8D 4 3 200 1670 150 1500
8DE, SD8DE 4 3 200 1670 150 1500 Separators should be provided after any gas cooler.
10G 5 4 250 1670 200 1670
GAS RECYCLE (BYPASS) LOOP
11S 6 5 300 1670 250 1670
11L 6 5 300 1670 250 1670 If a recycle (bypass) loop is required, the gas should be cooled prior to
return to suction. This will prevent overheating of the compressor due to
12S 8 6 400 1670 300 1670
recirculation of hot gas. The gas bypass loop must enter the gas piping
12L 8 6 400 1670 300 1670
upstream of the inlet separator to remove any free liquids.
17S 8 6 400 1670 300 1670
17L 8 6 400 1670 300 1670 When sizing coolers for bypass conditions, assume 100% bypass con-
19S, SD19S 10 8 500 1670 400 1670 dition (100% of volume being returned to suction).
19L, SD19L 10 8 500 1670 400 1670
19LE,
10 8 500 1670 400 1670
SD19LE
206, HP6 3 2* 150 1500 80 970
207, HP7 3 2* 150 1500 80 970
208B, HP8 3 2* 150 1500 80 970
210M, HP10 4 2.5* 200 1670 100 1375
211M, HP11 5 3* 250 1670 120 1500
212M, HP12 6 4* 300 1670 160 1670
217M 6 4* 300 1670 160 1670
219M 8 4* 400 1670 160 1670
* Vertical Orientation (top Discharge)
DISCHARGE CHECK VALVE

A process gas check valve is required after each compressor. This dis-
charge check valve should be mounted as close as possible to the com-
pressor discharge outlet to prevent reverse flow (and potentially reverse
rotation) when the compressor is shut down.
The discharge check valve is to be installed in the discharge line as close to

compressor discharge flange as possible, but after all protection devices
such as the safety valve and temperature/pressure sensors.
PRESSURE SAFETY RELIEF VALVE

A gas pressure safety relief valve is required on the discharge side of the
compressor before any other valve, set to operate at not more than the

HIGH PRESSURE MODELS LOW PRESSURE MODELS

206 THRU 219M 4CC, 5CC, & 7D
COOLANT INLET
COOLANT INLET
COOLANT DISCHARGE
COOLANT DISCHARGE
GAS
DISCHARGE
GAS GAS GAS
SUCTION SUCTION DISCHARGE
ALTERNATE
LOW POINT DRAIN COMPRESSOR CASING DRAIN COOLANT INLET
LOCATION
LOW PRESSURE MODELS LOW PRESSURE MODELS

COOLANT INLET
8D THRU 10G 11S THRU 19LE COOLANT INLET
COOLANT DISCHARGE
COOLANT DISCHARGE
GAS GAS
DISCHARGE DISCHARGE
GAS ALTERNATE ALTERNATE ALTERNATE ALTERNATE

SUCTION CASING DRAIN GAS
COMPRESSOR CASING DRAIN COOLANT INLET SUCTION COMPRESSOR CASING DRAIN COOLANT INLET CASING DRAIN
LOCATION LOCATION LOCATION LOCATION
FIGURE 9 - Ro-Flo® cylinder drain locations and arrangements. (Note:

All pipe & valve positions shown for clarity only, customer configuration
may differ per application.)
11 9 17
18
6 COOLANT
DISCHARGE
6
7 19 7 2
8
10
GAS
14 3
DISCHARGE
4 GAS
1 14 6 INLET
8
5
18 12
TO DRAIN
TO DRAIN
18
LEGEND
1. RO-FLO COMPRESSOR 13 6
2. DRIVE MOTOR
3. COUPLING
18 8
4. LUBRICATOR
5. INLET SCRUBBER 16 VENT
6. PRESSURE GAUGE w/BLOCK & BLEED VALVE TO SAFE
7. HIGH TEMPERATURE LIMIT SWITCH 15
8. TEMPERATURE GAUGE LOCATION
9. CHECK VALVE
10. AFTERCOOLER
11. DISCHARGE SEPARATOR
12. SAFETY RELIEF VALVE COOLANT INLET TO DRAIN
13. GAS RECYCLE CONTROL VALVE
14. ISOLATION VALVE
15. COOLANT SOLENOID VALVE
16. COOLANT STRAINER
17. COOLANT FLOW REGULATOR
18. SHUTOFF VALVE
19. TWO WAY THERMOSTATIC CONTROL VALVE
FIGURE 10 - Typical piping arrangement - open loop cooling system

shown. (Note: All pipe & valve positions shown for clarity only, customer
configuration may differ per application.)

LUBRICATION
LUBRICATION
!"#! $%$
Proper lubrication is required for successful compressor operation and
component life.
The PACKAGER shall select a block-type lubricator to insure that proper

flow will be provided to all points on the compressor under all operating
conditions, including the initial compressor break-in period. The break-in &'!$ ()*+,- ./,,0.(+/, &'!$ 1,2(
lube rate should be double the normal lube rate for the first 300 hours of
operation. Ideally, lubrication should be injected approximately 3 (or
more) times per minute. The lubrication cycle rate should not be more FIGURE 12 - Inlet Lubrication Quill.
than 1 minute between injection cycles.
Oil lubrication tubing should be adequately sized and supported.

TABLE 5 - Compressor Lubrication Accessories
In cold climates, heaters and thermostats within the lubricator reservoir
LUBRICATOR DRIVE
may be necessary to ensure proper oil viscosity. Use multi-viscosity or low INLET LUBRICATION QUILL
SHEAVE
viscosity grade oil in cold locations (below 32 ºF.). Lubricator must be NUMBER
Quill
MODEL OF LUBE Pitch Dia-
weather proof for outdoor locations. POINTS Length
Part Number meter Part Number
(inches)
(inches)
Refer to the compressor General Arrangement drawings for identification (“A” Dim.)
of all lubrication points on the compressor. 2CC, 4CC
5 3 16-630-888-034 3 16-132-506-501
5CC
The lubrication system must have provisions to shutdown the compressor
7D 7 4 16-630-888-035 3 16-132-506-502
when a no-flow condition exists.
8D, SD8D
Lubrication tubing must be clean and free of any debris. 8DE, 7 5 16-630-888-038 3 16-132-506-502
SD8DE
Lubrication rates vary directly with compressor speed. If a fixed speed lub- 10G 7 5 16-630-888-038 4 16-132-492-503
ricator is used (example: separate motor), the lubrication rate should be 11S, 11L 8 N/A N/A 5 16-132-534 501
set for the highest compressor operating speed.
12S, 12L 9 6 16-630-888-036 5 16-132-534-501
The lubrication system must be primed at the check valves on the com- 17S, 17L 9 6 16-630-888-036 5 16-132-399-501
pressor, prior starting the compressor. Pre-lube is not required prior to 19S,
starting the compressor. SD19S,
19L, (2 required) 16-
LUBRICATION SETUP 10 8 5 16-132-399-501
SD19L, 630-888-037
Ro-Flo Compressors recommends check valves at all lubrication points. SD19LE,
Ro-Flo Compressors offers the following lubrication components. 19LE
206, HP6
207, HP7
7 3 16-630-888-034 3 16-132-506-502
!"!# 208B,
HP8
210M,
7 4 16-630-888-035 4 16-132-492-503
HP10
$%!& '()* +,'',-. /0--*/',0-
211M,
HP11,
$%!& 1-2' 7 5 16-630-888-038 5 16-132-534-501
212M,
HP12
217M,
FIGURE 11 - Angled Double Check Valve for compressor lube points. 7 6 16-630-888-036 5 16-132-399-501
219M
* For detailed information on lubrication point locations refer TABLE 6
and FIGURE 13.

LUBRICATION
TABLE 6 - Oil injection points and approximate lubrication rates. The lub- TABLE 7 - Lubrication Rate Multiplier
rication rates listed in this table are for compressors operating on air at
maximum operating speed. Gas/Vapor Handled Multiplier
For air and dry inert gases 1.0
Lubrication Quantity Pints Approximate Water vapor, wet non-corrosive gases and vapors
Model Injection Of Lube Per Hr Drops/Min Per 1.1
Points Points Total Lube Point* Condenser service
2CC 4CC Refrigeration, sweet natural gas, methane, ethane,
1-2-7-14-15 5 .09 5 1.2
5CC propane, butane
1-2-3-4-7-14- Sour natural gas, sludge gas, heavy hydrocarbons
7D 7 .15 6 1.5
15 (pentane & heavier)
8D, 8DE, Vapor recovery, solvents, acids, ketones 2.0
1-2-5-6-7-14- Gasoline vapors 4.0
SD8D, 7 .19 7
15
SD8DE
1-2-11-12-7-
10G 7 .29 10
14-15
1-2-3-4-5-6-
COMPRESSOR LUBRICATION INJECTION POINTS
11S 8 .28 9 (INLET SIDE SHOWN)
28-29
1-2-3-4-5-6-
11L 8 .35 11 LOW PRESSURE MODEL
28-29
1-2-3-4-5-6-7- 14 3 5 9 7 8 6 4 15
12S 9 .36 10 27
28-29 26
1-2-3-4-5-6-7- 2
12L 9 .36 10
28-29
1-2-3-4-5-6-7-
17S 9 .37 10
28-29
1 2*
1-2-3-4-5-6-7-
17L 9 .45 12 10 13
28-29
29 11 12 28
19S, 1-2-8-9-10-11-
10 .42 10
SD19S 12-13-28-29
HIGH PRESSURE MODEL
19L, 19LE,
1-2-8-9-10-11-
SD19L, 10 .50 12 24 19 22 20 25
12-13-28-29
SD19LE
17 18
206, 207,
17-18-19-20-
208B, HP6, 7 .15 5
30-31-32
HP7, HP8
210M, 17-18-19-20-
7 .17 6
HP10 22-30-31
32
211M, 17-18-19-20-
7 .24 9
HP11 22-24-25 30 31
212M, 17-18-19-20-
7 .24 9
HP12 22-24-25
FIGURE 13 - Compressor lubrication injection points, inlet side
17-18-19-20- shown. For more specific locations see the compressor general
217M 7 .29 10
22-24-25 arrangement drawings available on the Ro-Flo Compressors web-
17-18-19-20- site.
219M 7 .29 10
22-24-25
*Assumes 14,000 drops per pint. Lubricator manufacturers use different
standard drops per pint which will affect the above drops/min lubrication
rate. See lubricator manufacturer’s manual for more information.

LUBRICATION
COMPRESSOR LUBE RATE CALCULATION

Normal Lube Rate
The following formula can be used to calculate the correct lubrication rate
for your compressor application:
Operating Speed
Lube Rate = Pints per hour × × Gas Multiplier
Compressor Max Speed
Pints per Hour from TABLE 6
Gas Multiplier from TABLE 7
Compressor Max Speed from TABLE 2 on page 11
Break-in Lube Rate

The break-in lubrication rate is double the normal operating lubrication
rate for the first 300 hours of operation when the compressor is new or
after a major overhaul.
Break in Lube Rate = 2 X Lube Rate
Compressor Lube Rate Calculation Example

Below is an example calculation for the calculation of the compressor lube
rate. The operating parameters for this lube rate calculation are:
l Ro-Flo model 10G

l Operating Speed 950 RPM
l Vapor recovery Service
With the information above we can determine the following:
l From TABLE 6, the base lube rate for a Ro-Flo® model 10G is
0.29 pints/hour.
l From TABLE 7, the gas multiplier is 2.0.
l From TABLE 2 on page 11 maximum compressor operating
speed is 1300 RPM.
Using the above equation we obtain:
950 RPM
Lube Rate = 0.29 pints / hr × × 2.0
1300 RPM
Lube Rate = 0.42 pints / hr
The above lube rate is the recommended lube rate for the compressor
running with the stated operating conditions. All operating conditions
should be considered when setting the lubrication rate.
The break-in lube rate is double the normal lube rate:

Break in Lube Rate = 0.84 pints / hr

LUBRICATION
OIL SYSTEM FOR DOUBLE BELLOWS TYPE & The upper connection of the oil reservoir should be connected to the
CARTRIDGE SHAFT SEALS top of the seal cage. For low pressure models use the connection
nearest the compressor suction flange. For high pressure models use
The double bellows shaft seal oil system is designed to keep the seal parts the connection nearest the compressor discharge flange.
submerged in oil and to maintain the pressure on this oil. If leakage occurs
at the outer seal, it will be towards the atmosphere and air will not be Use a minimum pipe diameter of 1/2 inch or minimum tubing diameter
drawn into the system. If leakage occurs at the inner seal, it will be into the of 5/8 inch. Locate oil reservoir so piping is as straight as possible to
compressor. minimize restriction to convective oil flow. Use large radius bends.
The double bellows seal consists of two carbon rings that rotate and seal NOTE: Be sure to maintain oil level in reservoir above upper pipe con-
against two highly polished stationary rings. The seal is filled with oil by a nection to provide proper oil circulation. Oil level will drop slightly dur-
reservoir mounted above the seal cage. The seal is both lubricated and ing initial start-up.
cooled by thermal circulation of the oil and rotation of the seal.
Refer to "Appendix IV - Example Single Stage Double Bellows &
The oil reservoir should be designed to contain 1 gallon of oil per inch of Double Opposed Cartridge Seal Support System P&ID" on page 34
shaft diameter. The reservoir must be connected as shown in FIGURE and "Appendix VII - Example Two Stage Double Bellows &
14. The lower connection on the oil reservoir should be connected to the DOUBLE OPPOSED CARTRIDGE Support System P&ID" on page
bottom of the seal cage. 40.
FIGURE 14 - Typical piping arrangement for double bellows seal.

COMPRESSOR COOLING SYSTEM
Solenoid valves should be used to start and stop coolant flow when the
COMPRESSOR COOLING SYSTEM compressor is started and stopped. Good piping practice typically
The compressor cooling system's function is to control thermal expansion includes a manual bypass system around the solenoid valve and the
to maintain internal compressor clearances. This system is not designed two-way flow regulator.
to control gas discharge temperatures.
In climates where freezing temperatures may occur, systems should
Cooling system piping must be designed / installed in such a manner that have automatic jacket water drain valves to drain water out of the com-
air can be vented prior to system start-up. pressor jacket when the unit stops to prevent damage to the com-
pressor.
The optimal coolant discharge temperature for the compressor is 105 ± 5
ºF (40.5 ± 2.7 °C). Coolant discharge temperatures below 100 °F (37.8
LEGEND
°C) should be avoided as there is risk of internal loss of clearance. For 1. RO-FLO COMPRESSOR
2. TWO WAY THERMOSTATIC CONTROL VALVE
closed loop cooling systems in hot ambient conditions, it may not be pos- 3. ISOLATION VALVE
4. COOLANT SOLENOID VALVE
sible to maintain the ideal coolant discharge temperature. For hot ambient 5. COOLANT STRAINER
6. CASING DRAIN VALVE
7. TEMPERATURE GAUGE
conditions it is acceptable to have coolant discharge temperatures up to
165 ºF (73.9 °C). Coolant discharge temperature shutdown should not 7 2 3
exceed 190 °F (87.8 °C).
COOLANT
DRAIN
CAUTION
3 5 4
Head gasket failure may occur with coolant discharge temperatures
1
above 190 °F (87.8 °C).
Coolant temperatures above 165 °F (73.9 °C) will increase internal

clearances, which will reduce compressor efficiency (resulting in COOLANT
increased recirculation of process gas and higher gas discharge tem- SUPPLY 6
perature).
FIGURE 15 - Typical open loop cooling system.
CLOSED LOOP COOLING

CAUTION In outdoor closed loop cooling systems, a mixture of 60% glycol and
Coolant flow must be stopped when the compressor is shutdown to pre- 40% water gives maximum protection (freezes at –70 ºF (-56.6 °C),
vent rotor/cylinder contact. boils at 280 ºF (137.7 °C).
Circulation of coolant during shutdown periods can cause loss of Closed loop glycol/water (FIGURE 16) radiator cooling systems may be
internal clearances, which may result in rotor/cylinder contact. designed for the approximate flow rates calculated in "Coolant Flow
Requirement". Higher compressor casing temperatures will result in
higher gas discharge temperatures.
A three-way coolant flow regulator, as shown in FIGURE 16, is

required to maintain compressor coolant outlet temperature above 100
CAUTION ºF (37.8 °C).
Water jacket pressure must not exceed 50 psig (3.45 barg)
On closed loop cooling systems, a 3-way flow regulator should be used;
OPEN LOOP COOLING 2-way regulators are unacceptable because they can stall (dead end)
the water pump.
Open loop cooling typically uses a two-way flow regulator installed near
the compressor cooling water discharge as shown in FIGURE 15. The Examples of closed looping cooling systems can be found in "Appendix
two-way thermostatic control valve should have a weep hole to allow a min- III - Example Single Stage P&ID" on page 32 and "Appendix VI -
imum amount of coolant flow so the temperature sensing element is Example Two Stage P&ID" on page 38.
exposed to hot coolant. The compressor cooling system must be filled with
coolant and purged of air prior to start-up.

COMPRESSOR COOLING SYSTEM
FILL PRESSURE TABLE 8 - Compressor coolant jacket capacities.

8 CAP
VENT LINE
APPROXIMATE APPROXIMATE
7
PRESSURE MODEL VOLUME MODEL VOLUME
CAP
FLOW Gallons (Liters) Gallons (Liters)
2CC 0.8 (3) 206, HP6 2.8 (10.6)
2
3 3
4CC 1.0 (3.8) 207, HP7 2.8 (10.6)
FLOW
5CC 1.3 (4.9) 208B, HP8 2.8 (10.6)
5 FLOW
1 FLOW 210M,
7D 3.0 (11.4) 6.0 (23)
HP10
LEGEND 211M,
FLOW 1. RO-FLO COMPRESSOR 8D, SD8D 5.5 (21) 9.0 (34)
2. THREE WAY THERMOSTATIC CONTROL VALVE
3. ISOLATION VALVE HP11
4. CASING DRAIN VALVE
5. TEMPERATURE GAUGE
6. CIRCULATING COOLANT PUMP 8DE, 212M,
7. VERTICAL RADIATOR 5.5 (21) 10.5 (40)
8. SURGE TANK SD8DE HP12
4
10G 8.0 (30) 217M 13.0 (49)
6
11S 10.0 (38) 219M 16.3 (62)
11L 10.5 (40)
FIGURE 16 - Typical closed loop cooling system. 12S 12.5 (47)
12L 13.8 (52)
COOLANT FLOW REQUIREMENT 17S 20.0 (76)
Compressor applications should have coolant piping capable of the flow 17L 24.5 (93)
rate (gallons per minute (GPM)) calculated by the following equation: 19S ,
27.0 (102)
Motor Horsepower
SD19S
GPM = 19L,
10
30.0 (114)
SD19L
Vacuum pump applications should have coolant piping capable of the flow 19LE,
rate (gallons per minute (GPM)) calculated by the following equation: 30.0 (114)
SD19LE
Motor Horsepower
GPM=
5
COOLING OF TWO STAGE SYSTEMS
The above estimated flow rates are based on a design coolant tem- Two stage compressor systems should have the coolant supply con-
perature rise of 15 ºF (8.3 °C). This flow rate will maintain 105 ºF (40.5 nected in parallel to each compressor. Each compressor should have
°C) coolant discharge temperature with 90 ºF (32.2 °C) incoming coolant. a thermostatic valve to control the coolant discharge temperature
independently. The compressor cooling circuit should not be con-
COOLING WATER CONTAMINANTS nected in series as this may cause excessive heat build up within the
The total water hardness (TDS) of the cooling water should not exceed compressor and may cause damage to the sealing elements and/or
300 ppm (mg/l). Deposits will build up over time and will require periodic premature cylinder bore wear/blade failure. Refer to the example in
acid cleaning of the compressor water jacket. "Appendix VI - Example Two Stage P&ID" on page 38.
Water containing suspended solids should not be used since the solids will
rapidly settle out in the compressor water jacket.
COOLING WATER PRESSURE DROP

A pressure drop of 5 PSI (35 kPa) may be assumed through the com-
pressor casing. The pressure drop through the water temperature reg-
ulating valve and inlet solenoid valve should be considered during system
design.

INSTRUMENTATION AND CONTROL SYSTEM
INSTRUMENTATION AND CONTROL LOCAL INDICATORS / GAUGES - MINIMUM

RECOMMENDATIONS
SYSTEM
1. Compressor suction/discharge gas pressure (each stage).
SHUTDOWNS - MINIMUM RECOMMENDATIONS 2. Compressor discharge gas temperature (each stage).
The following shutdowns are strongly recommended by Ro-Flo Com- 3. Compressor run time – hour meter
pressors as a minimum. The compressor application, package design, 4. Compressor cooling water outlet temperature (each stage)
and operation may dictate the necessity for additional shutdowns. Failure 5. Separator (scrubber) level.
to incorporate these shutdowns into the control system will put the safety 6. Coolant pressure.
of the operators and equipment at risk.
INSTALLATION OF LOCAL INDICATORS / GAUGES
Below are some good practices for installing instrumentation on a Ro-
WARNING Flo® package.
Do not tamper with or disable shutdown devices. The compressor discharge and coolant outlet temperature instru-
mentation shall be located as close as possible to the compressor as pos-
Tampering with or disabling shutdown devices may result in serious
sible. This will help provide accurate temperature measurements of the
injury or death.
compressor conditions.
A general recommendation is to set shutdown trip levels 10% above (or Process gas instrumentation is preferably located near the top of hori-
below, as appropriate) nominal operating conditions. zontal pipe runs to avoid any condensation that may be present at the
bottom of the pipe. Condensation may corrupt instrumentation meas-
1. High gas discharge pressure.
urements if allowed to contact the instrument.
2. High gas discharge temperature – must not be allowed to
exceed 350 ºF (176.6 °C). The compressor discharge instrumentation is preferably located
3. High coolant discharge temperature - must not exceed 190 ºF between the compressor and gas discharge check valve. This will help
(87.7 °C) ensure accurate measurements of the compressor gas discharge con-
4. Low jacket cooling water outlet temperature – must not be
ditions.
allowed to drop below 100 ºF (37.8 °C) or insufficient internal
clearances could result in failure. DRIVERS
5. Low lubricator oil flow and/or low lubricator supply tank levels.
6. High liquid level in suction separator (scrubber) and interstage Variable speed controllers should be equipped with limits to prevent
(if applicable). operation above or below the corresponding maximum and minimum
7. For units equipped with a double bellows seal or cartridge seal, operating speeds of the compressor.
low barrier fluid level and low barrier fluid pressure.
The driver manufacturer should be consulted for their recommendation
ALARMS of the number of allowable starts per hour.
Including alarms as part of the control system is good practice. A general LUBRICATION
recommendation would be to set alarm levels between shutdown levels
Lubrication is critical to the equipment health and Ro-Flo Compressors
and nominal operating conditions so that operators are alerted to con-
strongly recommends that instrumentation is included that ensures sat-
ditions that deviate from nominal. The necessity for alarms is ultimately up
isfactory operation of the lubrication system. The preferred method for
to the packager and end user, however, the following should be con-
accomplishing this it to monitor oil flow (e.g. no-flow switch). For lub-
sidered:
rication systems with divider blocks, one (1) flow sensor is typically suf-
1. Safety of operators and equipment. ficient. Lubrication systems with pump-to-point would ideally provide
2. Maintenance. For example, adding oil to the lubrication system. flow sensors on each pump-to-point line. Ro-Flo Compressors recog-
3. How critical is the equipment to the overall process? nizes the fact that this can result in many flow sensors, however, mon-
4. How remote is the installation? itoring only 1 or 2 pumps will still allow the compressor to run after
5. How much response time do operators have to address multiple pump failures.
alarms? Can corrective action be applied in a timely manner to
avoid equipment shutdown and/or damage? COMPRESSOR COOLING JACKET
The packager should consider a sight glass flow indicator in the com-
pressor jacket cooling system. A switch monitoring coolant pressure in
the jacket cooling system may also need to be considered for loss of
coolant and/or process contamination.

INSTRUMENTATION AND CONTROL SYSTEM
SEPARATORS (SCRUBBERS)
The separators (scrubbers) are critical pieces of equipment for the com- CAUTION
pressor and potentially other downstream equipment. The PACKAGER Caution should be taken to prevent pressure overshoots or deep
needs to consider how liquids are removed from the separator. If the sep- vacuum conditions being developed during starts, stops, and other
arator is operating near ambient pressures and/or sub-ambient pres- transient conditions.
sures, a pump will likely be required to remove liquids during compressor
operation (see P&ID example). If applicable, monitoring differential pres-
sure across the separator vessel provides the ability to assess filter ele-
ment condition. Additionally, some applications may require positive inlet
pressures (no vacuum pressure) to ensure that no air/oxygen is drawn
into the process. In these instances, a separator differential pressure
switch or compressor inlet vacuum pressure switch may be required.
HEAT EXCHANGERS
Monitoring temperature downstream of heat exchangers will allow the
user to determine if the heat exchanger is operating correctly or needs ser-
vice.
AIR QUALITY MONITORING/GAS DETECTOR

Often it is advisable for systems to have air quality monitoring/gas detect-
ors to protect operators. For units in enclosed environments this is often
critical to ensure operator safety. Use of these systems should be
reviewed with respect to applicable local, national, and international
codes.
OXYGEN (O2) SENSOR

When dealing with explosive or flammable gases, or when dealing with
process gas streams that are sensitive to oxygen in the gas stream , an
oxygen (O2) sensor may be advisable. Oxygen sensors are most often
employed when gas inlet pressures are near or below ambient pressures.
DRY-OUT CYCLE
For those units dealing with gases near their dew point, a dry-out cycle
should be considered. This will help to prevent accumulation of liquids in
the compressor due to process gas cooling. In oil & gas applications, these
dry-out cycles are often run with fuel gas or nitrogen (N2), as these are
clean-dry gases. If a dry-out cycle will be used, operating conditions
should be reviewed to ensure that the compressor remains within accept-
able operating limits.
CONTROL STRATEGY
The control strategy of the system should be developed to safely control
the compressor and auxiliary systems during both normal operation and
transient conditions. Examples of transient conditions to evaluate are com-
pressor start-up & shut-down events. Consideration should be given to
such aspects as valve timing / responsiveness and the inertia of the gases,
inertia of mechanical components, etc.

ASSEMBLY AND SHOP TESTING
ASSEMBLY AND SHOP TESTING

Several items need attention during assembly and shop testing:
When lifting the compressor, always sling the unit from underneath the
ends of the cylinder as shown in FIGURE 17. Do not use the eye-bolt
holes located on top of the cylinder heads for lifting the assembled com-
pressor. Do not lift the compressor by slinging around the compressor
shaft.
FIGURE 17 - Method of proper slinging for lifting the compressor.
During skid fabrication and shop testing care must be taken to insure dirt &
debris does not enter the machinery.
When testing the compressor in the shop, the operating conditions of the
test need to be evaluated using the Ro-Flo Performance software, taking
into consideration the test process gas, which is often air. Operating on air
generates different loads and temperatures than the actual process gas
being used in the field. Often operating conditions need to be modified to
prevent equipment overload or excessive temperatures from being gen-
erated. Fabrication shops do not always have the same power sources
available as the final installation site. In these instances, it may be neces-
sary to reduce compressor load by reducing discharge pressure and/or
suction throttling.
If the compressor is equipped with a double bellows seal, it should be pres-

surized prior to gas leaking testing of the piping system or operating the
compressor. Please see "Oil System for Double Bellows Type & Cartridge
Shaft Seals" on page 21 for more information.

START-UP, SERVICE, AND PARTS
START-UP, SERVICE, AND PARTS

1. The PACKAGER is responsible for providing competently
trained field start-up service and/or warranty investigations as
required. Ro-Flo Compressors, LLC can provide field service
for start-up and/or training.
2. The PACKAGER must provide the compressor unit operator
with Ro-Flo Installation, Operation, and Maintenance Manual
and lubrication information.
3. The PACKAGER shall insure that the Ro-Flo Installation, Oper-
ation, and Maintenance Manual is correct for the model and
serial numbers provided.
4. The PACKAGER shall record the serial and model number for
each unit shipped.
5. The END USE CUSTOMER should retain a copy of the Ro-Flo
Installation, Operation, and Maintenance Manual for each
installed unit.

APPENDIX I - EXPECTED SOUND PRESSURE LEVELS

The expected sound pressure levels shown in TABLE 9 and TABLE 10 are provided as a general reference. Actual sound characteristics will vary
by application due to changes in gas properties, gas pressures, gas temperatures, operating speeds, piping arrangements, and other factors of the
skid design.
TABLE 9 - Expected Sound Characteristics of Ro-Flo® Sliding Vane Compressors.
EXPECTED SOUND PRESSURE LEVELS (dB)

Disch OCTAVE CENTER FREQUENCIES (Hz)
Speed dBA @ dBC @
Model Press
(RPM) 3' 31.5 63 125 250 500 1000 2000 4000 8000 16000 3'
(PSIG)
1160 50 75 61 62 66 73 70 69 62 60 59 55 77
2CC
1740 50 78 63 64 69 76 72 72 71 68 64 60 80
1160 50 75 61 62 66 73 70 69 62 60 59 55 77
4CC
1740 50 78 63 64 69 76 72 72 71 68 64 60 80
1160 50 75 61 62 66 73 70 69 62 60 59 55 77
5CC
1740 50 78 63 64 69 76 72 72 71 68 64 60 80
865 50 76 66 72 74 72 69 67 63 61 66 63 79
7D
1160 50 80 66 71 76 78 72 71 67 69 74 70 83
865 50 86 78 69 77 83 79 82 74 70 62 63 88
8D, SD8D
1160 50 89 77 73 85 86 81 75 77 85 86 83 92
8DE, SD8DE 1160 50 90 76 74 81 87 80 77 78 86 79 82 92
865 50 89 78 85 87 86 81 78 72 80 72 61 90
10G
1160 50 90 69 73 85 89 84 80 77 74 84 66 93
11S 865 50 90 70 72 86 88 85 81 73 76 83 59 92
11L 865 50 91 72 76 88 84 83 78 76 77 86 60 93
12S 865 50 91 69 67 78 80 81 80 84 86 83 67 94
12L 865 50 94 71 74 86 91 83 80 78 80 89 70 97
17S 690 50 95 72 72 88 90 89 83 83 89 84 73 98
17L 690 50 96 70 73 82 90 90 81 87 90 94 90 99
19S, SD19S 575 50 94 67 81 85 84 91 86 91 86 90 77 100
19L, SD19L 575 50 95 69 78 87 89 86 88 89 93 91 90 101
19LE,
575 50 95 69 78 87 89 86 88 89 93 91 90 101
SD19LE
206, HP6 1160 40 85 59 62 71 84 76 73 70 78 80 70 87
207, HP7 1160 40 85 59 62 71 84 76 73 70 78 80 70 87
208B, HP8 1160 40 85 59 62 71 84 76 73 70 78 80 70 87
210M, HP10 1160 40 84 65 76 81 80 75 76 75 73 70 66 86
211M, HP11 865 40 85 63 75 80 82 74 77 76 71 73 69 87
212M, HP12 865 40 86 65 77 82 81 75 78 82 73 75 70 88
217M 690 40 87 66 76 80 84 72 79 85 82 84 73 89
219M 575 40 87 62 78 77 81 78 80 85 84 86 64 90

TABLE 10 - Expected Sound Characteristics of Ro-Flo® Sliding Vane Vacuum Pumps.
EXPECTED SOUND PRESSURE LEVELS (dB)

Suction OCTAVE CENTER FREQUENCIES (Hz)
Speed dBA @ dBC @
Model Press
(RPM) 3' 31.5 63 125 250 500 1000 2000 4000 8000 16000 3'
(Inches HgV)
1160 25 75 61 60 66 72 69 70 66 61 59 52 76
2CC
1740 25 76 62 61 68 73 74 70 69 63 60 55 57
1160 25 75 61 60 66 72 69 70 66 61 59 52 76
4CC
1740 25 76 62 61 68 73 74 70 69 63 60 55 57
1160 25 75 61 60 66 72 69 70 66 61 59 52 76
5CC
1740 25 76 62 61 68 73 74 70 69 63 60 55 57
865 25 80 66 65 69 74 77 71 71 62 59 64 82
7D
1160 25 82 63 70 68 72 78 76 73 64 65 59 84
865 25 85 64 73 72 76 79 74 75 66 61 56 87
8D, SD8D
1160 25 86 62 71 74 77 82 78 77 72 72 62 88
8DE,
1160 25 86 62 71 74 77 82 78 77 72 72 62 88
SD8DE
865 25 87 69 72 75 80 81 80 80 75 76 56 89
10G
1160 25 88 68 73 76 81 83 81 82 78 78 61 90
11S 865 25 88 72 71 76 82 81 84 81 77 80 57 89
11L 865 25 88 71 73 77 83 82 79 80 79 81 60 90
12S 865 25 88 71 72 76 82 80 77 79 80 70 63 89
12L 865 25 88 73 69 78 84 79 82 78 80 63 64 90
17S 690 25 88 74 74 81 84 81 81 81 79 69 60 90
17L 690 25 89 74 75 82 84 80 83 82 78 67 62 92
19S,
575 25 90 71 74 84 83 84 82 80 79 70 60 92
SD19S
19L,
575 25 91 73 77 85 82 83 83 81 78 73 65 93
SD19L
19LE,
575 25 91 73 77 85 82 83 83 81 78 73 65 93
SD19LE

APPENDIX II - EXAMPLE SINGLE STAGE BASIC P&ID


APPENDIX III - EXAMPLE SINGLE STAGE P&ID


APPENDIX IV - EXAMPLE SINGLE STAGE DOUBLE BELLOWS & DOUBLE OPPOSED CARTRIDGE SEAL SUPPORT SYSTEM P&ID
APPENDIX IV - EXAMPLE SINGLE STAGE DOUBLE BELLOWS & DOUBLE

OPPOSED CARTRIDGE SEAL SUPPORT SYSTEM P&ID

APPENDIX IV - EXAMPLE SINGLE STAGE DOUBLE BELLOWS & DOUBLE OPPOSED CARTRIDGE SEAL SUPPORT SYSTEM P&ID
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APPENDIX VI - EXAMPLE TWO STAGE BASIC P&ID


APPENDIX VI - EXAMPLE TWO STAGE P&ID


APPENDIX VII - EXAMPLE TWO STAGE DOUBLE BELLOWS & DOUBLE OPPOSED CARTRIDGE SUPPORT SYSTEM P&ID
APPENDIX VII - EXAMPLE TWO STAGE DOUBLE BELLOWS &

DOUBLE OPPOSED CARTRIDGE SUPPORT SYSTEM P&ID

APPENDIX VII - EXAMPLE TWO STAGE DOUBLE BELLOWS & DOUBLE OPPOSED CARTRIDGE SUPPORT SYSTEM P&ID
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CONTACT RO-FLO COMPRESSORS
CONTACT RO-FLO COMPRESSORS

The people at Ro-Flo Compressors know that communication is key in
providing a world class product. For that reason we have provided the fol-
lowing methods of contacting our team:
GENERAL INQUIRIES
Toll Free Phone: (+1) 855-427-6356
Main Phone: (+1) 920-574-2651
www.roflocompressors.com
NEW COMPRESSOR AND VACUUM PUMP SALES

Toll Free Phone: (+1) 855-427-6356
Main Phone: (+1) 920-574-2651
Email: sales@roflocompressors.com
PARTS INQUIRIES
Phone: (+1) 920-574-2653
Email: parts@roflocompressors.com
SERVICE AND SUPPORT

Phone: (+1) 920-574-2653
Email: service@roflocompressors.com

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PACKAGING GUIDELINES FOR

RO-FLO® COMPRESSORS AND VACUUM PUMPS

Ro-Flo Compressors, LLC

UNDERSTAND THE CUSTOMER SPECIFICATIONS 8

PROVIDING THE CUSTOMER WITH NECESSARY INFORMATION 8

PROVIDE PROPER STORAGE 8

ITEMS PROVIDED BY RO-FLO COMPRESSORS 9

SKID DESIGN AND COMPRESSOR MOUNTING 10

COMPRESSOR OPERATING LIMITS 10

COMPRESSOR SYSTEM SOUND CONTROL 10

Electric Motor Drives 11

Belt Drive With Jackshaft 12

Two (2) Stage Compressor Train 12

PIPING SYSTEMS AND VESSELS 15

Ro-Flo Compressors, LLC -3- 16-620-107-000 REV 02 (May 2018)

SEPARATOR VESSELS / DRIP LEGS 15

DISCHARGE CHECK VALVE 16

PRESSURE SAFETY RELIEF VALVE 16

GAS RECYCLE (BYPASS) LOOP 16

COMPRESSOR LUBE RATE CALCULATION 20

Normal Lube Rate 20

Break-in Lube Rate 20

Compressor Lube Rate Calculation Example 20

COMPRESSOR COOLING SYSTEM 22

CLOSED LOOP COOLING 22

COOLANT FLOW REQUIREMENT 23

COOLING WATER CONTAMINANTS 23

COOLING WATER PRESSURE DROP 23

COOLING OF TWO STAGE SYSTEMS 23

INSTRUMENTATION AND CONTROL SYSTEM 24

LOCAL INDICATORS / GAUGES - MINIMUM RECOMMENDATIONS 24

INSTALLATION OF LOCAL INDICATORS / GAUGES 24

COMPRESSOR COOLING JACKET 24

Ro-Flo Compressors, LLC - 4- 16-620-107-000 REV 02 (May 2018)

AIR QUALITY MONITORING/GAS DETECTOR 25

OXYGEN (O2) SENSOR 25

ASSEMBLY AND SHOP TESTING 26

APPENDIX I - EXPECTED SOUND PRESSURE LEVELS 28

CONTACT RO-FLO COMPRESSORS 42

NEW COMPRESSOR AND VACUUM PUMP SALES 42

SERVICE AND SUPPORT 42

Ro-Flo Compressors, LLC -5- 16-620-107-000 REV 02 (May 2018)

FAILURE TO FOLLOW OPERATING INSTRUCTIONS MAY RESULT IN SERIOUS INJURY OR DEATH.

Ro-Flo Compressors, LLC - 6- 16-620-107-000 REV 02 (May 2018)

Ro-Flo® sliding vane compressors are normally installed on a structural

A PACKAGER is defined as any Ro-Flo Compressors authorized party

This STANDARD is not intended to be an engineering data book. It is a

The wide range of possible uses of Ro-Flo® compressors will periodically

PACKAGER DESIGN REVIEW - GRATUITOUS ADVICE

Gratuitous Advice: If Ro-Flo Compressors furnishes the

Ro-Flo Compressors, LLC -7- 16-620-107-000 REV 02 (May 2018)

Ro-Flo Compressors, LLC - 8- 16-620-107-000 REV 02 (May 2018)

ITEMS PROVIDED BY RO-FLO COMPRESSORS

1. Ro-Flo Packaging Guidelines

The following services are also available from Ro-Flo Compressors.

l Witnessed Hydrostatic Test

Please contact your sales representative for more information.

Ro-Flo Compressors, LLC -9- 16-620-107-000 REV 02 (May 2018)

SKID DESIGN AND COMPRESSOR COMPRESSOR OPERATING LIMITS

The skid should provide sufficient mass to absorb vibration transmitted by