Manual SULZER Compressor

Burckhardt Compression AG
Im Link 5
P.O. Box 65
CH-8404 Winterthur
Switzerland
Tel. +41 52 262 55 00
Fax +41 52 262 00 51
www.burckhardtcompression.com
Instruction Manual Compressor Type

2D200B-1A_1
IM 102609en
Serial No.
102609
for Process Gas
Laby® Compressor Oxygen (O2+)
Project No.
2001904
Key Word
Linde Gdansk
Purchaser
Linde AG, Engineering Division, Pullach,
Germany
Order No.
001 2KD9950 Sup.000
Operating Company
Grupa LOTOS, Gdansk, Poland
Item No.
3250-K2
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 and Waste Disposal
12 Spare Parts
13 Appendix
14 Index
17.01.2017 Rev. 001/vonstuerle_g 2D200B-1A_1 IM 102609en

Table of Contents
IM 102609en 2D200B-1A_1 Rev. 001/vonstuerle_g 17.01.2017

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.9.1 Level of Hazard Seriousness . . . . . . . . . . . . . . . . 1-8
1.9.2 Useful Information . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.9.3 Warning Symbols Used in this Instruction Manual 1-8
1.10 Registered Trademarks and Brands . . . . . . . . . . . . . . . . . . 1 - 10
17.01.2017 Rev. 001/vonstuerle_g 2D200B-1A_1 IM 102609en 1–1

1–2 IM 102609en 2D200B-1A_1 Rev. 001/vonstuerle_g 17.01.2017

Revisions
1.1 Revisions
Book Chapter Page Technical Date Description

revision writer
Preliminary 001 gvs 16.12.16 Preliminary edition
001 gvs 17.01.17 First release
Tab. 1-1 Revisions
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 Burckhardt Compression’s 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. The smooth operation can only be assured if the
content of this Instruction Manual is completely read and understood.
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 must be read and understood by all who are responsible
for the compressor described. Personnel 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
Tab. 1-2 Target groups

Compressor Designation
1.5 Compressor Designation

Name Plate
LA_XX_0031b_01
Fig. 1-1 Location of the name plate
1 Name plate
The serial number is located on the name plate (1).

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.
4 D 250 B - 4 H_X
LA_XX_0002b_03
1 2 3 4 5 6 7
Fig. 1-2 Example for compressor designation
1 Number of cranks 3 Piston stroke

2 Type of compression: 4 Design of crankgear
D, K = double acting 5 Number of stages
E = single acting 6 Design of cylinder
H = high pressure 7 Revision index
L = long interspace

Contact Address
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

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

Term Cross Reference to API Standard
Designation according to API Designation according to

Burckhardt Compression
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
Motor end Drive end
Oil pump end Non drive end
Outboard bearing External bearing
Pulsation suppressor Pulsation damper
Shaft key Sunk key
Single-piece piston Solid piston
Slinger Oil shield
Slugging wrench Flogging spanner
Valve cage, valve hold down Lantern
Wiper packing rings Wiper elements
Tab. 1-3 Term cross reference

Warnings and Symbols
1.9 Warnings and Symbols
1.9.1 Level of Hazard Seriousness

The following signal words are used in this Instruction Manual:
DANGER
Severe injury or death can be the consequence if such warnings are ig-
nored.
 Follow the prevention instructions carefully.
WARNING
Severe injury or damage to the equipment can be the consequence if such
warnings are ignored.
CAUTION
Damage to the equipment or tools can be the consequence if such warn-
ings are ignored.
1.9.2 Useful Information
Notes illustrated like this contain useful information and tips. Follow these
notes for 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:

Warnings and Symbols
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!

Registered Trademarks and Brands
Read instruction for operation and maintenance
Wear hearing protection
Do not remove Instruction Manual from compressor site
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.
Laby® is a trademark of Burckhardt Compression AG, Im Link 5, 8404 Win-
terthur, Switzerland.
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.
RHODORSIL CAF® is a trademark of Rhodia Silicone Europe, 55 avenue
des Frères Perret, F-69192 Saint-Fonds, France
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-8500, Frauenfeld, 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.
1 – 10 IM 102609en 2D200B-1A_1 Rev. 001/vonstuerle_g 17.01.2017

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
17.01.2017 Rev. 001/vonstuerle_g 2D200B-1A_1 IM 102609en 1 – 11


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

2.2 Legal Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Obligations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
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 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 11
2.6 Compressor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 11
2.6.1 Operation with Oxygen . . . . . . . . . . . . . . . . . . . . . 2 - 12
2.7 Safe Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . 2 - 12
2.7.1 Cleaning of Compressor Plant . . . . . . . . . . . . . . . 2 - 12
2.7.2 Compressor Maintenance . . . . . . . . . . . . . . . . . . 2 - 13
2.7.3 Commissioning after Maintenance . . . . . . . . . . . . 2 - 14
2.8 Process Gas and Purge Gas . . . . . . . . . . . . . . . . . . . . . . . 2 - 15
2.8.1 Gas Specification . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 15
2.8.2 Hazard Identification Diamond . . . . . . . . . . . . . . . 2 - 15
2.8.3 Ar Argon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 17
2.8.4 N2 Nitrogen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 18
2.8.5 O2 Oxygen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 19


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 the quality documentation for the applicable declaration of
conformity issued for this project:
• EC Machinery Directive 2006/42/EC
• Pressure Equipment Directive 2014/68/EU
• Atmospheric Explosion Protection 2014/34/EU
Guidelines for The specific guidelines in the IGC-documents (Industrial Gas Committee)
Oxygen Plant “Reciprocating Compressors for Oxygen Service”, IGC Doc 10/09/E, “Fire
Hazards of Oxygen and Oxygen Enriched Atmospheres”, IGC Doc 04/09/
E and “Cleaning of Equipment for Oxygen Service”, IGC Doc 33/06/E are
valid for the operation and construction of oxygen compressor plants.
The compressor is cleaned according to Burckhardt Compression cleaning
instructions accepted by all well-known customers. In Germany, for ex-
ample, the safety work rules BG RCI M34 are valid, of which, among other
things, the following must be taken into account:
• plant construction and operation (areas, rooms and ventilation in-
cluded),
• material for fittings, pipes, sealing compounds and lubricants,
• guidelines for planning, installation, construction and marking,
• cleaning and maintenance work, work clothes and personal safety
outfit,
• customer specific cleaning and material specification.

Obligations
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.
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 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.

Intended Use
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 Intended Use

Correct Application This compressor type is exclusively designated for the compression of gas
as specified for this application (see section 2.8.1 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.
If you want to extend the contractual range of application, please consult

our Services Division in Switzerland. Address see section 1.6 Contact Ad-
dress.
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!
2.6 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.

Safe Maintenance Practices
2.6.1 Operation with Oxygen

The personnel involved with operating must be specially trained for oxygen
compressor plants and must strictly follow applicable rules and regulations.
DANGER
Fire hazard!
Powerful oxidizing power. Clothing may catch fire!
In high oxygen content atmospheres, common combustible materials can
become highly flammable. Clothing absorbs O2 which leads to an ex-
tremely high risk of fire with very fast combustion.
 No open fire.
 No smoking.
 Do not use grease or oil.
 Degrease and clean all parts and surfaces of the plant components ex-
posed to process gas to required cleanliness standard (oxygen ser-
vice).
 Use lint-free cleaning rags only.
 Depressurize the installation and purge with dry nitrogen before you
open the compressor.
2.7 Safe Maintenance Practices
2.7.1 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 8.4 Maintenance
Schedule.

2.7.2 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.
Special Notes for The personnel involved with maintenance must be specially trained for ox-
Oxygen Plants ygen plants and must strictly follow applicable rules and regulations.

DANGER
Fire hazard!
Powerful oxidizing power.
become highly flammable.
 Make sure that no greasy ropes, chains, hooks etc. are used.
 Protect all compressor parts against oil drip from travel trolleys.
posed to process gas to required cleanliness standard (oxygen ser-
vice).
2.7.3 Commissioning after Maintenance

Before commissioning,
• check working order of compressor and motor by turning the flywheel
several times by hand – with the bar – in running direction,
• fit flywheel guard and assure working order.
• purge plant according to section 6.2.3 Purge Plant with Nitrogen.

Process Gas and Purge Gas
2.8 Process Gas and Purge Gas
2.8.1 Gas Specification
Process gas composition Normal case [mol%]
Ar Argon 4.50
N2 Nitrogen 5.50
O2 Oxygen 90.00
O 2+ Oxygen mixture 100.00%
Purge 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 2.8.
For in-depth safety information, please consult the respective Material

Safety Data Sheets, e.g. on the Internet.
2.8.2 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

2.8.3 Ar Argon
NFPA-rating for argon. Explanation see section

2.8.2 Hazard Identification Diamond.
0 Health = 0
0 0 Fire = 0
Reactivity = 0

DANGER
Health hazard!
Risk of suffocation! Argon gas is an asphyxiant and presents a health
hazard by displacing the oxygen in the atmosphere. At high concen-
trations, unconsciousness or death may occur.
Contact with rapidly expanding gas can cause severe burns and frost-
bite.
 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 argon could occur without any significant warning symp-
toms.
 During an emergency situation, before entering the area, check for ox-
ygen-deficient atmospheres.
Argon is a colorless, odorless, tasteless gas.
Fire-Fighting Measures Argon does not burn – however, containers, when involved in fire, may rup-
ture or burst in the heat of the fire.
• Firefighters must wear personal protective equipment and fire-fighting
turnout gear, as appropriate for the surrounding fire.
• Extinguish fire with some suitable agent – choose the one most appro-
priate for type of surrounding 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.

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

0 Health = 0
0 0 Fire = 0
Reactivity = 0

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.
centrations of nitrogen could occur without any significant warning
symptoms.
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.

• Give artificial respiration if necessary.

2.8.5 O2 Oxygen
NFPA-rating for oxygen. Explanation see section

0 Health = 0
0 0 Fire = 0
Reactivity = 0
OX Specific precautions = OX

DANGER
Fire hazard!
Powerful oxidizing power. Clothing may catch fire!
become highly flammable. Clothing absorbs oxygen which leads to an ex-
tremely high risk of fire with very fast combustion.
 No smoking.
 No open fire.
posed to process gas to required cleanliness level (oxygen service).
DANGER
Health hazard!
Over-exposure to oxygen may cause nausea, dizziness, shortage of
breath and spasm.
 Do not enter an area if the oxygen content exceeds 23.5%.
Fire-Fighting Measures Oxygen does not burn; however, oxygen will support and accelerate com-
bustion. In case of fire:
• Shut off the gas source when possible without risk.
• Use extinguishing media appropriate for surrounding fire.

Leak Response • Wear self-contained breathing apparatus and fire-retardant personal

protective equipment to rescue people and to seal leak.
• Eliminate any possible sources of ignition.
• Use ventilation to reduce the oxygen levels,

• Get 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
3.3 Gas System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3.1 Suction Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3.2 Purge System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.3 Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.4 Gas Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.5 Pulsation Damper . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4 Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.4.1 Avoiding Deposits. . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.5 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.5.1 Schematic Overview. . . . . . . . . . . . . . . . . . . . . . . 3-9
3.6 Control and Operating Elements . . . . . . . . . . . . . . . . . . . . 3 - 10
3.6.1 Local Instrument Board (LIB) . . . . . . . . . . . . . . . . 3 - 10
3.7 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10
3.7.1 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11
3.7.2 Temperature Monitoring . . . . . . . . . . . . . . . . . . . . 3 - 11
3.7.3 Pressure Monitoring . . . . . . . . . . . . . . . . . . . . . . . 3 - 12
3.7.4 Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 12
3.7.5 Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 12
3.7.6 Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 12
3.7.7 Non-Return Valve . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 12
3.7.8 Vibration Monitoring . . . . . . . . . . . . . . . . . . . . . . . 3 - 12
3.7.9 Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13
3.7.10 Flywheel Guard . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13
3.8 Fire Protecting Wall. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13


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 seal 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 Laby® com-

pressor 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
LA_L1_0059b_02
Fig. 3-1 Laby® compressor type D with flexible coupling (typical view)
The compressor is driven by a flexible coupled electric motor. The flexible

coupling is able to absorb shaft heat expansions, angular deviations and
parallel shifts. For better illustration, Fig. 3-1 shows a typical view without
flywheel guard.

Gas 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 and the flexible coupling refer to
the documentation of the manufacturers.
3.3 Gas System

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

The suction strainer is fitted in the suction line before the first stage to pre-
vent large foreign particles from getting into the compressor. Its mesh size
is 0.15 mm.
1 2 3 4
XA_XX_0101b_01
Fig. 3-2 Suction strainer
1 Flange
2 Flow direction
3 Intermediate piece
4 Conical suction strainer
CAUTION
Heavily contaminated gas or very hard foreign particles can damage the
suction strainer.
 Observe the specifications concerning the gas composition.

Gas System
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 prior to After operation of the compressor with oxygen, the compressor plant must
Maintenance or Normal be purged with oil-free, dry nitrogen prior to performing any cleaning or
Operation maintenance work. The same applies after maintenance and prior to
normal operation with oxygen or if contamination of the process gas with
air must be prevented.
3.3.3 Bypass
For detailed description of the bypass and bypass valves, please refer to
section “Control Description” in chapter 13 Appendix.
Bypass Overall The compressor is equipped with a bypass. This allows to start the com-
pressor without back pressure and a continuous capacity control within a
certain range.
The bypass valve is used for commissioning, maintenance, capacity con-
trol and for running-in of new pistons.
3.3.4 Gas Cooler

Gas Cooler Depending on the discharge temperature of the 1st stage, gas will be
after 1st Stage cooled down by 1st stage gas cooler. The concerning valves in the gas line
are controlled automatically.
3.3.5 Pulsation Damper

Up- and downstream pulsation dampers are fitted to reduce gas pulsations
in the piping. For further reduction of pulsations, orifice plates are fitted on
the pulsation damper.

Cooling System
XA_P3_0001b_01
Fig. 3-3 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-
ficiently low freezing point must be used. The coolant is led to the individual
elements via a supply manifold.
During commissioning, the various control valves must be adjusted: the
coolant flow rates must still be sufficient at minimum allowable coolant
pressure – even during the summer months – to prevent the outlet flow
temperature of the coolant from rising above the maximum admitted value.
Manually operated control valves are installed in the individual coolant lines
allowing to optimize the outlet temperature of the coolant.
CAUTION
Risk of crosshead seizure!
 If the coolant supply temperature is less than 15 °C: do not restart the
compressor immediately after a shutdown. Wait at least half an hour to
restart the compressor.

Cooling System
CAUTION
Risk of water in the lubricating oil!
If the crankgear is cooled too much, condensate can build up under certain
ambient conditions. Excessive wear on the bearings due to dilution of the
lubricating oil.
 Avoid excessive cooling.
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.

Lubricating System
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.
During normal operation, the gear oil pump sucks oil from the crankgear
through the built-in oil strainer, forcing it through the oil filter to the com-
pressor bearings and crossheads.
Oil Pressure The oil pressure has been checked and adjusted by the relief valve during
test run. The oil pressure can be checked on the respective pressure
gauge.
Oil Heater The lubricating system is equipped with an electric oil heater. The oil heater
keeps the lubricating oil temperature at a minimum level. In combination
with the oil heater, a temperature controller is installed to protect the heater
from low lubricating oil level.
Oil Strainer An oil strainer is installed in the oil sump of the crankgear to prevent solid
contaminants in the lubricating system.
Valves 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.
The shut-off valves up- and downstream of the prelubrication pump remain
normally open. They are closed for maintenance work on the prelubrication
pump.

Lubricating System
3.5.1 Schematic Overview
4 5 6 7 8 9 10 11 12
LD_P0_0010b_01
Fig. 3-4 Lubricating oil flow diagram
1 Oil flow upstream to gear oil pump 7 Non-drive end of compressor

2 Oil flow downstream from gear oil 8 Oil strainer
pump 9 Main bearing
3 Oil flow in crankshaft and crosshead 10 Crosshead
4 Relief valve 11 Connecting rod bearing
5 Gear oil pump 12 Drive end of compressor
6 Prelubrication pump

Control and Operating Elements
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.
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
3.7 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 insulated, 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).
For set values of safety devices see section “Instrumentation” in chapter 13
Appendix.
Various temperature indicators allow local observation and remote moni-
toring of temperature values.
Temperature Monitoring of The temperatures of bearings and windings are monitored. Elevated tem-
Electric Motor peratures are a result of defective bearings etc. Temperature monitoring is
also used to prevent the winding temperatures from exceeding the thermal
limits of used insulation materials. If the temperature is above the critical
value, an alarm is triggered.

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.
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 is installed on the frame cover to prevent pressure fluctuation
(due to pump effect of crosshead) in the crankgear.
3.7.7 Non-Return Valve

A non-return valve is installed in the discharge line to prevent 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

A vibration transmitter 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 de-
fined limit, the compressor will be shut down.

Fire Protecting Wall
3.7.9 Level Indicator

Lubricating System A sight glass in the crankgear allows local observation of lubricating oil
level.
3.7.10 Flywheel Guard

A proximity switch is installed on the flywheel guard to prevent the com-
pressor from starting with engaged bar or barring device.
3.8 Fire Protecting Wall

The fire protecting wall encloses the hazard area around the oxygen com-
pressor. The primary purpose of a fire protecting wall is to prevent injury to
personnel. In case of a fire, its secondary function is that it lessens damage
to adjacent equipment.

Fire Protecting Wall

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 - 10
4.2.3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 12
4.2.4 Connecting Rod and Crosshead . . . . . . . . . . . . . 4 - 14
4.2.5 Guide Bearing and Oil Scraper. . . . . . . . . . . . . . . 4 - 16
4.2.6 Distance Piece . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 18
4.3 Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 19
4.3.1 Piston Rod Gland . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 20
4.3.2 Piston Rod and Piston . . . . . . . . . . . . . . . . . . . . . 4 - 22
4.3.3 Suction Valves and Discharge Valves . . . . . . . . . 4 - 25
4.3.4 Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 28


Overview
4.1 Overview
This chapter describes the general design and function of a compressor of
type D with non-gastight design and a crankcase that is cast in one piece.
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.
This compressor has a crankgear that is under atmospheric pressure. It is

typically used for non-toxic and non-hazardous gases with low suction
pressure.
The two main parts of this compressor are crankgear and cylinder.
The labyrinth principle, developed by Burckhardt Compression, allows a
contact-free sealing between piston and cylinder wall. As the labyrinth prin-
ciple needs no cylinder lubrication, the compressed gas is not contami-
nated by oil. The crosshead and the guide bearing maintain the precise
linear movement of the piston.

Overview
11 12 13
10
6 1
3 2
LD_XX_0069b_01
Fig. 4-1 Laby® compressor of type D with non-gastight design
1 Crankgear 8 Distance piece

2 Drive end 9 Piston rod gland
3 Non-drive end 10 Cylinder
4 Crankshaft 11 Piston rod
5 Connecting rod 12 Piston
6 Crosshead 13 Valves
7 Guide bearing

Overview
Crankgear The crankgear (1) consists of the crankcase and its compressor compo-
nents. Main components are crankshaft, crankshaft seal, gear oil pump,
connecting rod, crosshead and guide bearing.
The crankcase is cast in one piece.
The oil reservoir is in the crankgear.
During operation, the crankgear is under atmospheric pressure. One or
more frame covers are equipped with breathers.
The crosshead guide is water cooled.
Drive End At the drive end (2) of the crankgear, a flywheel is fitted to the crankshaft.
The flywheel compensates irregular torque from the compressor to the
motor.
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 Flange Connected Gear Oil Pump

At the non-drive end (3), the crankcase is closed by the gear oil pump.
The crankshaft driven gear oil pump ensures the lubrication of bearings
and crossheads during compressor operation.
The crankshaft driven gear oil pump provides lubricating oil to the crank-
shaft bearings throughout the runout time of the compressor.
External Oil Pump

If an external lubricating system is implemented, there might be two ex-
ternal oil pumps instead of a crankshaft driven gear oil pump. Thus, instead
of the crankshaft driven gear oil pump, a cover is installed at the non-drive
end of the compressor.
Crankshaft The crankshaft (4) is coupled to the electric motor on the drive end via the
flywheel.
The crankshaft is supported by the crankshaft bearings.
Counterweights on the crankshaft are used to equalize rotating masses on
compressors with up to three cranks.
Connecting Rod and The rotation of the crankshaft is transformed via the connecting rod (5) into
Crosshead a reciprocating movement of the crosshead (6). The exact guided cross-
head moves the piston rod.
During compressor operation the connecting rod bearing, the crosshead
bearing and the crosshead itself are lubricated either by the crankshaft
driven gear oil pump or by an external oil pump.
Guide Bearing and The guide bearing (7) is the second guide for the piston rod (the first is the
Oil Scraper crosshead).
The wiper elements installed above the bearing bush remove the oil from
the piston rod.
The guide bearing is water cooled.

Overview
Distance Piece The distance piece (8) is the area between piston rod gland and guide
bearing.
The distance piece of this compressor type is typically part of the crank-
gear.
Exceptions are the 1D150, 1D130 and 1D100 compressors where the dis-
tance piece is part of the cylinder.
Cylinder In the cylinder (10), the process gas is compressed to the required pres-
sure by a labyrinth piston. The number of stages depends on the total pres-
sure ratio between suction and final discharge pressure or the specified
discharge temperature.
There are different cylinder configurations (mono blocks, single blocks,
etc.).
The cylinder and cylinder covers are water cooled.
Piston Rod Gland The piston rod gland (9) seals off the gas compression area. Apart from the
bottom gland ring, all gland rings are of labyrinth type design. The 3-piece
gland ring at the bottom is slightly pressed to the piston rod by two garter
springs.
The piston rod gland has a small gas leakage caused by the small clear-
ance between gland rings and piston rod. The leak gas is returned to the
1st stage suction side and/or to a process gas dependent safe location.
Piston Rod and Piston The piston rod (11) is connected to the crosshead by a conical connection.
The conical piston rod end is fitted to the crosshead with wedges.
An exception is the 2D205 compressor which has a bolted connection with
two piston rod nuts.
The piston (12) is fastened to the piston rod by a SUPERBOLT® nut. For
very small pistons another type of special nut is used.
The piston is of labyrinth type design. The labyrinth creates a contact-free
seal between piston and the cylinder wall and requires no lubrication.
Valves The suction and discharge valves (13) 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
10 11
6 4
LD_M0_0043b_01
5
Fig. 4-2 Crankgear (typical view)
1 Crankcase 7 Connecting rod

2 – 8 Crosshead
3 – 9 Guide bearing
4 Drive end 10 Distance piece
5 Crankshaft 11 Breather (on frame cover)
6 Non-drive end
Crankgear The crankgear consists of the crankcase (1) with distance piece (10) and
its compressor components, i.e. drive end (4), non-drive end (6) with gear
oil pump, crankshaft (5), connecting rod (7), crosshead (8) and guide
bearing (9).
The crankgear is of non-gastight design.
In the crankgear the rotating movement of the crankshaft is converted to
the reciprocating movement of the crossheads by the connecting rods.
During operation, the crankgear is under atmospheric pressure. All ports
below the distance piece are closed by frame covers and sealed with flat
gaskets.
Breathers (11) prevent a slight pressure rise in the crankgear due to in-
creasing temperature during operation. They are installed on the frame
covers.
Depending on the number of cranks, one ore more breathers are installed.

Crankgear
Crankcase
The crankcase is cast in one piece.
The standard material is EN-GJL-250.
Components of Lubrication
Lubricating System
The oil reservoir is in the crankgear.
During compressor operation, the lubrication of bearings and crossheads
is ensured by the gear oil pump (see section 4.2.2 Non-Drive End). If two
external oil pumps are installed instead of a gear oil pump, they ensure the
lubrication.
The oil return from the guide bearing is led back to the crankgear through
an oil syphon. The resulting oil column in the oil syphon prevents oil mist
from entering the distance piece.
Oil Sight Glass

A sight glass allows local observation of the lubricating oil level. The sight
glass is installed in the crankcase. When the compressor is in operation,
1/2 of the oil sight glass should be covered.

Crankgear
4.2.1 Drive End
1 3 5
LD_M1_0049b_01
Fig. 4-3 Drive end (typical view)
1 Frame 6 Main bearing, drive end

2 – 7 –
3 Oil trap 8 Bore
4 – 9 Flywheel
5 Lip-seal
The drive end is of oil-tight design.

The flywheel (9) which is fitted to the crankshaft compensates irregular
torque from the compressor to the motor.
The connection between flywheel and crankshaft is conical with a castel-
lated nut and a split pin.
Crankshaft Seal
The crankshaft is sealed at the drive end by a non-gastight crankshaft seal
(5). It is located in the oil trap (3) on the drive end side and consists of two
lip-seals. The outer lip-seal prevents contaminants from entering the com-
pressor; the inner lip-seal prevents oil loss.
Main Bearing
For design and function of the main bearing (6) see section 4.2.3 Crank-
shaft.

Crankgear
4.2.2 Non-Drive End
10
LD_M2_0033b_01
11
Fig. 4-4 Non-drive end (typical view)
1 Relief valve 7 Driven gearwheel

2 Pressure gauge 8 Main bearing, non-drive end
3 Gear oil pump 9 Crankshaft
4 Eccentric disk 10 Lubricating oil bore
5 Throttle valve 11 Oil strainer (and oil heater)
6 Driving gearwheel
Gear Oil Pump

The gear oil pump (3) is fitted to the crankcase at the non-drive end of the
compressor. During compressor operation, the lubrication of bearings and
crossheads is ensured by the gear oil pump.
The gear oil pump is driven by the crankshaft (9). It consists of a driving
gearwheel (6) and a driven gearwheel (7). The driving gearwheel is driven
by the crankshaft via an eccentric disc (4).
The lubricating oil is distributed to the main bearings and center bearings
(if present) by the oil pipes. In very small compressors the lubricating oil is
distributed by the bores in the crankshaft.

Crankgear
From the crankshaft bearings the lubricating oil continues to the connecting
rod bearings, the crosshead pin bearings and the crosshead body. The
guide bearing is splash-lubricated through the upward movement of the
crosshead.
The crankshaft driven gear oil pump provides lubricating oil to the crank-
shaft bearings throughout the runout time of the compressor.
Oil Strainer
The lubricating oil in the oil sump of the crankgear is filtered through the oil
strainer (11). The oil strainer prevents particles from entering the gear oil
pump.
The oil strainer is located in the crankcase on the suction side of the gear
oil pump.
For applications with an external oil tank, the oil strainer is located in the oil
tank.
Oil Heater and Oil Level Switch

The oil heater (11) is surrounded by the oil strainer. It keeps the lubricating
oil temperature at a minimum level. In combination with the oil heater, a
level switch must be installed in the crankgear to protect the heater from
low lubricating oil level. When no oil heater is installed, a level switch is op-
tional.
Oil Pressure
The effective oil pressure can be checked at the pressure gauge on the
gear oil pump.
For a Laby® compressor of type D with non-gastight design, the crankgear
pressure equals atmospheric pressure. Therefore, the pressure that is read
at the gear oil pump outlet is the effective oil pressure.
Relief Valve
The relief valve (1) keeps the oil pressure at the desired pressure.
It is typically installed inside the gear oil pump at the non-drive end side.
The oil flowing through the relief valve returns to the crankgear.
The oil pressure can be adjusted by the relief valve.
Main Bearing
For design and function of the main bearing (8) see section 4.2.3 Crank-
shaft.

Crankgear
4.2.3 Crankshaft
1 2 4 5 6 7
LD_M1_0051b_01
Fig. 4-5 Crankshaft (typical view)
1 Main bearing, non-drive end 5 Counterweight

2 Connecting rod 6 Lubricating oil bore
3 – 7 Main bearing, drive end
4 Crankshaft
The rotation of the crankshaft (4) is transformed into the reciprocating

movement of the crosshead via the connecting rod (2).
Depending on the number of cranks, the crankshaft is supported by two or
more bearings. The lubricating oil from the main bearings (1 and 7) to the
connecting rod passes through bores (6) in the crankshaft.
Crankshafts of Burckhardt Compression are always forged.
Counterweights (5) on the crankshaft are used to equalize rotating masses
on compressors with up to three cranks.

Crankgear
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
The main bearing at the drive end (7) and the main bearing at the non-drive
end (1) are designed as bearing bushes with a small shoulder (one piece).
Center Bearing
If more than two crankshaft bearings are necessary, special center bear-
ings must be used. As the crankcase is made of one piece, these bearings
differ from the main bearings.
The center bearing consists of a split housing which is bolted together and
two bearing halves that are clamped in this housing. Clearance adjustment
within a small range can be done with shims.
The lubricating oil is distributed to the main bearings and center bearings
(if present) by the oil pipes. In very small compressors the lubricating oil is
distributed by the bores in the crankshaft.

Crankgear
4.2.4 Connecting Rod and Crosshead
10
LD_M3_00xxb_01
11
12
13
Fig. 4-6 Connecting rod and crosshead (typical view)
1 Piston rod 8 Crosshead pin

2 Wedge 9 Connecting rod
3 – 10 Connecting rod bearing halves
4 – 11 Crankshaft
5 – 12 Connecting rod bolt
6 Crosshead 13 Connecting rod cover
7 Crosshead pin bearing
Connecting Rod The connecting rod (9) is the link between crankshaft (11) and
crosshead (6). It converts the rotation of the crankshaft into the recipro-
cating movement of the crosshead.
The forged connecting rod and connecting rod cover (13) have been ma-
chined together and matchmarked as pairs. The connecting rod bearing
halves and the connecting rod bolts (12) are also marked.

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.
The nuts for the connecting rod bolts are tightened mechanically.
Connecting Rod Bearing

The connecting rod has two bearings. At the big end is the connecting rod
bearing. It consists of two halves (10) which are identical. They have no
shims. Therefore, the bearing clearance cannot be readjusted.
Exceptions are the 1D150, 1D130 and 1D100 compressors which are
equipped with thick-walled bearings with shims.
The design of the connecting rod bearing is of a trimetallic type with a white
metal running layer as a standard. A galvanic running layer is an option.
The lubrication of the connecting rod bearing takes place from the crank-
shaft bearing via the bore in the crankshaft.
Crosshead Pin Bearing

The crosshead pin bearing (7) 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
bimetallic (steel and white metal) layer type. These bearings are lubricated
via the bore in the connecting rod.
Crosshead The crosshead is moved up and down by the connecting rod. The guide
bearing and the exact guided crosshead ensure an accurate guidance for
the piston rod (1) and piston.
Crossheads are made of nodular cast iron with a white metal layer in the
area of sliding.
The crosshead guide is part of the crankcase and is always water cooled.
The lubrication of the crosshead takes place from the crankshaft bearing
via the bore in the connecting rod along the crosshead pin (8) to the cross-
head body.
Connection between The piston rod is connected to the crosshead. In general, this connection
Crosshead and Piston Rod is conical. This ensures an exact positioning of the piston rod to the cross-
head. The conical piston rod end is fitted to the crosshead with wedges (2).

Crankgear
4.2.5 Guide Bearing and Oil Scraper
1 2 3 4 5 6 7 8
LA_M5_0058b_01
Fig. 4-7 Guide bearing (typical view)
1 Guide bearing housing 5 Oil shield with garter spring

2 Wiper elements 6 Piston rod
3 Spring plate 7 Crown ring
4 Guide bearing cover 8 Bearing bush
The guide bearing maintains the precise linear movement of the piston rod
(6). The guide bearing is the second guide for the piston rod (the first is the
crosshead).
The replaceable bearing bush (8) is made of steel with a thin white metal
layer. The crown ring (7) may be part of the bearing bush e.g. for small
compressors or be absent at all. In the latter case, a circlip is installed
below the bearing bush.
The guide bearing is water cooled. The water cooled guide bearing helps
to cool the piston rod.
Lubrication of Guide The guide bearing is splash-lubricated through the upward movement of
Bearing the crosshead. The oil is carried through the guide bearing clearance by
the piston rod to lubricate the bearing bush.

Crankgear
An auxiliary lubrication pipe may be installed to guarantee sufficient lubri-

cation at low rotation speed of the crankshaft, e.g. with rotation speed con-
trol or soft-start of compressor. Two jets of lubricating oil then lubricate the
piston rod directly below the guide bearing.
Oil Scraper Redura® is Burckhardt Compression’s brand for oil scrapers.

The wiper elements (2) remove the oil which passes the guide bearing
bush from the piston rod.
Depending on the diameter of the piston rod, two or three wiper elements
are installed – two for compressors of type 1D150, 1D130 and 1D100,
three for all other types.
The wiper elements are kept in place by a spring plate (3) which is fixed
under the bearing cover (4). The standard wiper elements are 1-piece
metal rings with a garter spring. As an option, 3-piece plastic rings can be
implemented. The entire set of the two types of oil scrapers can be inter-
changed.
In combination with the wiper elements, the oil shield (5) installed above the
guide bearing prevents oil creepage along the piston rod and ensures an
oil-free cylinder.
Oil Return The oil return from the guide bearing is led back to the crankgear through
an oil syphon. The resulting oil column in the oil syphon prevents oil mist
from entering the distance piece.
The standard oil syphon is a short u-pipe connected to the lower part of the
guide bearing. If the distance piece is purged, the oil syphon must be a long
u pipe (increasing the p).

Crankgear
4.2.6 Distance Piece
5 6 7
LD_M0_0041b_01
Fig. 4-8 Distance piece (typical view)
1 Crankgear 5 Oil shield

2 Guide bearing 6 Piston rod
3 Distance piece 7 Piston rod gland
4 Cylinder
The distance piece (3) is the area between piston rod gland (7) and guide
bearing (2). It separates the lubricated crankgear (1) from the oil-free, pro-
cess gas loaded area in the cylinder (4).
The distance piece of this compressor type is typically part of the crank-
gear.
Exceptions are the 1D150, 1D130 and 1D100 compressors where the dis-
tance piece is part of the cylinder.
In order to fit an oil shield (5) on the piston rod (6), the distance between
guide bearing and piston rod gland is longer than the piston stroke. In com-
bination with the oil scraper, the oil shield installed above the guide bearing
prevents oil creepage along the piston rod and ensures an oil-free cylinder.
In compressors of type D with non-gastight design, the distance piece can
be open. It is closed and purged with nitrogen or a suitable gas for applica-
tions with hazardous process gases like e.g. CO2.
For a non-toxic process gas, e.g. oxygen and nitrogen, all ports of the dis-
tance piece are closed by Plexiglas frame covers. The purge gas is re-
leased through a swing type cover. If the plant is indoors, the purge gas is
lead to a safe location.

Cylinder
4.3 Cylinder
LD_C0_0034b_01
3 2
Fig. 4-9 Sectional view of cylinder (typical view)
1 Cylinder 4 –
2 Piston rod gland 5 Labyrinth piston
3 Piston rod 6 Valve
In the cylinder (1), the process gas is compressed to the required pressure
by a labyrinth piston (5). The number of stages depends on the pressure
ratio between suction pressure and final discharge pressure or the speci-
fied discharge temperature.
There are different cylinder configuration (mono blocks, single blocks, etc.).
The standard material is grey cast iron. Depending on the application, nod-
ular cast iron or special castings can be applied.
The cylinder is accurately aligned with the piston and is pinned and
screwed onto the crankcase. The cylinder and the cylinder cover are water
cooled.
The cylinder wall is roughened by means of a fine thread to facilitate the
running-in of the piston.
For a high pressure application ( 100 bar/10MPa), the single acting HD
Laby® piston with a special cylinder design is used. In this case, the valves
are located in the steel cylinder head.
Spacer Ring
A spacer ring can be 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.

Cylinder
4.3.1 Piston Rod Gland
1 2 3 4
LA_C5_0030b_01
Fig. 4-10 Piston rod gland (typical view)
1 Gland rings, 1-piece rings 5 Intermediate ring

2 Spring 6 Gland ring, 3-piece ring
3 Piston rod 7 Leak gas pipe
4 Gland chambers 8 Gland flange
The piston rod gland seals off the gas compression area. It is equipped with
1-piece gland rings (1), with exception of the bottom gland ring (6) which is
a 3-piece ring. The 3-piece gland ring at the bottom is slightly pressed to
the piston rod by two garter springs. The 1-piece gland rings are of labyrinth
type design.
Multiple tiny throttling points create the seal in the same way as with the
labyrinth piston (see section 4.3.2 Piston Rod and Piston). At each of these
throttling points, pressure energy is transformed into kinetic energy. This
process continues as the gas travels down the piston rod gland.
Between gland ring and piston rod is a small clearance which results in a
gas leakage. The intermediate ring (5) collects the leak gas (7) and leads
it back to the 1st stage suction. In special cases, the leak gas is lead to a
safe location.

Cylinder
If the suction pressure is higher than 1.25 bar a/0.125 MPa a/

1.25 kg/cm2 a, two intermediate rings are installed. The upper one leads
the collected leak gas back to the 1st stage suction side, the lower one
leads it to a safe location.
The piston rod gland is fitted to the bottom side of the cylinder. To prevent
axial movement, the gland rings are equipped with springs (2). The springs
are placed in the bores of the gland rings.

Cylinder
4.3.2 Piston Rod and Piston
1 2 3 4 5 6
12 11 10 9 8 7
XA_C1_0004b_01
Fig. 4-11 Labyrinth piston (typical view)
1 Piston 7 Throttling point

2 Piston nut SUPERBOLT® 8 Key
3 Hardened washer 9 Washer (one or several pieces)
4 Piston crown (upper and lower) 10 Piston rod
5 Piston skirt 11 Groove for oil shield
6 Cylinder wall 12 Relief bore
Piston Rod The piston rod (10) is connected to the crosshead by a conical connection.
At the upper piston rod end there is a rolled thread for the piston nut.

Cylinder
The piston rod is divided in a lubricated and an oil-free area by a groove

(11). In this groove an oil shield is installed which prevents oil creepage fur-
ther up along the piston rod.
The standard piston rod is made of nitrided steel with a nitrided surface in
the oil scraper area and a chromium plated surface in the area of the piston
rod gland. In accordance with the application, other materials are used.
Piston The labyrinth piston and its guiding system – developed by Burckhardt
Compression – allow a contact-free sealing between piston skirt (5) and
cylinder wall (6). Multiple tiny throttling points (7) along the piston create the
seal. The labyrinth design requires no lubrication.
As the piston of this compressor type has no contact seals, there is no fric-
tion in the compression area, and therefore no hot spots. The seal has only
minimal wear and the system is therefore exceptionally durable and reli-
able.
Piston Design The standard labyrinth piston consists of three parts, the piston skirt as well
as the upper and lower piston crowns. The labyrinth grooves are machined
into the piston skirt.
3-piece pistons have a relief bore (12) machined into the piston skirt.
The relief bore has two functions: Through this bore the remaining process
gas inside the piston is released when the compressor is evacuated for
maintenance purposes. During operation, the relief bore ensures no over-
pressure inside the piston.
If the diameter of a piston is rather small, solid pistons are used. Solid lab-
yrinth pistons are machined of one part. The labyrinth grooves are ma-
chined into the outer face of the piston.
For special high-pressure applications (discharge pressure > 100 bar a/
10 MPa a), HD Laby® pistons are used. The HD Laby® piston consists of a
separate head section, a ring insert, and ring elements. The labyrinth
grooves are machined into the outer face of the ring elements. The ring el-
ements have a small clearance to the cylinder wall.
Double Acting and Single Acting Pistons

A labyrinth piston is usually double acting i.e. it compresses the process
gas on its upper as well as on its lower piston side. Some pistons are single
acting i.e. they compress the process gas only on their upper piston sides.
3-piece pistons and solid labyrinth pistons can be single or double acting.
HD Laby® pistons are always single acting.
This type of compressor is usually equipped with double acting pistons.
However, it may be equipped with different piston types, double acting pis-
tons and single acting pistons if the discharge pressure exceeds
60 bar g/6 MPa g.
Piston Clearance
The piston clearance is the gap between piston and cylinder wall. It is cre-
ated by the running-in procedure. The piston clearance and therefore the
running-in procedure depend on the operating temperature.

Cylinder
The cylinder wall has been roughened by means of a fine thread to facilitate
the running-in process. Both structures, the labyrinth grooves and the
thread, have an anti-seizing effect.
Cylinder Clearance
The cylinder clearance is the gap between the piston and the cylinder cover
in the top dead center (TDC), and between the piston and the cylinder
bottom in the bottom dead center (BDC).
The cylinder clearance is adjusted by inserting washers (9) between the
lower piston crown (4) and piston rod.
For 2D205 compressors with bolted connection between crosshead and
piston rod, the cylinder clearance is adjusted by the lower piston rod nut.
The position of the nut is fixed by a set screw.
Connection between Piston Nut SUPERBOLT®

Piston Rod and Piston
Labyrinth pistons are fastened to the piston rod with a piston nut SUPER-
BOLT® (2).
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.
For very small labyrinth pistons there is not enough room for a SUPER-
BOLT®. Therefore another type of special nut is used.

Cylinder
4.3.3 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
5 6
LD_CX_0004b_02
1
Fig. 4-12 Location and fixation of valves (typical view)
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), valve cover bolts (4) and pressure screws (5). For gas tightness,
the pressure screws are assembled with gaskets and cap nuts. 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 Valves™ type SB, in which the center bolt is fastened with
a nut instead of being screwed into either valve seat or valve guard, do not
meet the API 618 requirements – nor does the too small difference in the
diameter of the suction valve and discharge valve.
Burckhardt Plate Valve™
1 2 3 4
XA_CX_0076b_01
10 9 8 7 6 5
Fig. 4-13 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. 4-14 Sectional view of 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. 4-15 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.
4.3.4 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.
Oxygen compressors:
Capacity is not controlled by suction valve actuators and controlled suction
valves but by rotation speed control or bypass control.

Cylinder
9 1
4
7
5
LD_C3_0001b_01
Fig. 4-16 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 on smaller 9 Control medium return pipe
valves)
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.

Cylinder
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).
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.
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 . . . . . . . . . . . . . . . 5-4
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 Skid . . . . . . . . . . . . . . . . . . . 5-7
5.2.5 Check Scope of Supply . . . . . . . . . . . . . . . . . . . . 5-7
5.2.6 Store Components prior to Installation . . . . . . . . . 5-8
5.3 Dimensions, Weights, Space Requirement. . . . . . . . . . . . . 5 - 10
5.4 Lifting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 12
5.4.1 Tightening Torques for Attachment Gear . . . . . . . 5 - 12
5.4.2 Lift Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 13
5.4.3 Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 14
5.4.4 Lift Compressor Skid . . . . . . . . . . . . . . . . . . . . . . 5 - 15
5.4.5 Lift Plant Components . . . . . . . . . . . . . . . . . . . . . 5 - 16
5.5 Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 18
5.6 Grouting Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 20
5.7 Install Compressor Skid on Foundation . . . . . . . . . . . . . . . 5 - 22
5.7.1 Prepare Installation. . . . . . . . . . . . . . . . . . . . . . . . 5 - 22
5.7.2 Place and Level Compressor Skid . . . . . . . . . . . . 5 - 24
5.7.3 Grout Foundation Bolts. . . . . . . . . . . . . . . . . . . . . 5 - 25
5.7.4 Fine-Tuning Adjustment . . . . . . . . . . . . . . . . . . . . 5 - 28
5.7.5 Grout Supporting Surface of Skid. . . . . . . . . . . . . 5 - 29
5.7.6 Tighten Foundation Bolts of Skid . . . . . . . . . . . . . 5 - 30
5.7.7 Further Steps for Skid Installation (Optional) . . . . 5 - 30
5.8 Install Pipe Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 31
5.8.1 Prepare Fabrication . . . . . . . . . . . . . . . . . . . . . . . 5 - 31
5.8.2 Fabricate Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 32
5.8.3 Check Fabrication. . . . . . . . . . . . . . . . . . . . . . . . . 5 - 35
5.8.4 Pickle and Passivate Piping . . . . . . . . . . . . . . . . . 5 - 37
5.8.5 Sandblast Piping. . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 41
5.8.6 Recommendation for Pipe Support . . . . . . . . . . . 5 - 42
5.8.7 Recommendation for Tube Fittings . . . . . . . . . . . 5 - 50
5.8.8 Final Assembly of Piping . . . . . . . . . . . . . . . . . . . 5 - 62
5.8.9 Hydrostatic Pressure Test. . . . . . . . . . . . . . . . . . . 5 - 64
5.9 Non-Return Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 65
5.10 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 66
5.10.1 Fit Grounding Wire . . . . . . . . . . . . . . . . . . . . . . . . 5 - 66
5.11 Pre-Commissioning of Compressor Plant. . . . . . . . . . . . . . 5 - 68

5.11.1 Prerequisite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 68
5.11.2 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 68
5.11.3 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . 5 - 69
5.11.4 Check Cleanliness of Gas System . . . . . . . . . . . . 5 - 70
5.11.5 Turn Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 70
5.11.6 Blowing out the Gas Piping System . . . . . . . . . . . 5 - 71
5.11.7 Running in Pistons. . . . . . . . . . . . . . . . . . . . . . . . . 5 - 74
5.11.8 Assess Vibrations . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 77
5.11.9 Frame Vibration Measurement . . . . . . . . . . . . . . . 5 - 79
5.11.10 Inspect Compressor Plant . . . . . . . . . . . . . . . . . . . 5 - 80
5.11.11 Preserve Compressor Plant after Installation . . . . 5 - 80
5.11.12 Maintain Plant during Decommissioning . . . . . . . . 5 - 82
5.11.13 Recommission Plant . . . . . . . . . . . . . . . . . . . . . . . 5 - 83

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 5.11.8 As-
sess Vibrations) and, therefore, to problems and/or service interruptions.
Examples of possible consequences are: bursting of pipes, excessive wear
of piston, gland rings and bearings.
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 our Services Division (address see sec-
tion 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 oxygen or with process gas have been
cleaned either in our works or by sub-suppliers according to Burckhardt
Compression cleaning instructions, accepted by all well-known customers.
They have been checked for cleanliness and labeled “Cleaned for oxygen
service”.
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.
The main contaminants to be avoided and/or eliminated are hydrocarbon
oils and greases, which are easily combustible and particulate matter,
which can easy ignite or cause ignition.
If any cleaning of surfaces is necessary, refer to chapter 10 Clean and
Degrease Plant and Compressor Components.
DANGER
Fire hazard!
Powerful oxidizing power!
posed to process gas to required level of cleanliness (oxygen service).
 Use lint-free cleaning tissue only.

Important Notes
DANGER
Fire hazard!
It is of outmost importance, that all components coming in contact with pro-
cess gas are checked for cleanliness prior to their installation.
 Parts without label “Cleaned for oxygen service” must be cleaned ac-
cording to the cleaning specification.
 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.
Compressor For tightening methods of bolted connections see section 8.7.3 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.
WARNING
Plant components like coolers, pulsation dampers, separators can fall!
 Store them securely.
 Keep them from falling.
DANGER
Suspended loads!
Falling loads can cause serious injury or death.
 Protect carrying ropes/straps against sharp edges.
 Do not stand beneath suspended loads.
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 and Gas Cooler

To protect the internal parts against corrosion, the vessels are filled with dry
nitrogen prior to dispatch. An adhesive label with corresponding warning
sign is affixed to the vessel.
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 conditions depend on the transport circumstances, local situ-
ation and lifting tackle available on site.
As a general rule, the compressor should be transported as completely as-
sembled as possible. When leaving the packager, the compressor is skid
mounted and will be delivered separated into the following component
groups:
• skid with compressor complete and motor,
• individual components palletized.
5.2.4 Unload Compressor Skid

Please proceed according to sections 5.2.1 Safety of Transport and 5.4
Lifting Procedure.
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).

Transport
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 our Services
Division (address see section 1.6 Contact Address) concerning protec-
tive 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.
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.

Transport
CAUTION
Corrosion due to improper preservation during long-term storage.
 For long-term storage consult our Services Division (address see sec-
tion 1.6 Contact Address) concerning protective measures 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.
To protect the internal parts against corrosion, some components are filled
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 oxygen in the atmosphere. At high
concentrations, they can lead to unconsciousness or death.
 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 1749 mm
Width 1216 mm
Height 2933 mm
Electric Motor Dimensions
Length 2110 mm
Width 1070 mm
Height 1490 mm
Weights (Approximative)
Compressor complete (without flywheel) 6900 kg

Skid with compressor complete and motor 30000 kg
Electric motor 4500 kg
Flywheel 800 kg
Crankgear complete 3900 kg
st
Cylinder 1 stage (including covers, valves, 3000 kg
and piston rod gland)
Cylinder cover 1st stage 120 kg
st
Piston with piston rod 1 stage 94 kg
Crankshaft 364 kg

Dimensions, Weights, Space Requirement
Space Requirements
2
h
B
3 H
LA_XX_0071b_03
D
7 6 5 L F
Fig. 5-3 Space requirements (typical view)
1 Eye bolt 5 Cylinder

2 Piston 6 Grouting material
3 Compressor 7 Flywheel
4 Crankshaft
H Minimum height for piston removal 4200 mm

h Height of assembled piston rod and piston 1326 mm
L For crankshaft removal 2000 mm
D Diameter of flywheel 1200 mm
B Space 1700 mm
F For flywheel removal 1080 mm
CAUTION
Crane way too low
Damage to piston rod and cylinder due to too low crane way. If the crane
way is too low, it may even be impossible to remove the pistons.
 Make sure that the crane way is high enough to account for additional
height of all attachment gear.
 Add sufficient height to the value H (minimum height for piston re-
moval).

Lifting Procedure
5.4 Lifting Procedure
This section describes also the lifting procedure for cylinder – despite the
fact that the compressor is transported completely assembled and is in-
stalled on the skid frame – to use for a later dismantling of the compressor
e.g. for maintenance reasons.
5.4.1 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
M27 4.0 t 400 Nm
RUD VLBG
M30 5.0 t 500 Nm

M36 7.0 t 700 Nm
M42 15.0 t 1500 Nm
Tab. 5-1 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
5.4.2 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
LD_T9_0058a_01
Fig. 5-4 Transport and lifting of compressor

Lifting Procedure
5.4.3 Lift Cylinder

Transport.
DANGER
Suspended loads!
 Lift cylinder only in the correct manner as described and illustrated in
this Instruction Manual.
°
45
n.
mi
LD_T9_0039a_02
Fig. 5-5 Transport and lifting of cylinder

Lifting Procedure
5.4.4 Lift Compressor Skid

Transport.
DANGER
Suspended loads!
 Lift skid only in the correct manner as described and illustrated in this
Instruction Manual.
4000
LD_T9_0060b_01
7900 3200
Fig. 5-6 Transport of skid
1 Crane hook
2 Spreader bar

Lifting Procedure
5.4.5 Lift Plant Components

Transport.
DANGER
Suspended loads!
 Lift plant components only in the correct manner as described and illus-
trated in this Instruction Manual.
to the weight of the heaviest individual component.
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. 5-7 Transport and lifting of a damper (horizontal design)

Lifting Procedure
Example for Damper

(Typical View)
Fig. 5-8 Transport and lifting of a damper (vertical design)
Example for Cooler

(Typical View)
Fig. 5-9 Transport and lifting of a cooler

Foundation
5.5 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 skid, 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. 5-10 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. Use inorganic material for
oxygen plants.
2. Do not arrange building parts close to the compressor foundation block
(see Fig. 5-10, 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. 5-10, detail (3) shows the incorrect
design).

Foundation
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. 5-12, 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.

Grouting Material
5.6 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 
ITW Philadelphia Resins Chockfast® Orange Marine application1 
® 2
BASF Construction MASTERFLOW 648 On concrete foundation 
Chemicals PCI Repaflow EP Plus
BASF Construction MASTERFLOW® 928 Foundation bolts and ac- 
Chemicals MASTERFLOW 870 ® cessories
PCI Repaflow
1.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.
2. MASTERFLOW products may in certain regions be on the market under different product names.
Tab. 5-2 Grouting material product information
For grouting of the compressor’s supporting surface, Burckhardt Compres-

sion recommends to use one of the in Tab. 5-2 listed epoxy grouting mate-
rials.
If another grouting material than listed in Tab. 5-2 will be used, please con-
sult your local civil engineer for support.

Grouting Material
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.

Install Compressor Skid on Foundation
5.7 Install Compressor Skid on Foundation
CAUTION
Material damage caused by non-professional installation!
 Installation of the skid must be done by Burckhardt Compression field
service engineers. For damage caused by non-professional installa-
tion, Burckhardt Compression will not assume any liability.
5.7.1 Prepare Installation

Prepare Jackscrews
Fig. 5-11 Jackscrew
1. To avoid clogging, lubricate the threads of the jackscrews before set-

ting them, using MOLYKOTE® G-N Plus or ball-bearing grease.
2. For each foundation bolt, use a jackscrew and adjust to required
height. Adjustment range is 12 to 22 mm, depending on jackscrew
type.
3. For additional height adjustment, add shims.
4. Ensure that the jackscrews have sufficient distance to the foundation

bolts. Sufficient distance is essential for the encasing and removal of
the jackscrews.
5. Level the jackscrews accurately. It must be ensured that the jackscrews
are kept absolutely horizontal in all directions by using a precision spirit
level.
6. Use mortar for temporary fixation of the jackscrews.
CAUTION
Damage to the foundation, crankgear and/or compressor can occur.
 Ensure that all jackscrews and leveling bolts are removed after
grouting.
 Encase all jackscrews and leveling bolts accordingly.

Prepare Skid 7. Clean the bottom side of the skid, getting into contact with the grouting
material. The supporting surface must be clean and absolutely free of
oil, rust, paint and grease.
Prepare 8. Insulate the foundation bolts at least for 1/3 length from the top with
Foundation Bolts thick tape or using an insulating tube of foam material (free expansion
length of foundation bolt).
9. Center the foundation bolts in the through holes of the compressor and
the skid using cardboard or sealing material. This procedure enables a
later readjustment of the compressor.
A B
1
1/3
1/3
3
5
2/3
2/3
6
XA_XX_0036b_03
Fig. 5-12 Preparation of 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
skid!
 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 10. Before placing the skid on the foundation, specify how to encase the
supporting surfaces to be poured. Do not cast in the jackscrews.
Specify the encasing accordingly.

CAUTION
Stress cracks in the epoxy grouting material due to it’s thermal expan-
sion during curing time.
 Provide expansion joints every 1.5 meter.
5.7.2 Place and Level Compressor Skid

Transport and For transport and lifting of the skid, take care to avoid any damage; please
Lifting of Skid refer to section 5.4 Lifting Procedure.
DANGER
Suspended loads!
 Lift skid only in the correct manner as described and illustrated in this
Instruction Manual.
Place Skid 1. Remove transportation bolts between compressor and skid from the
on Foundation foundation bolt holes of the compressor.
2. Remove transportation bolts between motor and skid from the founda-
tion bolt holes of the motor.
3. Fix compressor and motor onto skid by means of clamps or transporta-
tion bolts.
4. Place skid including its foundation bolts onto the jackscrews.
 The skid must evenly sit on all jackscrews.
5. 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.
6. If required add additional jackscrews or shims. Stress on the structure

or piping must be avoided.
Level Skid 7. Level the complete skid lengthwise, crosswise and in diagonal direction
by turning the jackscrews using a spanner. Use a long leveling bar
(min. 2 m) and a precision spirit level.
The display accuracy (scale lines) of the spirit level must show at least
0.2 mm/m.

5.7.3 Grout Foundation Bolts
The goal of the following procedure is to install and grout the foundation
bolts as shown below:
Grout Foundation Bolts The compressor on the skid will be installed and grouted as follows, see
of Compressor Fig. 5-13:
9
XA_XX_0358d_01
Fig. 5-13 Installation of compressor with skid steel structure on foundation
1 Nut 6 Jackscrew
2 Foundation bolt 7 Insulation
3 Compressor 8 Non-shrink grouting material
4 Plate 9 Concrete foundation
5 Skid

Grout Foundation Bolts The motor on the skid will be installed and grouted as follows, see
of Motor Fig. 5-14:
10
XA_XX_0361c_01
Fig. 5-14 Installation of compressor with skid steel structure on foundation
1 Motor 6 Skid
2 Leveling bolt 7 Jackscrew
3 Foundation bolt/nut 8 Insulation
4 Shims 9 Non-shrink grouting material
5 Sole plate 10 Concrete foundation

Grout Foundation Bolts The skid will be installed and grouted as follows, see Fig. 5-15:
of Skid Steel Structure
1
XA_XX_0362b_01
Fig. 5-15 Installation of skid steel structure on foundation
1 Nut and washer 5 Insulation

2 Foundation bolt 6 Non-shrinking grouting material
3 Skid 7 Concrete foundation
4 Jackscrew
Procedure
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. 5-16 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.
5.7.4 Fine-Tuning Adjustment
1. Level the frame according to the leveling protocol of the skid manufac-
turer by using the reference points (notches), starting at the master
point. Take care that proper reference is observed from top of the ma-
chined compressor support to the master point.
2. Proceed until all reference points are within the maximum allowable tol-
erance of ± 0.25 mm of recorded measurement. An optical level is rec-
ommended; however a water hose level may be used as well.
3. Fix the frame by partly tightening all foundation bolts (to avoid buoying
of skid on grout).
4. Recheck reference points according to the leveling protocol of the skid
manufacturer.
5. Check compressor skid for distortion by checking crankshaft deflec-

tions (see section 8.8.1 Check Crankshaft Deflection).
6. Check for soft foot and verify alignment.
7. Install flexible elements or discs of the coupling.
8. Check for stress- and strain-free pipes by loosening some of the pipe
flanges.

5.7.5 Grout Supporting Surface of Skid

For information about foundation see section “Foundation” in chapter 13
Appendix.
The actual grouting procedure must be done in two steps.
CAUTION
Inappropriate use of grouting material can lead to deformation of
steel frame!
 Strictly follow grout manufacturer’s instructions (e.g. layer thickness,
treatment temperature etc.).
 Grouting must be carried out or supervised by an authorized company.
1. Check preparations according to section 5.7.1 Prepare Installation:

• Sufficient distance between jackscrews and foundation bolts.
2. Do not cast-in the jackscrews as they must be removable after

grouting. Prepare the encasing accordingly.
1st Step of Grouting 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 it’s thermal expan-
sion during curing time.
 Provide expansion joints every 1.5 meter.
2nd Step of Grouting 4. Remove jackscrews after the grouting material has hardened and grout
cavities.
CAUTION
Deformation of crankgear/skid due to premature pressure load of
grouting material.
 Remove jackscrews only after the grouting material has hardened or
has at least reached a resistance to pressure of 40 N/mm2.
 Please refer to manufacturer’s instructions.

5.7.6 Tighten Foundation Bolts of Skid
CAUTION
Deformation of skid due to premature pressure load of grouting ma-
terial.
 Tighten foundation bolts only after the grouting material has hardened
or has at least reached a resistance to pressure of 40 N/mm2.
1. After the setting times for all used grouting materials have expired,
loose the nuts of the foundation bolts.
2. Slightly grease the threads of foundation bolts and contact areas of the
nuts with MOLYKOTE® G-N Plus.
3. Finally tighten the foundation bolts with the mandatory tightening
torque.
 Check with dial gauge: the crankcase level is not permitted to
change (sink or drop) any more than 0.05 mm when tightening the
foundation bolts. This applies to each foundation bolt.
5.7.7 Further Steps for Skid Installation (Optional)
1. If required by the Client, the remaining void at the inner part of the base
frame may also be filled with concrete. If drain pipes are installed on the
frames, do not forget to install drain piping before the grout is filled in.
2. Burckhardt Compression recommends the application of an oil-resis-
tant coating on the concrete surface.

Install Pipe Work
5.8 Install Pipe Work
5.8.1 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.
5.8.2 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. 5-18).
• Parallelism, of the aligned flange faces, sometimes referred as angular
alignment (Fig. 5-17).
X1
XA_XX_0103a_03
Fig. 5-17 Parallelism of aligned faces
X1 Deviation X1
X2
X2
XA_XX_0073a_02
Fig. 5-18 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. 5-19 Stub-end welding
1 Pipe
2 Weld
3 Stub end
4 Flange
• 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
5.8.3 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.
For specific tightening methods and a comprehensive table with tightening

torques please see section 8.5.1 Tightening Torques and Method.

Install Pipe Work
Standard Flange
X
Connections 3
XA_XX_0074a_02
Fig. 5-20 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. 5-20).
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.

Install Pipe Work
Cleaning After the pipes have been fitted, they are to be dismantled and cleaned,
e.g. by sandblasting, acid treatment (see section 5.8.4 Pickle and Pas-
sivate Piping) or mechanical action.
DANGER
Fire hazard!
 Degrease and clean process gas pipes with an oil and grease re-
moving solvent to required level of cleanliness (oxygen service).
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 5.11.8 Assess Vibrations.
5.8.4 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 5.8.2
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.

Install Pipe Work
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.
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. 5-21. 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. 5-21 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. 5-22).
3
2
XA_XX_0049b_01
1
Fig. 5-22 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 2.7 Safe Maintenance Practices.

Install Pipe Work
5.8.5 Sandblast Piping
Sandblasting may only be applied to carbon steel items.
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 5.8.4 Pickle and Passivate
Piping.

Install Pipe Work
5.8.6 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".
XA_XX_0075b_01
Fig. 5-23 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. 5-24 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 (Gliding For insulated gas piping from DN20/ ¾" to DN500/ 20", Burckhardt Com-
Point) for Insulated Gas pression recommends to use a pipe support of this type (gliding point), con-
Piping sisting of 2 pipe clamps.
Z1
XA_XX_0079b-02
4
1 Pipe clamp
2 Shim
4 Support beam
The thickness of insulation depends on the application and customer spec-

ification.
During installation, the gap Z1 (theoretically 7–25 mm) must be bridged

with 2 shims (2).
The pipe must remain movable in longitudinal direction.
A non-metallic shim must be mounted between the pipe and the pipe clamp
in order to absorb vibrations.

Install Pipe Work
Pipe Support (Gliding For insulated gas piping from DN20/ ¾" to DN500/ 20", Burckhardt Com-
Point) for Insulated Gas pression recommends to use a pipe support of this type (gliding point), con-
Piping sisting of 2 pipe clamps.
Z1
XA_XX_0172b-01
4
1 Pipe clamp
2 Shim
4 Support beam

ification.
During installation, the gap Z1 (theoretically 7–25 mm) must be bridged

with 2 shims (2).
The pipe must remain movable in longitudinal direction.

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. 5-27 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 (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 insulated gas piping from DN20/ ¾" to DN500/20", Burckhardt Com-
for Insulated Gas Piping pression recommends to use a pipe support of this type (fixed point), con-
sisting of 2 pipe clamps.
Z1
XA_XX_0080b_02
4
1 Pipe clamp
2 Open distance
4 Support beam

ification.

Install Pipe Work
Pipe Support (Fixed Point) For insulated gas piping from DN20/ ¾" to DN500/20", Burckhardt Com-
for Insulated Gas Piping pression recommends to use a pipe support of this type (fixed point), con-
sisting of 2 pipe clamps.
Z1
XA_XX_0173b_01
4
1 Pipe clamp
2 Open distance
4 Support beam

ification.

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
1 Pipe clamp
2 Plate
3 Support beam
beam.

Install Pipe Work
5.8.7 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.
XA_XX_0052a_01
Fig. 5-31 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. 5-32 SERTO® union
1 Basic component
2 Compression ferrule
3 Nut
4 Stiffener sleeve
d Tube outside diameter
s Wall thickness
DANGER
Fire hazard!
Procedure:
1. Preparation
XA_XX_0054a_01
Fig. 5-33 SERTO® preparation

Install Pipe Work
• 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).
2. Reinforce Tube and Insert
XA_XX-0055a_01
Fig. 5-34 SERTO® reinforcement
• Stiffener sleeves are required to reinforce plastic tubes and thin

walled tubes.
Tube material Diameter Wall thickness (s)

Copper tubes from 10 mm < 1.0 mm
from 12 mm < 1.5 mm
Stainless steel tubes from 6 mm < 0.5 mm
from 10 mm < 1.5 mm
Tab. 5-5 Tube dimensions
• Align tube and union.

• Insert tube up to the stop.

Install Pipe Work
3. Tightening, Stress Relieving, Checking
XA_XX_0056a_01
Fig. 5-35 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.
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. 5-36 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.

Install Pipe Work
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. 5-37 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.
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).

Install Pipe Work
XA_XX_0059a_01
Fig. 5-38 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. 5-39 Tube cut using pipe cutter: considerable burr formation/tube not cut off
square
XA_XX_0061a_01
Fig. 5-40 Sawn off tube: hardly any burr formation
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. 5-41 EO parts
• Slide nut and progressive ring onto end of tube.

Install Pipe Work
XA_XX_0063a_01
Fig. 5-42 EO ring on tube
• Do not slide on progressive ring backwards!
XA_XX_0064a_02
2
Fig. 5-43 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.
XA_XX_0065a_01
Fig. 5-44 Tightening of nut by hand
• Mark a line on nut and tube in order to observe the required number of
turns.

Install Pipe Work
XA_XX_0066a_01
Fig. 5-45 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. 5-46 Tightening of 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).
XA_XX_0068a_01
Fig. 5-47 Loosening of nut
Reassembly:
• After every reassembly, retighten nut without applying more force than
for the first assembly. Firmly hold fitting body during the assembly.

Install Pipe Work
XA_XX_0069a_01
Fig. 5-48 Reassembly
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.
XA_XX_0070a_01
XA_XX_0048a_01
Fig. 5-49 SWAGELOK® union
Fig. 5-50 SWAGELOK® parts

Install Pipe Work
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:
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. 5-51 SWAGELOK® step 1
2. Before tightening of SWAGELOK® nut, mark nut at the 6 o’clock posi-

tion.
XA_XX_0046a_01

Install Pipe Work
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.
XA_XX_0044a_01
Fig. 5-54 Gauge check
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.

Install Pipe Work
XA_XX_0043a_01
Fig. 5-55 Gauge check
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. 5-56 Disconnected fitting
2. Insert tube with ferrule into fitting until it stops.

XA_XX_0041a_01
Fig. 5-57 Tube insertion
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

Install Pipe Work
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. 5-58 Tightening of nut
5.8.8 Final Assembly of Piping
Flange Connections
1. Clean nuts and bolt threads.
2. Grease stainless steel bolts with Burckhardt Lubrication Grease

BLG05.
3. Remove spare gaskets that were used for piping adjustments (as rec-
ommended in section 5.8.2 Fabricate Piping). Install final, undamaged
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. 5-59.
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).
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.

Install Pipe Work
1 9
15 5
8 13
12 3
4 11
XA_XX_0083a_02
14 7
6 16
10 2
Fig. 5-59 Tightening sequence of nuts
Gas pipes must be installed stress-free (see section 5.8.6 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
5.8.2 Fabricate Piping and “Acceptance Criteria for Misalignment” in sec-
tion 5.8.3 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.

Install Pipe Work
5.8.9 Hydrostatic Pressure Test
DANGER
Flammable residues of solvent in gas system.
These residues can cause fire or explosions.
 Never use solvents for pressure tests.
 Only use liquids which are approved for oxygen service.
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.
If a pneumatic test is to be carried out, approved additional local safety reg-

ulations must be considered.
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.
Cleaning After the hydrostatic pressure test, clean all parts and surfaces of the plant
components exposed to process gas according to chapter 10 Clean and
DANGER
Fire hazard!
Guidelines for The specific guidelines of the IGC-document (Industrial Gas Committee)
Oxygen Plant “Cleaning of Equipment for Oxygen Service”, IGC Doc 33/06/E give more
detailed information and are valid for oxygen compressor plants.

Non-Return Valve
5.9 Non-Return Valve

Installation Install the non-return valve according to following figure.
• 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.
2 3 4 5 6 7
XA_L2_0002b_01
Fig. 5-60 Non-return valve (typical view)
1 Flow direction 5 Housing

2 Threaded bolt 6 Non-return valve
3 Flange 7 Nut
4 Gasket

Electrical Installation
5.10 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!
5.10.1 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.
XA_XX_0081b_02
Fig. 5-61 Grounding connection (typical view)
1 Washer
2 Spring washer
3 Grounding wire

Electrical Installation
LA_M0_0007b_02
3
Fig. 5-62 Grounding connection on crankgear (typical view)
1 Crankgear
2 Grounding connection
3 Spring washer
4 Washer
Facing the flywheel, the grounding connection (Fig. 5-62) 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.
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.

Pre-Commissioning of Compressor Plant
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.
5.11 Pre-Commissioning of Compressor Plant
We strongly recommend to perform pre-commissioning under the supervi-

sion of a specialist from Burckhardt Compression. For damage caused by
non-professional commissioning, Burckhardt Compression will not assume
any liability.
5.11.1 Prerequisite
Emergency Stop for To permit an immediate shutdown of the compressor in an emergency
Running-In Procedure during running-in procedure, the electrician must install a temporary emer-
gency stop push button with a sufficiently long cable around the com-
pressor.
WARNING
An emergency situation may occur.
 Before starting the running-in procedure, check the emergency stop
push button for proper functioning.
Instruction of Our field service engineer (FSE) will instruct your personnel which is in
Operating Personnel charge of the monitoring of operation (e.g. instructions, no training).
5.11.2 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. Remove the upper cover of the frame. Let the coolant circulate
and visually check the tightness of the system.
CAUTION
Specially check the internal screwed pipe connections of the guide bearing
for tightness while the upper cover of the frame is removed, as any entry of
water into the compressor will cause extensive damage.

Do not operate any equipment at conditions which exceed those specified

on the name plate(s).
Consult 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.
Bolted Joints All external bolted joints may require retightening 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.
5.11.3 Lubricating System

Clean the crankgear with a new, unused sponge (do not use any fibrous,
fuzzy cloth). Fill the compressor sump with lubricating oil until 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
Switch on the prelubrication pump, immediately check rotation of the pump
and that the lubricating system is tight.
Turn the flywheel several times by hand – using the bar – in running direc-
tion. Check that lubricating oil is being distributed to all the bearing points
of the crankshaft and the crossheads.
The lubricating oil pressure must rise to about 3.5 to 4.0 bar g/0.35 to 0.40
MPa/3.5 to 4.0 kg/cm2.
Required Checks Check tightness of lubricating system. If the lubricating system is tight, fill
oil to about 3/4 of the sight glass. Required lubricating oil quantity: see sec-
tion 8.7.6 Oil Change.

5.11.4 Check Cleanliness of Gas System

Before the initial start-up of the compressor, make absolutely sure that the
suction and discharge lines are properly cleaned (see section 5.8.4 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.
5.11.5 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 several
times by hand – using the bar – in running direction. Verify that everything
is in proper mechanical condition. While turning the flywheel, lavishly
smear the piston rods below the guide bearing with the operating oil of the
compressor.
LA_XX_0021a_02
Fig. 5-63 Remove bar after use

DANGER
Rotating components, drawing in and crush hazard!
 Always remove bar from flywheel after use.
 Do not operate the compressor with flywheel guard removed.
5.11.6 Blowing out the Gas Piping System
WARNING
 Before switching on the motor (= compressor start), check the emer-
gency stop push button for proper functioning.
Before running in the compressor, blow out the suction line – and its acces-
sories – 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.
Special Tools Blind flange with distance piece (see Fig. 5-65); not supplied by Burckhardt
Compression.
General Procedure of 1. Prepare the cylinder for blowing-out: Remove the valve covers, lan-
Blowing-Out terns and valves on the suction sides.
2. Remove covers of distance piece.
3. Remove suction strainer.

XA_XX_0101a_01
4. Blow out the suction line upstream of the first stage:

• Insert blind flanges (5) with mounted distance pieces (4) on the
suction side. 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. The threaded bolts (2)
of the valve covers must be tightened.
LA_CX_0005b_01
5 4 3 2
Fig. 5-65 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 upstream and the valve chambers (3) 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.
5. 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 several times 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.
6. Remove the steel wire screen from the suction line and close the
opening.
7. If a suction strainer was installed, re-install it.

5.11.7 Running in Pistons
WARNING
 Before starting the running-in procedure, check the emergency stop
push button for proper functioning.
General Remarks Important Prerequisites
The running-in procedure is also applicable to new pistons after replace-

ment (except bearing temperature checks and blowing out of piping). Refer
to section “Control Description” in chapter 13 Appendix.
DANGER
Ignition sparks possible during running-in of pistons.
In the presence of oxygen, ignition sparks can set compressor parts to fire.
 Use only dry, oil-free nitrogen or dry instrument air for running-in!
Measure piston clearances before running-in (see section 8.9.4 Piston

Clearance Measurement).
Labyrinth pistons require a specially careful method of running-in due to the

very small diametrical clearance between cylinder and piston. During run-
ning-in, piston and cylinder wall may slightly rub against each other, thus
nitrogen is used for this procedure.
There could be always vibrations. If necessary, additional pipe supports
must be fitted prior to start-up of the plant (example of pipe fastenings see
section 5.8.6 Recommendation for Pipe Support).
Refer to section 5.11.8 Assess Vibrations if there are vibrations.
WARNING
Temperatures increased too fast, overheating of components
Damage to bearings and piston may occur.
 During the entire running-in period, the compressor must be carefully
observed.
 Keep the temporary emergency stop push button (with sufficiently long
cable) at hand during the entire running-in period.
Running-In Start up and let the gas temperatures and gas pressures stabilize. Gradu-
ally increase the discharge pressure during a period of several hours.
Throttle the gas in the discharge line until the outlet temperatures are ap-

prox. equal to the maximum predicted temperatures reached under most

extreme conditions (see Tab. 5-6). Throttling is done by increasing the
stage discharge temperatures 10 to 15°C every 15 minutes.
Closely observe the running of the compressor. Listen for abnormal noise
at the compressor frame. Record gas temperatures and pressures regu-
larly.
Should a piston start to seize at the cylinder wall during running-in, stop the
compressor at once. Seizing can be noticed by a suddenly increasing irreg-
ular noise from within the compressor. For continuation of the running-in
procedure, wait with restarting until pistons are cooled off (15 minutes).
Stage Minimum Discharge Temperature

st
1 stage 189°C
Tab. 5-6 Minimum discharge temperatures for running-in procedure
Further Steps 1. After the final stage running-in temperatures are reached, keep the
and Checks compressor at this load for at least 1 hour. A final bearing temperature
check must be made after this period.
2. When the lubricating oil has reached operating temperature, the oil
pressure must be adjusted to approx. 3.5 to 4.0 bar g/0.35 to 0.40 MPa/
3.5 to 4.0 kg/cm2 via the relief valve fitted to the gear oil pump / the
bearing bracket at the drive end.
To adjust the oil pressure, the valve must be unscrewed through the service
cover.
 The spring tension can be increased by placing washers between
screw plug and spring.
5
LA_M2_0004c_01
Fig. 5-66 Relief valve on gear oil pump
1 Gear oil pump 4 Washers

2 Screw plug 5 Spring
3 Gasket 6 Valve body

3. The oil scrapers must seal properly. In case oil leaks over the oil shield
onto the piston rod, the oil scrapers must be checked as described in
section 8.8.7 Guide Bearing. For this procedure, the respective piston
must be removed from the compressor.
4. Adjust the safety instruments in accordance with section “Instrumenta-

tion” in chapter 13 Appendix and check their proper functioning.
5. Check piston clearances with a feeler gauge according to the table of

clearances (see section “Compressor” in chapter 13 Appendix). Check
tightening torque of piston nut according section “Compressor” in
6. It is recommended to remove all the valves for cleaning and to dry out
all condensate in the valve chambers, flash drums and gas pipes. All
flanged connections and pipe fastenings must be re-tightened. Due to
pulsating delivery of the gas through pipes and coolers, powerful forces
and hence pronounced vibrations may set up, especially on long gas
lines with several bends. Apart from damaging the weld seams, this
may also lead to the smooth running of the compressor being impaired.
If necessary, additional pipe supports must be fitted prior to start up of
the plant.

5.11.8 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. 5-67):
XA_XX_0072a_01
Fig. 5-67 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. 5-68):
XA_XX_0071a_01
Fig. 5-68 Pipes without stress raisers
Accessories (e.g. Cooler and 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 labyrinth piston compressors are indicated on the foun-
dation drawing. These values represent the basis for the final determina-
tion of the foundation by the civil engineer. The compressor is considered
to be a rigid body. Under these considerations the given values of ampli-
tudes apply to measurements made on the cylinder block and are below
the values in ISO 10816-6.
Effective Vibrations The maximum specified acceptable vibration velocity values are not ex-
on the Installation ceeded under normal circumstances, see Tab. 5-7. 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 5.8.6 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. 5-7 Maximum vibration values
5.11.9 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.
5.11.10 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 5.11.8 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
5.11.11 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 our Services Division, 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. Blow out the cooling chambers of the piston rod guide bearing with
compressed air (if an antifreeze solution is used, drainage is not nec-
essary under certain circumstances).
3. Fill crankgear with lubricating oil.

A special corrosion protecting oil from a reputable supplier may be
used during the standstill period.
4. Oil the piston rods well by hand up to the oil shield. Turn the flywheel
several times by hand – with the bar – in running direction.
Generally, the gas conducting compressor and plant components should

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

through continuously with nitrogen, or kept under a slight overpressure of
0.20 bar g/0.02 MPa g/0.20 kg/cm2 g.
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.
6. Alternative solution:
To prevent corrosion in the vicinity of the cylinder and down to the guide
bearings, insert moisture absorbent agent – e.g. VCI mats (Volatile
Corrosion Inhibitor) – in the cylinder, 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.
5.11.12 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 (ap-
proximately 10 rotations).
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.).

For the description of the electric motor refer to the documentation of the
motor manufacturer.
4. Annually conduct a condition check of the complete compressor

system.
5.11.13 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.
Address.
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 Prerequisites for Commissioning on Oxygen . . . . 6-4
6.2.2 Prepare Operation . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.2.3 Purge Plant with Nitrogen. . . . . . . . . . . . . . . . . . . 6-6
6.3 Operation with Process Gas . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.3.1 Safety of Operation. . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.3.2 Initial Run on Oxygen . . . . . . . . . . . . . . . . . . . . . . 6-8
6.3.3 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.3.4 Clean Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.4 Standstill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 11

Operation

Operation
Design Data
6.1 Design Data
Specification Value
Key word Linde Gdansk
Compressor type 2D200B-1A_1
Serial no. 102609
Weight of compressor (without flywheel) 6900 kg
Weight of compressor skid xxxxx kg
Year of manufacture 2016
Process gas Oxygen (O2+)
Mass flow 3501 kg/h
Standard volume 2439 Nm3/h
Suction volume 2299 m3/h
Suction temperature 38 °C
Suction pressure 1.21 bar a/0.121 MPa a/
1.21 kg/cm2 a
Discharge pressure 4.26 bar a/0.426 MPa a/
4.26 kg/cm2 a
Shaft power (coupling) 162 kW
Electric motor rating 220 kW
Rotation speed 595 rpm
Tab. 6-1 Design data

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

trol Description” in chapter 13 Appendix.
6.2.1 Prerequisites for Commissioning on Oxygen

Before any attempt is made to run the compressor on oxygen, make sure
that:
• All test objectives have been met.
• The entire compressor system has been certified “cleaned for oxygen
service”.
• Running-in with inert gas or dry air has been successfully performed
and no leaks and/or abnormal running conditions have been detected.
• There is satisfactory proof that the piping upstream of the compressor
has been cleaned for oxygen service.
• The hazard area is clean, tidy and free from all combustible material.
6.2.2 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 gas coolers and dampers for liquid by briefly opening drain
valves.
7. Open required coolant valves to the gas coolers and 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 crankgear (must be roughly at 3/4 of oil sight glass).
10. Check lubrication for motor bearings according to manufacturer’s rec-
ommendation.
After maintenance work or after long standstill periods:

Operation
Commissioning
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 several times by hand – using the bar – in
running direction and verify that everything is in proper mechanical
condition.
LA_XX_0021a_02
DANGER
12. Open discharge line valve.

Operation
Commissioning
6.2.3 Purge Plant with Nitrogen
DANGER
Explosion and/or fire hazard!
Explosive and/or flammable process gas in the compressor system!
 Purge the compressor plant with dry nitrogen prior to operating com-
pressor with process gas.
The final procedure of purging should be completed on site with the agree-
ment of the end user and our commissioning engineer.
The following instruction shall be used as guide line.
1. Close shut-off valves in suction and discharge line.

2. Set all spectacle flanges in position for normal operation (if applicable).
3. Open vent valves of process line to atmosphere.
4. Open vent valve of distance piece.
5. Close bypass valves (if not already done).
6. Supply nitrogen to the suction line and to the distance piece. Purge
compressor system for approximately 15 minutes.
7. Close all vent valves (of process line and of distance piece).
8. Pressurize the plant section between the shut-off valves in the suction
and discharge line with nitrogen to the lowest safeguarded pressure
limit within this plant section (usually lower than set pressure of crank-
gear safety valve).
9. Close nitrogen supply.
10. After two minutes, open vent valves of process line to atmosphere.
11. Vent the nitrogen-air mixture in the compressor system. Maintain a min-
imum pressure of 0.20 bar g/0.02 MPa g/0.20 kg/cm2 g.
12. Repeat steps 8–11 until the analysis of the vented gas shows that the
content of O2 is below the limits set by work rules.
Make sure the bypass lines will be purged efficiently.

Operation
Operation with Process Gas
6.3 Operation with Process Gas
6.3.1 Safety of Operation

Access to the Hazard Area When the compressor is operating on oxygen, access to the hazard area
is not permitted. Post warning notices to this effect.
Safety Precaution Process gas may be dangerous. Read the detailed gas description and
warnings in section 2.8 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.
WARNING
Slip hazard!
 Watch your step.

Operation
6.3.2 Initial Run on Oxygen

• Before running the compressor on oxygen, clear the hazard area of all
personnel.
• Introduce oxygen to the operating compressor by slowly blending it in
until design purity is reached.
• During start-up and until establishment of constant operation, con-
stantly watch all indicating instruments. Pay special attention to gas
pressures, gas temperatures, valves temperatures and vibration level.
• Log the indicated values at short intervals (about every 15 min.). After
about 4 h of operation, readings may be taken and logged at hourly in-
tervals.
6.3.3 Handling
Detailed information about starting and stopping of the compressor, see
section “Control Description” in chapter 13 Appendix.
CAUTION
Loss of oil, resulting from crankgear purging!
Continuous loss of oil via shaft seal or oil migration from crankgear to the
distance piece possible.
 Avoid purging of the crankgear during normal operation.
 Purge crankgear with nitrogen before/after maintenance only.
WARNING
 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.

The following values must be monitored:
• Suction, (intermediate, if applicable) and final pressure. The hands of
the pressure gauges must continuously oscillate slightly.
• Lubricating oil pressure.
The oil pressure must be between 3.5 to 4.0 bar g/0.35 to 0.4 MPa g/
3.5 to 4.0 kg/cm2 g with the lubricating oil warm from operation of the com-
pressor.
Check the oil pressure at the pressure gauge on the gear oil pump. The oil
pressure can be adjusted via the relief valve (see section 5.11.7 Running
in Pistons).
• Gas temperatures at suction and discharge side of the compressor.

Operation
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.
6.3.4 Clean Piston Rod
DANGER
Fire hazard!
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.
Check piston rod regularly. If inspection indicates that piston rod requires
cleaning, stop the compressor and proceed as follows:
DANGER
 Before beginning any inspection or repair, switch off the power at the
switch box and padlock the switch in the OFF position.
1. Turn flywheel until piston rod is at the Bottom Dead Center (BDC).
2. Moisten a lint-free cleaning tissue with an organic solvent and clean the
piston rod above the oil shield.
CAUTION
Risk of corrosion of piston rod.
 Wash the piston rod with the cleansing agent so that the solvent does
not affect the oil shield or does not enter the guide bearing housing.
3. Clean the gland flange and the guide bearing cover in the same
manner.
4. Turn the flywheel until the piston rod is at its Top Dead Center (TDC).

Operation
5. Wipe the piston rod below the oil shield with a dry lint-free cleaning
tissue. Do not use any solvent on this part of the piston rod because an
oil film is required for the proper functioning of the oil scrapers.
6. Apply proper maintenance guidelines to clean the bottom, top and the
walls of the distance piece.
7. Restart the compressor with the usual start-up procedure.

Operation
Standstill
6.4 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 0.20 bar g/0.02 MPa g/0.20 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):
compressed air.
If an antifreeze solution is used, drainage is not necessary under certain

circumstances.

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 our Services Division (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 . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.2.4 Compressor Noise . . . . . . . . . . . . . . . . . . . . . . . . 7 - 15
7.2.5 Compressor Vibrations . . . . . . . . . . . . . . . . . . . . . 7 - 19
7.2.6 Compressor Shutdown . . . . . . . . . . . . . . . . . . . . . 7 - 20
7.2.7 Compressor Start-Up Interlock . . . . . . . . . . . . . . . 7 - 21

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:
SERV1) Please contact our Services Division, address see section 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 • Check piston clearance 8.9.3 Piston
about 2 months)
IM 102609en
Wear of cylinder • Replace piston or piston skirt 8.9.6 Piston Nut SUPER-
• Repair/replace cylinder BOLT®
P
9.10 Piston and Piston Rod
9.14 Cylinder
SERV1)
Discharge side of a stage Increased suction pressure • Reduce suction pressure/flow CD2)
rate
2D200B-1A_1
Rev. 001/vonstuerle_g
17.01.2017
17.01.2017
Pressure Drop Location Cause Trouble Elimination See Section

Piping Fracture • Repair/replace piping 5.8 Install Pipe Work
9.13 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 5.8.3 Check Fabrication
through thermal stress
Suction side 1st stage Insufficient gas flow in suction • Increase suction pressure/ CD2)
pipe flow rate
Clogged suction strainer • Clean/repair suction strainer 5.11.10 Inspect Compressor
Plant
2D200B-1A_1
Wrong position of shut-off • Adjust valve position TD3)

valve in suction pipe 1st stage • Check/repair control system
Wrong position of bypass • Adjust valve position TD3)
valve overall • Check/repair control system
Wrong position of vent valve • Adjust valve position TD3)
• Check/repair control system
st
Discharge side 1 stage Clogged suction strainer • Clean/repair suction strainer 5.11.10 Inspect Compressor
IM 102609en
Plant
Leaking of pressure safety • Repair/replace PSV TD3)
valve (PSV)
Defective suction or discharge • Repair/replace valve 8.10.2 Valve Failures (Mal-
valve function)

Trouble Shooting
9.5 Suction Valves and Dis-
charge Valves
7–5
7–6

Trouble Shooting
Defective piston • Replace piston or piston skirt 9.10 Piston and Piston Rod
Pressure ratio over a stage Wear of piston • Replace piston or piston skirt 9.10 Piston and Piston Rod
(within about 2 months)
P
Piston rod gland Wear of lowest gland ring • Replace gland ring 9.12 Piston Rod Gland
(three-piece ring)
IM 102609en
Temperature Rise Location Cause Trouble Elimination See Section

Suction side (general) Defective suction valve • Repair/replace valve 8.10.2 Valve Failures (Mal-
function)
charge Valves
T
Suction side 1st stage Too hot process gas • Check function of previous 8.6.5 Cooling System
gas cooler (if applicable)
2D200B-1A_1
Insufficient cooling of bypass • Clean/repair cooler, if present 8.6.5 Cooling System

cooler (if present)
Leaking piston rod gland • Replace gland rings 9.12 Piston Rod Gland
Discharge side (general) Defective suction or discharge • Repair/replace valve 8.10.2 Valve Failures (Mal-
valve on corresponding stage function)
charge Valves
Wear of piston on correspond- • Replace piston or piston skirt 9.10 Piston and Piston Rod
ing stage
Wear of piston on following • Replace piston or piston skirt 9.10 Piston and Piston Rod
stage
Insufficient coolant flow • Adjust setting CD2)
through cylinder
Fouled cooling chamber of cyl- • Clean cooling chamber 8.6.5 Cooling System
inder
Too small cylinder clearance • Adjust piston position 9.10 Piston and Piston Rod
17.01.2017
17.01.2017

Pressure difference, from sup- Restricted cross-section due • Clean cooling system (interior) 8.6.5 Cooling System
ply to return to fouling

Coolant return Restricted cross-section due • Clean cooling system (interior) 8.6.5 Cooling System
to fouling
Leakage • Repair/replace defect compo- 8.6.5 Cooling System
2D200B-1A_1
P
nents 8.6.3 Flange Connections and
Pipe Fastenings

Coolant supply Incorrectly maintained and/or • Service cooling system 8.6.5 Cooling System
adjusted cooling system • Adjust setting CD2)
Too high ambient temperature • Adjust setting CD2)
IM 102609en
T (summer)
Temperature difference from Insufficient flow in the respec- • Adjust setting CD2)
inlet to outlet of a cooling sec- tive cooling section
tion
CD2)

Insufficient coolant differential • Adjust setting
pressure
Trouble Shooting
7–7
7–8

Trouble Shooting
Temperature Drop Location Cause Trouble Elimination See Section
Coolant supply Incorrectly maintained and/or • Service cooling system 8.6.5 Cooling System
adjusted cooling system • Adjust setting CD2)
Too low ambient temperature • Adjust setting CD2)
T (winter)
Coolant return Fouling in cooling chambers: • Clean cooling system (interior) 8.6.5 Cooling System
IM 102609en
deposits of mud, sand, algae,

calcium carbonate etc.
Poor coolant quality (no or • Change coolant 8.6.5 Cooling System
wrong coolant treatment) • Correct coolant quality
Temperature difference from No coolant flow/too low flow • Clean cooling system (interior) 8.6.5 Cooling System
inlet to outlet of a cooling sec- rate in respective section
tion through fouling
Excessive coolant flow in re- • Adjust setting CD2)
2D200B-1A_1
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
17.01.2017
17.01.2017

Crankgear Too low ambient temperature • Change oil viscosity 8.7.6 Oil Change
(oil too thick)
Gear oil pump (inlet) Wrong adjusted relief valve • Adjust setting 5.11.7 Running in Pistons
P
Defective relief valve • Replace/repair valve 5.11.7 Running in Pistons

Crankgear Clogged oil strainer in crank- • Clean oil strainer 9.9.3 Oil Strainer
gear
Too low oil level • Refill oil 9.8 Drain Lubricating Oil
2D200B-1A_1
P
8.7.7 Lubricating Oil Specifica-
tions
Blocked gear oil pump • Remove foreign object 9.22 Gear Oil Pump
• Check oil pump components
for damages
• Replace defect components
Switched off oil heater • Switch on heater CD2)
IM 102609en
Defective oil heater • Repair/replace heater 9.9.2 Oil Heater

TD3)
Excessive oil loss at the crank- • Replace main bearing 9.27 Bearing Bracket and
shaft bearing through exces- Main Bearing
sive bearing clearance

Trouble Shooting
Excessive oil loss at the con- • Replace bearing shell 9.18 Connecting Rod Bearing
necting rod bearing through
excessive bearing clearance
7–9
7 – 10

Trouble Shooting
Excessive oil loss at the cross- • Replace bearing bush 9.20 Crosshead Pin Bearing
head pin bearing through worn (with Cylinder Removal)
bearing 9.21 Crosshead Pin Bearing
P (without Cylinder Removal)
Fouled cooling chamber in • Clean cooling chamber 8.6.5 Cooling System
IM 102609en
crosshead area
Defective oil pressure gauge • Replace pressure gauge 9.22 Gear Oil Pump
Relief valve Wrong adjusted relief valve • Adjust setting 5.11.7 Running in Pistons
TD3
Defective relief valve • Repair/replace valve 5.11.7 Running in Pistons
TD3
Gear oil pump (inlet) Too low oil viscosity • Change oil 8.7.6 Oil Change
2D200B-1A_1
8.7.7 Lubricating Oil Specifica-

tions
Too high oil temperature due • Clean cooling system/compo- 8.6.5 Cooling System
to fouled coolant chambers in nents interior
crosshead area
Broken drive of gear oil pump • Repair pump drive 9.22 Gear Oil Pump
Prelubrication pump Too long suction piping • Rework piping/suction system 5.8.3 Check Fabrication
SERV1)
Too small piping cross-section • Rework piping 5.8.3 Check Fabrication

Air in the suction piping • Repair leak on piping 8.6.3 Flange Connections and
• Fill piping with oil (use prelu- Pipe Fastenings
brication pump, if applicable)
Leaking or defective non-re- • Repair/replace valve 8.6.3 Flange Connections and
turn valve Pipe Fastenings
TD3)
Wrong adjusted relief valves • Adjust setting 8.6.7 Safety Devices
17.01.2017
Defective relief valves • Repair/replace valve 8.6.7 Safety Devices

17.01.2017

After repair: wrong direction of • Correct electrical connection TD3)
rotation
Power failure • Repair power supply TD3)
P
Blocked pump • Remove foreign object TD3)
• Check oil pump components
for damages
• Replace defect components

Crankgear Insufficient coolant flow • Adjust setting of cooling CD2)
through cooling chamber of system
crosshead area
Fouled cooling chamber in • Clean cooling chamber 8.6.5 Cooling System
2D200B-1A_1
T
crosshead area
Temperature Drop Location Cause Trouble Elimination See Section

Oil temperature indicator Excessive cooling • Adjust setting of cooling CD2)
system
T
IM 102609en

Trouble Shooting
7 – 11
7 – 12

Trouble Shooting
Level Rise Location Cause Trouble Elimination See Section
Crankgear Leaking of internal coolant • Repair/replace cooler 8.6.3 Flange Connections and
pipes (emulsion) Pipe Fastenings
TD3)
Generation of condensate in • Adjust cooling system setting 8.7.6 Oil Change
IM 102609en
crankgear (emulsion) • Change oil 8.7.7 Lubricating Oil Specifica-

tions
CD2)
Generation of condensate in • Increase process gas tem- 8.7.6 Oil Change
cylinder (emulsion) perature 8.7.7 Lubricating Oil Specifica-
• Adjust cooling system setting tions
• Change oil CD2)
2D200B-1A_1
Leaking cooler or cylinder • Replace/repair cooling system 8.6.5 Cooling System

cooling chamber (emulsion) component 9.14 Cylinder
Level Drop Location Cause Trouble Elimination See Section

Crankgear Leaking oil scraper (into the • Replace wiper elements 9.15 Oil Scraper
distance piece)
Leaking oil piping • Repair/replace piping 8.6.3 Flange Connections and
Pipe Fastenings
Leaking gasket/O-ring on • Replace gasket/O-ring 9.22 Gear Oil Pump

bearing bracket drive end or 9.27 Bearing Bracket and
non-drive end Main Bearing
Crankshaft seal Cured/brittle rubber shaft seal- • Replace sealing rings 9.26 Oil Trap and Crankshaft
ing rings Seal
Cured packing cord (if pres- • Replace packing cord, if 9.26 Oil Trap and Crankshaft
ent) present Seal
17.01.2017
17.01.2017

Pressure fluctuations in crank- • Clean/service crankgear vent 9.26 Oil Trap and Crankshaft
gear (due to pump effect of system Seal
crossheads) • Install long oil syphon on SERV1)
guide bearing
• Install crankgear vent system
Crankgear pressure exceeds • Clean/service crankgear vent SERV1)

10–30 mm water column system
• If not installed, check possi-
bility of installation
Oil scraper (leaking into the Too low oil viscosity • Change oil 8.7.6 Oil Change
distance piece) 8.7.7 Lubricating Oil Specifica-
tions
Pressure fluctuations in crank- • Clean/service crankgear vent 9.26 Oil Trap and Crankshaft
2D200B-1A_1
gear (due to pump effect of system Seal

crossheads) • Install long oil syphon on SERV1)
guide bearing
• Install crankgear vent system
Insufficient cooling of guide • Adjust setting of cooling 8.6.5 Cooling System
bearing system CD2)
• Clean coolant cavity
Wear of wiper elements • Replace wiper elements 9.15 Oil Scraper
IM 102609en
Wear of spring plate • Replace spring plate 9.15 Oil Scraper

Trouble Shooting
7 – 13
7 – 14

Trouble Shooting
Insufficient tension force of • Replace garter springs 9.15 Oil Scraper
garter springs
Damaged piston rod surface • Repair/replace piston rod sur- 9.10 Piston and Piston Rod
(rough, scratched) face 9.15 Oil Scraper
• Check wiper elements SERV1)
IM 102609en
• Replace wiper elements

Incorrectly installed wiper ele- • Replace wiper elements 9.15 Oil Scraper
ments: rings tilted on piston
rod, no offset of inclined cuts
between the rings or contact
surface to piston rod too nar-
row
2D200B-1A_1
17.01.2017
17.01.2017
7.2.4 Compressor Noise
Regular Dull Location Cause Trouble Elimination See Section

Knocking
Connecting rod Loose connecting rod bolts • Tighten bolts 9.18 Connecting Rod Bearing
Excessive clearance of con- • Replace bearing shell 9.18 Connecting Rod Bearing
necting rod bearing
Excessive clearance of cross- • Replace bearing bush 9.20 Crosshead Pin Bearing
head pin bearing (with Cylinder Removal)
9.21 Crosshead Pin Bearing
(without Cylinder Removal)
Crosshead Insufficient crosshead clear- • Rework crosshead 9.19 Crosshead and Connect-
ance ing Rod
2D200B-1A_1
SERV1)
Piston Piston seizure • Replace piston or piston skirt 8.9.3 Piston
• Check/repair cylinder 9.10 Piston and Piston Rod
9.14 Cylinder
SERV1)
Loose piston nut • Tighten piston nut 8.9.6 Piston Nut SUPER-
BOLT®
IM 102609en

Piston rod Loose connection piston rod to • Tighten connection 9.10 Piston and Piston Rod
crosshead

Trouble Shooting
7 – 15
7 – 16

Trouble Shooting
Irregular Dull Location Cause Trouble Elimination See Section
Knocking
crosshead
4)
Crankshaft Loose counterweight on • Tighten counterweight
IM 102609en
crankshaft
Piston Loose piston nut • Tighten nut 8.9.6 Piston Nut SUPER-
BOLT®
Excessive pretension of piston • Adjust pretension 8.9.6 Piston Nut SUPER-
BOLT®
Chafing piston, due to one- • Correct guide bearing clear- 9.16 Guide Bearing Bush
2D200B-1A_1
sided heating of piston rod ance 9.12 Piston Rod Gland

caused by insufficient clear- • Replace gland rings
ance between guide bearing
and piston rod or between
gland rings and piston rod
Piston seizure • Replace piston or piston skirt 8.9.3 Piston
• Check/repair cylinder 8.9.6 Piston Nut SUPER-
BOLT®

9.14 Cylinder
SERV1)
17.01.2017
17.01.2017
Irregular Dull Location Cause Trouble Elimination See Section

Knocking
Liquid knock • Check piston or piston compo- 8.9.3 Piston
nents for cracks 8.9.6 Piston Nut SUPER-
• Check piston rod to crosshead BOLT®
connection for mandatory 9.10 Piston and Piston Rod
tightening torque.
9.18 Connecting Rod Bearing
• Check connection rod bearing
for mandatory tightening
torque.
Cylinder Damaged suction or discharge • Replace/repair valve 8.10.2 Valve Failures (Mal-
valve function)

charge Valves
2D200B-1A_1
Loose valve lantern • Tighten lantern 9.5 Suction Valves and Dis-
charge Valves
Foreign object in the cylinder • Remove foreign object 8.9.3 Piston
• Check piston 8.9.6 Piston Nut SUPER-
• Replace piston or piston com- BOLT®
ponent 9.10 Piston and Piston Rod
• Check cylinder 9.14 Cylinder
IM 102609en
• Repair/replace cylinder SERV1)

Trouble Shooting
7 – 17
7 – 18

Trouble Shooting
Regular Metallic Location Cause Trouble Elimination See Section
Knocking
crosshead
Piston Insufficient pretension of the • Adjust pretension 8.9.6 Piston Nut SUPER-
IM 102609en
piston crowns BOLT®

Loose piston skirt • Adjust pretension 8.9.6 Piston Nut SUPER-
BOLT®
Cylinder Loose valve lanterns • Inspect lantern 9.5 Suction Valves and Dis-
• Repair/replace lantern charge Valves
• Tighten lantern
2D200B-1A_1
Too small cylinder clearance • Adjust piston position 8.9.6 Piston Nut SUPER-
BOLT®
Regular High Location Cause Trouble Elimination See Section

Pitched Ringing
crosshead
Cylinder Axial lantern clearance • Inspect lantern 9.5 Suction Valves and Dis-
• Repair/replace lantern charge Valves
• Tighten lantern
17.01.2017
17.01.2017
7.2.5 Compressor Vibrations
Vibrations Location Cause Trouble Elimination See Section

Chafed areas on: Loose mounting parts • Repair/replace defective parts 8.6.3 Flange Connections and
– piping Check chafed parts for func- Pipe Fastenings
•
– supports tion 8.5.1 Tightening Torques and
– accessories Method
• Tighten loose parts
Cracks in: Loose mounting parts • Repair/replace defective parts 8.6.3 Flange Connections and
– piping, pipe connection • Tighten loose parts Pipe Fastenings
– supports 8.5.1 Tightening Torques and
– accessories Method
Insufficient elongation length • Rework piping/supports 5.8.3 Check Fabrication
through thermal stress SERV1)
2D200B-1A_1
Process gas piping Inadmissible pulsations • Installation/replacement of ori- 5.8.3 Check Fabrication
fice plates 5.11.8 Assess Vibrations
• Elimination of stress raisers SERV1)
5)
IM 102609en

Trouble Shooting
7 – 19
7 – 20

Trouble Shooting
7.2.6 Compressor Shutdown
Safety Shutdown Location Cause Trouble Elimination See Section

Instrumentation Failure of instrument air (con- • Repair control medium system TD3)
trol medium)
IM 102609en
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)
2D200B-1A_1
17.01.2017
17.01.2017
7.2.7 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)
Flywheel guard Not correctly closed • Close guard correctly TD3)
Incorrect position of safety • Adjust safety switch TD3)
switch
CD2)
2D200B-1A_1
Bypass valves Wrong valve position due to • Adjust valve position

pneumatic shutoff TD3)
Main motor 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
turer’s instruction
IM 102609en

Trouble Shooting
7 – 21
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 . . . . . . . . . . . . . . . 8-7
8.2.2 Clean Compressor Plant . . . . . . . . . . . . . . . . . . . 8-8
8.3 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
8.3.1 Standard Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
8.3.2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 12
8.4 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 14
8.4.1 Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 15
8.4.2 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 16
8.5 Plant in General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 17
8.5.1 Tightening Torques and Method . . . . . . . . . . . . . . 8 - 17
8.6 Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 19
8.6.1 Electric Motor and Coupling . . . . . . . . . . . . . . . . . 8 - 19
8.6.2 Gas System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 19
8.6.3 Flange Connections and Pipe Fastenings . . . . . . 8 - 20
8.6.4 Suction Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 21
8.6.5 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 21
8.6.6 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . 8 - 24
8.6.7 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 25
8.6.8 Hydrostatic Pressure Test. . . . . . . . . . . . . . . . . . . 8 - 26
8.7 Compressor in General. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 27
8.7.1 Dimensions, Weights, Space Requirements. . . . . 8 - 27
8.7.2 Marking of Compressor Components. . . . . . . . . . 8 - 27
8.7.3 Tightening Methods . . . . . . . . . . . . . . . . . . . . . . . 8 - 29
8.7.4 Locking of Threaded Connections with LOCTITE® 8 - 30
8.7.5 NORD-LOCK® Securing System . . . . . . . . . . . . . 8 - 30
8.7.6 Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 32
8.7.7 Lubricating Oil Specifications . . . . . . . . . . . . . . . . 8 - 34
8.8 Crankgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 35
8.8.1 Check Crankshaft Deflection . . . . . . . . . . . . . . . . 8 - 35
8.8.2 Main Bearing and Connecting Rod Bearing . . . . . 8 - 37
8.8.3 Crankshaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 38
8.8.4 Connecting Rod Bearing . . . . . . . . . . . . . . . . . . . 8 - 39
8.8.5 Crosshead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 40
8.8.6 Crosshead Pin Bearing. . . . . . . . . . . . . . . . . . . . . 8 - 41
8.8.7 Guide Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 42
8.9 Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 43
8.9.1 Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 43
8.9.2 Piston Rod Gland . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 44
8.9.3 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 45
8.9.4 Piston Clearance Measurement . . . . . . . . . . . . . . 8 - 51
8.9.5 Cylinder Clearance Measurement . . . . . . . . . . . . 8 - 52

8.9.6 Piston Nut SUPERBOLT® . . . . . . . . . . . . . . . . . . . 8 - 54

8.10 Suction Valves and Discharge Valves . . . . . . . . . . . . . . . . . 8 - 61
8.10.1 Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 8 - 61
8.10.2 Valve Failures (Malfunction) . . . . . . . . . . . . . . . . . 8 - 62
8.11 Complete Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 62

Importance of Preventive Maintenance
8.1 Importance of Preventive Maintenance

By doing preventive maintenance at regular intervals, these improvements
arise:
• 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
When the compressor is operating on oxygen, access to the hazard area
inside the fire protecting wall is not permitted!
Before entering the hazard area, after the compressor has been stopped
or changed over to nitrogen, analyze the atmosphere within the enclosure
to ensure that it is safe to enter.
Guidelines for Oxygen The specific guidelines in the IGC-documents (Industrial Gas Committee)
Plant “Reciprocating Compressors for Oxygen Service”, IGC Doc 10/09/E, “Fire
Hazards of Oxygen and Oxygen Enriched Atmospheres”, IGC Doc 04/09/
E and “Cleaning of Equipment for Oxygen Service”, IGC Doc 33/06/E are
valid for the operation and construction of oxygen compressor plants.
The compressor is cleaned according to Burckhardt Compression cleaning
instructions accepted by all well-known customers. In Germany, for ex-
ample, the safety work rules BG RCI M34 are valid, of which, among other
things, the following must be taken into account:
• plant construction and operation (areas, rooms and ventilation in-
cluded),
• material for fittings, pipes, sealing compounds and lubricants,
• guidelines for planning, installation, construction and marking,
• cleaning and maintenance work, work clothes and personal safety
outfit,
• customer specific cleaning and material specification.

Prerequisites for Maintenance
WARNING
Fire hazard!
 Make sure that no greasy ropes, chains, hooks etc. are used.
 Protect all compressor parts against oil drip from travelling trolleys.
DANGER
Fire hazard!
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, switch off the power at the
• Always comply 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).
Lockout and Tagging of

Electric Circuits
DANGER
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.
Lubricants, Tightening
Torques and Methods
For applicable lubricants, mandatory tightening torques as well as appro-

priate tightening methods: see sections “Lubricating System” and “Com-
pressor” in chapter 13 Appendix.
Restart Compressor Perform functional test on protective devices after maintenance.

Turn flywheel of compressor several times by hand – with the bar – in run-
ning direction and verify that everything is in proper mechanical condition.
LA_XX_0021a_02

WARNING

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.
1. Close the shut-off valves in the suction and discharge line.

2. Slowly open vent valve to atmosphere. Always run prelubrication
pump, as it removes process gas that is solved in the oil.
3. Supply nitrogen to the suction line and to the distance piece of the com-
pressor. Purge the compressor system.
4. Close nitrogen supply.
5. Close bypass valve (if not already done).
6. Close vent valves of process gas line and distance piece.
7. Pressurize the plant section between the shut-off valves in the suction
and the discharge line with nitrogen to the lowest safe pressure limit
within this section (usually lower than set pressure of crankgear safety
valve).
8. Vent gas in the distance piece first, then vent gas in the process gas
line.
9. Repeat steps 7 to 8 until the analysis of the vented gas shows that the
content of process gas is below the limits set by work rules.
10. Set spectacle flanges in process gas lines to maintenance position
(gas flow blocked).
Make sure that all spectacle flanges are set in maintenance position
before starting any maintenance work at the compressor or accesso-
ries.
Further information, see section “Control Description” in chapter 13 Ap-

pendix.

Tools
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.
XA_T9_0007a_01
Fig. 8-2 Flogging spanner
T96111: 36 mm
T96112: 55 mm

Tools
XA_T9_0005a_01
Fig. 8-3 Combination spanners
T96100: Set of combination spanners 17–46 mm

T96101: 55 mm
LA_T9_0024a_01
Fig. 8-4 Flogging spanner for crankshaft nut
T97040: 110 mm

Tools
LA_T9_0009a_01
Fig. 8-5 Eye bolt
T96061: 2 eye bolts M12

Fig. 8-6 Torque wrench
T96010: 20–100 Nm
XA_T9_0009a_01
Fig. 8-7 Extension for sockets
T96031: 3/8" x 240mm

XA_T9_0010a_01
Fig. 8-8 Hexagonal socket
T96021: 7-1/4"
T96022: 13-3/8"

Tools
XA_T9_0012a_01
Fig. 8-9 Square insert for socket
T96041: 3/8"–1/4"
XA_T9_0003a_01
Fig. 8-10 Inner circlip pliers
T96070
XA_T9_0004a_01
Fig. 8-11 Outer circlip pliers
T96080

Tools
8.3.2 Special Tools
Txxxxx = code no. for ordering special tools and standard tools.
XA_T9_0013a_02
Fig. 8-12 Round bar for turning of flywheel
T97230: Dia. 32 mm x 1050 mm
1 2 3
LA_T9_0027b_01
Fig. 8-13 Valve dismantling and assembling device for lightweight valves with
pressure screws
1 Cylinder
2 Valve
3 Dismantling and assembling device
T97061
XA_T9_0076a_02
Fig. 8-14 Tapered sleeve for installing wiper elements
T97050: Sleeve for piston rod 75mm

Tools
1 2 3
LA_T9_0023b_01
Fig. 8-15 Pull-off device for dismantling of flywheel
(complete with threaded rod and nut)
1 Crankshaft
2 Flywheel
3 Pull-off device
T97030
1 2 3
LA_T9_0022b_02
Fig. 8-16 Cotter key in 3 pieces
1 Crosshead
2 Piston rod
3 Cotter key
T97010

Maintenance Schedule
9
5 4
6 3 10
2
7 1
1 7
2
3 6
XA_T9_0014b_01
4 5
Fig. 8-17 Piston nut wrench for piston nut SUPERBOLT® (position 1–7 = SUPER-
BOLT® size)
1 G 1" 6 G 2 1/2"
2 G 1 1/4" 7 G 3"
3 G 1 1/2" 8 Piston nut wrench
4 G 1 3/4" 9 Pin (dia. 6 mm/dia. 8 mm)
5 G 2" 10 Hexagon 22 mm
T97364
8.4 Maintenance Schedule
The indications on the following tables serve as general guideline only. The
final schedule should be worked out together with our Services Division.
We refer to the specific maintenance requirements in this Instruction
Manual.

8 – 15
8.4.1 Plant
Maintenance Work See Hours of operation

section
IM 102609en
4000 8000 16000 24000 32000 40000 48000

Check set points of the safety devices, conduct function tests
8.6.7 x x x x x x x
and complete the corresponding life passports.
Suction strainer(s):
8.6.4 x x x x x x x
Check cleanliness of suction strainer and its components
Piping:
Check bolted connections, flanges and pipe clamps for tight- 8.6.3 x x x x
ness
2D200B-1A_1
Damper(s):
3.3.5 x x x x x x
Check proper condition of damper
Gas cooler(s):
8.6.5 Every 16000 hrs., depending on fouling factor and water treatment
Clean gas and cooling spaces, replace gaskets
Auxiliaries:
Clean compressor-related auxiliaries to avoid dust accumula- 10 x x x x x x x
tion on surfaces.
Safety and relief valves:

8.6.7 x x x
Check proper functioning of safety valves
Non-return valve(s) for process gas:
9.4 x x x
Check condition and function of non-return valve
17.01.2017
8.4.2 Compressor
8 – 16
Maintenance Work See Section Hours of operation
8000 16000 24000 32000 40000 48000

Visual check and cleaning: distance piece must be free of oil, check on
8.2.1 Monthly and after each stop
guide bearing cover, piston rod and piston rod gland.
IM 102609en
Drain oil, clean oil strainer, crankgear and duplex oil filter (if applicable).
8.7.6 x x x x x x
First time after 200 hours of operation.
Check suction valves and discharge valves. 8.10 x x x x x x
Check clearance between guide bearing and piston rod (with feeler
8.8.7 x x x x x x
gauge or dial gauge).
Check gland rings and replace if required. 8.9.2 x x x x x x
Dismantle piston and piston rod. Check wiper elements and piston rod
9.10, 9.15 In case of insufficient function of oil scrapers
surface.
2D200B-1A_1
Check clearances of: crankshaft bearing, connecting rod bearing,

crosshead pin bearing and crosshead without removing (by feeler 8.8 x x x
gauge or dial gauge).
Check tightening of connecting rod bolts. 9.18 x x x
Check piston clearance by feeler gauge and the preload force/tighten-
8.9.3, 8.9.6 x x x
ing of piston nut.
Check pretension of piston crowns (piston with diameter 480 mm and
8.9.3 x x x
larger).
Check alignment of flexible coupling. At least every 16000 hours but each time after coupling of elec-
9.24
tric motor
Remove crankshaft bearings, connecting rod and crosshead pin bear- If there is an indication of excessive bearing wear and tear
ings for inspection. 8.8 (bearing clearance out of tolerance, white metal flakes in oil,
high temperature).
Clean the cooling chambers of the compressor. Check the correspond-
8.6.5 Depending on fouling factor and water treatment
ing gaskets.
Clean compressor surfaces to avoid dust accumulation. 10 x x x x x x
17.01.2017
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
8.7.3 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. 8-18).
Should any questions arise, please contact our Services Division (address
see section 1.6 Contact Address).
1
XA_XX_0111b_01
Fig. 8-18 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 • Burckhardt Lubrication Grease BLG05

• Other admitted lubricants for oxygen
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 30 3.1 22.1 48 4.9 35.4
M14 47 4.8 34.7 76 7.7 56.1
M16 72 7.3 53.1 118 12 87
M18 100 10.2 73.8 164 16.7 121
M20 141 14.4 104 229 23.4 168.9
M22 189 19.3 139.4 308 31.4 227.2
M24 223 22.7 164.5 396 40.4 292.1
M27 324 33 239 576 58.7 424.9
M30 403 41.1 297.3 790 80.6 582.7
M33 545 55.6 402 967 98.6 713.3
M36 645 65.8 475.8 1246 127.1 919
M39 – – – 1606 163.8 1184.6
M42 – – – 1993 203.2 1470
Data valid only using Burckhardt Lubrication Grease BLG05

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 8.8.1 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 9.23 Electric Motor.
Coupling Inspections are limited to a visual assessment of the condition of the cou-
pling. Pay attention to damage or cracks in the rubber disc element, con-
necting bolt and any damage caused by force. The inspection of the
coupling should always be carried out at the same time as the inspection
of the entire system, or at least once a year.
8.6.2 Gas System

Cooler and Damper Pressurized plant components, such as pressure vessels, coolers,
dampers, etc. must be inspected periodically for deposits or corrosion ac-
cording to local and/or work rules. If pressure test must be repeated peri-
odically, see section 8.6.8 Hydrostatic Pressure Test.
Non-Return Valve Check gaskets of non-return valve on a regular basis and use them only
once.
WARNING
Unsuitable gaskets!
Damage of compressor or plant is possible.
 Use only gaskets according to ANSI B 16.21.

Plant
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/ Check all flange connections and pipe fastenings on a regular basis.
Pipe 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 5.8.6 Recommendation for Pipe
Support.
Information regarding admissible vibrations, see section 5.11.8 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 5.8.6 Recommendation for Pipe
Support.
For information regarding vibrations, see section 5.11.8 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

Plant
8.6.4 Suction Strainer

Inspect suction strainer for cleanliness.
1 2 3 4
XA_XX_0101b_01
1 Flange
2 Flow direction
3 Intermediate piece
4 Conical suction strainer

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
Freezing cooling water!
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.

Plant
Inspecting 1. Drain the cooling system(s) and open the covers on each cylinder
Cooling Chambers leading to the cooling chambers.
2. Inspect the cooling chambers of the cylinders and clean them if neces-
sary.
If there are deposits of sand, chalk or algae in the cooling chambers, we

recommend subcontracting 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.
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 3. Circulate the cleaning agent by means of a pump in order to ensure a
Calcium Carbonate reliable decomposition of the deposit.
WARNING
Corrosion hazard!
 Avoid contact with caustic substances.
 Consult manufacturer’s instructions.
4. Remove calcium carbonate deposits with (for example):

• Diluted formic acid (HCOOH)
• Diluted sulphamic acid (NH2SO3H) with inhibitor.
CAUTION
Oxidizing materials!
Cast iron, steel, nonferrous heavy metals and aluminum must not be cor-
roded by these chemicals.
Proceed according to following section “Leak Test”.
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
Corrosion hazard!
 Avoid contact with caustic substances.
 Consult manufacturer’s instructions.

Plant
5. 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.
Proceed as described in section “Leak Test” below.
Removing 6. Remove solidified crusts of sand manually and flush out the cooling
Deposits of Sand chambers afterwards.
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.

Plant

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).
Oil Heater
For detailed description of the oil heater refer to the documentation of the
manufacturer (see Technical Documentation).
Instrumentation
For detailed description of the instrumentation refer to the documentation

of the manufacturer (see Technical Documentation).

Plant
8.6.7 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/ Safety valves and relief valves are the last inline safety devices for vessels
Relief Valves and piping. Establish inspection intervals with regard to ambient and/or
plant operating conditions as well as regulations and work rules.
Control and Maintenance for control and shut-off valves should be carried out regularly
Shut-Off Valves according to manufacturer’s instructions.
CAUTION
Observe instructions of the manufacturer (see Technical Documentation).

Plant
8.6.8 Hydrostatic Pressure Test
DANGER
Flammable residues of solvent in gas system.
These residues can cause fire or explosions.
 Never use solvents for pressure tests.
 Only use liquids which are approved for oxygen service.
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.
Cleaning After the hydrostatic pressure test, clean all parts and surfaces of the plant
components exposed to process gas according to chapter 10 Clean and
DANGER
Fire hazard!

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

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 a V1 from the non-drive
end and ascends to V2, V3 etc. towards the drive end. Furthermore, the se-
rial 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 main bearing – bearing cover
• Connecting rod – connecting rod bolts

3
4
5
7
8
9
10
11
LD_XX_0007b_01
12
Fig. 8-20 Important markings on a Laby® compressor type D
1 Cylinder cover 7 Name plate

2 Upper piston crown 8 Wedge (V1/V2 etc. only)
3 Gland flange 9 Crosshead
4 Cylinder (serial no. only) 10 Crosshead pin
5 Frame 11 Connecting rod
6 Guide bearing 12 Connecting rod cover

8.7.3 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 • Lubricate the bolts at the cylinder with Burckhardt Lubrication Grease
BLG05.
• Lubricate the bolts at the frame, and at the base plate (if applicable),
with 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 piston nut SUPERBOLT® see section 8.9.6 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.

8.7.4 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.
8.7.5 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. 8-21, Fig. 8-22 and Fig. 8-23), 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. 8-21 NORD-LOCK® locking principle

XA_CX_0039b_01
XA_CX_0074b_01
1 2
1 Cams
2 Radial teeth
Fig. 8-22 NORD-LOCK® washer pair Fig. 8-23 Correct assembly of NORD-
LOCK® washer pairs
For lubrication of bolts, please refer to section 8.7.3 Tightening Methods.

8.7.6 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)
Wear particles as per ISO 4406
max. 0.3% not less than 80%
max. 0.2mg KOH/g Cleanliness Level 22/20/17 (cor-
(for mineral oil) of the new oil
relates with NAS 11) or better
Tab. 8-1 Permissible values of lubricating oil in use (reference values)
Oil Quantity Oil
Specification Quantity
in liters
The working capacity of the oil in the crankgear 120
The total oil quantity (including oil for associated pipes, oil cooler and filters) 150
Tab. 8-2 Oil quantity
The oil filling of the compressor is contained in the crankgear. 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.
When the compressor is running, 1/2 of the oil sight glass should be cov-
ered.

3/4
LA_M2_0008b_01
2
Fig. 8-24 Check oil level
1 Oil sight glass

2 Lubricating oil
3 Crankgear
Procedure
5
LD_M2_0005b_01
Fig. 8-25 Gear oil pump
1 Pressure gauge for lubricating oil 5 Oil sight glass

2 (not applicable) 6 Oil drain
3 Gear oil pump 7 (not applicable)
4 Oil strainer (and heater, if appli-
cable)
Proceed as follows when changing oil:

1. Shut down the compressor.
2. Protect main motor, prelubrication pump, etc. against unintended start-

up.

Depressurize and purge the compressor plant (see section 8.2.1 Depres-
surize and Purge Plant).
3. Remove frame covers.
Drain
4. Drain the oil from the oil sump.
5. Drain the piping of the lubricating system.
6. Remove oil heater.
Clean
7. Remove and clean the oil strainer of the compressor.

8. Clean the crankgear with a new, unused sponge (do not use fibrous
textile).
Refill
Check for proper lubricating oil quality and quantity see Fig. 8-24 and sec-
tions 8.7.6 Oil Change and 8.7.7 Lubricating Oil Specifications.
9. Shut oil outlets, refit oil strainer, etc. and fill the compressor with fresh
oil.
Use the prelubrication pump to fill the complete lubricating system.
8.7.7 Lubricating Oil Specifications

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

Crankgear
8.8 Crankgear
8.8.1 Check Crankshaft Deflection
1. Measure crankshaft deflection on the drive end crank in 5 positions ac-

cording to following figures. Record all measured values as well as the
measuring position (i.e. offset from crankweb) of the dial indicator.
The maximum permissible deflection on the dial indicator after installation

of coupling and electric motor for a complete turn of the crankshaft is 0.08
mm with flexible coupling. Measure the deflection at the outer most point.
2. If the deflection exceeds this limit, consult our Services Division; ad-
dress see section 1.6 Contact Address.
XA_M0_0001a_01
Fig. 8-26 First measurement
XA_M0_0002a_01
Fig. 8-27 Second measurement

Crankgear
XA_M0_0003a_01
Fig. 8-28 Third measurement
XA_M0_0004a_01
Fig. 8-29 Fourth measurement

XA_M0_0005a_01
Fig. 8-30 Fifth measurement

Crankgear
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 sump, oil strainer and/or duplex oil filter for deposits of white
metal.
For applicable clearances see section “Compressor” in chapter

13 Appendix.

Crankgear
8.8.3 Crankshaft Seal
1 2 3 4 5
LA_M1_0026b_01
Fig. 8-31 Components of crankshaft seal
1 Frame 4 Lip seals

2 Gasket 5 Crankshaft
3 Oil trap
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

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 (Fig. 8-32). For appli-
cable tightening torque (elongation) see section “Compressor” in chapter
13 Appendix.
We recommend, checking the correct tightening of the connecting rod bolts
periodically, every 16000 operating hours. For safety reasons, the locking
plate of the connecting rod bolts (if applicable) should be checked at each
oil change.
WARNING
Loose connecting rod bolts!
After a liquid knock, the connecting rod bolts must be checked immediately
for mandatory tightening torque!
6
LA_M4_0004b_02
Fig. 8-32 Connecting rod bearing
1 Connecting rod 5 Connecting rod bolt

2 Crosshead pin bearing 6 Connecting rod bearing
3 Crosshead pin 7 Connecting rod cover
4 Circlip 8 Locking plate

Crankgear
Clearance Check of Turn crank to Bottom Dead Center (BDC) and measure clearance between
“Crankshaft Journal – crankshaft journal and connecting rod lower bearing shell with a feeler
Connecting Rod Bearing” gauge.
For applicable clearances: see section “Compressor” in chapter 13 Ap-
pendix.
8.8.5 Crosshead
The crosshead often rubs slightly against the upper part. This is often
caused by starting in winter with a warm crosshead and a very cold coolant
directly after stopping the compressor (oil acts as an insulator). After a
shut-down we recommend waiting at least half an hour before restarting
the compressor with a cold coolant.
Clearance Check

13 Appendix.
1. Move connecting rod/crosshead in Top Dead Center (TDC) by turning

the crankshaft.
2. Press the crosshead in the crosshead bore of the frame to one side and
measure the clearance with the feeler gauge at various points.
3. Check clearance between crosshead and crosshead bore with the

feeler gauge.
 The crosshead does not need to be replaced as long as the cross-
head clearance in the lower half is tolerable.
4. Keep a record of measured clearances. If required, you can order tem-

plates for measurement log sheets from our Service Division (see sec-
tion 1.6 Contact Address).
Should doubts arise about the admissibility of the measured clearance,

consult our Services Division, address see section 1.6 Contact Address.
Connection between Connection between crosshead and piston rod, please see section 9.10
Crosshead and Piston Rod Piston and Piston Rod.

Crankgear
8.8.6 Crosshead Pin Bearing

The crosshead pin is fitted to the crosshead and secured by circlips. The
crosshead pin bearing is fitted to the connecting rod´s small end with a tight
fit. It is secured by circlips. A pin prevents its rotation in the connecting rod.
LA_M3_0008b_01
10
Fig. 8-33 Crosshead pin bearing
1 Piston rod 6 Crosshead pin bearing

2 Crosshead 7 Crosshead pin
3 Wedges 8 Circlip
4 Locking screw 9 Pin
5 Circlip 10 Connecting rod
Bring crank to Top Dead Center (TDC) and measure clearance with a dial
gauge by lifting the crosshead. Pay attention to measure only the cross-
head pin bearing clearance! If in doubt, eliminate the connecting rod
bearing clearance and the crankshaft bearing clearance by lifting and
blocking the connecting rod from the bottom side.
For applicable clearances: see section “Compressor” in chapter 13 Ap-
pendix.

Crankgear
8.8.7 Guide Bearing
1 2 3 4
LA_M5_0028b_01
9 8
Fig. 8-34 Guide bearing with cooling and open design (typical view)
1 Bearing housing 6 Crown ring

2 Piston rod 7 Bearing bush
3 Oil shield 8 Adjustable elbow union
4 Guide bearing cover 9 Oil syphon
5 Wiper elements
Guide Bearing Before dismantling the piston rod, the clearance between guide bearing
Clearance Check and piston rod must be checked with a feeler gauge. If the clearance be-
tween bush and piston rod exceeds the value given in the table of clear-
ances, the bush must be replaced.
Should doubts arise about the admissibility of the measured clearance,
consult our Services Division, address see section 1.6 Contact Address.

13 Appendix.
For guide bearing replacement, please see section 9.17 Guide Bearing.
Checks after Liquid Knock Check tightness of connection between crosshead and piston rod immedi-
ately after a liquid knock (tightness of crosshead wedges).
Removal of Piston Rod and For removal of piston rod and oil scrapers please see section 9.10 Piston
Wiper Elements and Piston Rod and 9.15 Oil Scraper.

Cylinder
8.9 Cylinder
8.9.1 Piston Rod

Clean Piston Rod
DANGER
Fire hazard!
Chemicals.
Check piston rod regularly. If inspection indicates that piston rod requires
cleaning, stop the compressor and proceed as follows:
DANGER
1. Turn flywheel until piston rod is at the Bottom Dead Center (BDC).
2. Moisten a lint-free cleaning tissue with an organic solvent and clean the
piston rod above the oil shield.
CAUTION
Risk of corrosion of piston rod.
 Wash the piston rod with the cleansing agent so that the solvent does
not affect the oil shield or does not enter the guide bearing housing.
3. Clean the gland flange and the guide bearing cover in the same
manner.
4. Turn the flywheel until the piston rod is at its Top Dead Center (TDC).
5. Wipe the piston rod below the oil shield with a dry lint-free cleaning
tissue. Do not use any solvent on this part of the piston rod because an
oil film is required for the proper functioning of the oil scrapers.

Cylinder
6. Apply proper maintenance guidelines to clean the bottom, top and the
walls of the distance piece.
7. Restart the compressor with the usual start-up procedure.
8.9.2 Piston Rod Gland

The gland rings must be inspected every year or two 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 glands,
• increase of pressure in the crankgear,
• reduced discharge rate,
• changes in the intermediate pressure,
• increase of gland temperature, etc.
The piston rod gland is equipped with 1-piece gland rings, with exception
of the bottom gland ring which is a 3-piece ring.
The 3-piece gland ring at the bottom is pressed directly onto the piston rod
by two garter springs. To avoid excessive wear of the bottom rings, do not
exceed the specified suction pressure.
The gland rings are to be handled with great care. In particular the labyrinth
combs and the faces are to be free of damage. The same applies to the
surface quality of the piston rod in the area where it enters the gland.
To prevent contamination of the rings when fitting them in their chambers,
the area of the piston rod which enters the gland must be clean and com-
pletely free of oil.
Take care that the diametrical clearance (see section 9.12 Piston Rod
Gland) between the gland rings and the piston rod is not too small.
To reduce wear on the rings to a minimum, the piston rod above the oil
shield should be cleaned periodically with a lint-free cleaning tissue, see
section 8.9.1 Piston Rod. The distance piece must be kept clean as well.
WARNING
Incorrect modification 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.

Cylinder
8.9.3 Piston
Markings on Piston and piston rod have no key. Therefore all components are match-
Piston and Piston Rod marked and precisely aligned when leaving our works. These marks define
the position of all piston components and the piston rod relative to each
other. When installing new parts, reference mark them accordingly.
This also applies to inspections, whether components are replaced or not
(e.g. when checking the piston pretension). During reassembly of the com-
ponents, these markings will help to recover the correct position of the
piston in relation to the cylinder. The marking should be stamped or en-
graved only.
In addition to the above mentioned markings, mark the piston with its Vx-
number (see section 8.7.2 Marking of Compressor Components). The
marking should be stamped or engraved only. When assembled and in-
stalled these piston markings should always be on the “V”-side (name plate
side) of the compressor.
The marks that define the position of all piston components and the piston
rod relative to each other plus the Vx-marks define the position of the piston
to the cylinder. It is very important that this relative position does not
change.
Matchmark and When new piston parts are installed or the piston rod is replaced, all com-
Align New Parts ponents must be matchmarked and precisely aligned as indicated in
Fig. 8-35.
1 2 3
6
LA_C1_0030b_01
Fig. 8-35 Marking of piston, piston crown and skirt
1 Piston rod 4 Marking on piston rod

2 Piston crown, upper 5 Markings on piston crown, upper
3 Piston skirt 6 Markings on piston skirt

Cylinder
Check the Pretension of 1. The pretension of the piston crowns to the piston skirt is measured
Piston Crowns when a 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 distance “A” as shown in Fig. 8-36 with the piston crowns
clamped together without the piston skirt.
Pretension = Dimension B - Dimension A
1 2 4
A B
LA_C1_0027b_02
5
Fig. 8-36 Check pretension of piston crowns
1 Piston crown 4 Piston skirt

2 Piston nut 5 Piston rod
3 –
Piston Diameter in mm Pretension in mm

1st stage 400 0.241 to 0.300
Tab. 8-3 Pretension of piston crowns
WARNING
Risk of piston seizure or loose piston skirt!
Check for correct pretension and tightening of piston nut.
 The measured values must be within the tolerances given above.
 Tighten piston nut in accordance with section 8.7.3 Tightening Methods
and section “Compressor” in chapter 13 Appendix.
Installation of 1. When a new piston skirt is installed, it must be matchmarked and pre-
New Piston Skirt cisely aligned with the piston rod, the top piston crown and the bottom
piston crown (see Fig. 8-35 and subsection “Markings on Piston and
Piston Rod” earlier in this section).
2. If the piston crowns need no re-machining, proceed with section 9.10.4
Assemble and Install Piston.

Cylinder
Re-machining of Piston Piston crowns which have to be re-machined because of pretension loss
Crowns must not be reduced more than 1.5 mm in height. Face runout must not ex-
ceed 0.02 mm.
LA_C1_0028b_02
Fig. 8-37 Overview
Pretension hmin Face runout (mm)

h -1.5 mm > 0.02
Tab. 8-4 Pretension loss and face runout
After facing the outer contact surface (1) and the inner contact surface (2)
of the upper and lower piston crown proceed as follows:
LA_C1_0029b_02
1 2
Fig. 8-38 Contact surfaces to be faced
1 Outer contact surface

2 Inner contact surface
1. Clamp the piston crowns together without the piston skirt, see
Fig. 8-36.
2. Compare the measured pretension with the values in Tab. 8-3.
3. Re-machine the pretension by facing the outer contact surface (1) and
the inner contact surface (2).
Measure
Piston Clearance
Prior to measuring, clean all measuring tools, according to chapter 10

Clean and Degrease Plant and Compressor Components.
For procedure and values see chapter 8.9.4 Piston Clearance Measure-
ment.

Cylinder
Measure Check cylinder clearances and record measured values. If required, you
Cylinder Clearance can order templates for measurement log sheets from our Service Division
(see section 1.6 Contact Address).

Measure cylinder clearance, according to chapter 8.9.5 Cylinder Clearance

Measurement.
Failures and Repairs on Gas loss between cylinder and piston influences the intermediate pres-
Cylinder and Piston sures as well as the outlet temperatures on the corresponding cylinders
(suction and final pressures maintained).
“Inadequate pistons” are defined as follows:
Piston with Excessive Diameter Clearance (possibly Labyrinth OK)

Possible causes:
• excessive vibrations at the foundation/compressor,
• piston rod gland in bad condition,
• excessive clearance between piston rod and guide bearing,
• excessive crosshead clearance,
• pretension of piston too small, i.e. piston or piston skirt rotates.
Piston Seizure, i.e. Piston Entirely or Partially with “Flattened” Laby-

rinth
Piston seizure often leaves piston residues in the cylinder. They are visible
as smooth spots on the labyrinth.
Removal of such deposits according to section “Dissolving of Deposits in
Cylinder after Piston Seizure“ in this chapter.
Possible causes:
• rapid temperature increase, e.g. due to:
– valve defect,
– failure of cylinder cooling.
• Impurities inside gas piping and/or plant accessories getting into the
cylinder.
• Broken valve parts getting into the cylinder.
• Liquid knock, e.g. leaky cooler during commissioning/condensate.

Cylinder
Following maintenance and/or repair work:

• rapid pressure raise during running-in of a new piston,
• insufficient clearance between guide bearing and piston rod,
• inadequate concentricity of guide bearing/guide bearing bush,
• insufficient clearance between piston rod and gland ring,
• excessive pretension of piston.
Excessive Pretension of Piston
Excessive pretension of piston can

be noticed, when the piston skirt
LA_C1_0007a_01
shows an oval-shaped, concave,
flat spot, mainly in direction of the
valve (Fig. 8-39). This is the result
of buckling of the warm piston skirt
due to excessive tension in the
Fig. 8-39 Oval-shaped spot skirt.
Insufficient Piston Pretension

Insufficient piston pretension leads to a loose piston skirt, noticeable by a
clear knocking of the compressor. Piston parts may be re-machined.
Should questions arise, please get in touch with our Services Division (see
1.6 Contact Address).
Damaged Pistons Damaged pistons and/or pistons with excessive clearance must be re-
placed. If the clearance is still excessive, the cylinder must be rebored and
oversized pistons have to be installed.
For further instructions, contact our Services Division.
Dissolving of Deposits To remove large residues of piston material from the cylinder walls, it is ad-
in Cylinder Liner visable to use a chemical solvent. The cylinder does not need to be dis-
after Piston Seizure mantled when using a solvent.
For deposit removal, do not use mechanical means such as grinding discs.
Solvent: Watery solution of ammonia, concentration about 20 to 25 %.
Description: In case solvent is not available, blow ammonia into the water.
Keep the bottle upright so that only gas enters the water!
The solution is saturated as soon as the characteristic crackle stops and
gas bubbles begin to rise.
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.

Cylinder
Result: The portion of copper (approx. 90 %) contained in the bronze will

be transformed into copper oxide.
Procedure
1. Remove loose parts, dirt, oil and grease from the cylinder.
2. Close piston rod glands and valve openings carefully.
3. Prepare facilities for draining and a connection for oil free air.
4. Fill the cylinder carefully with the solution of ammonia. Activate the pro-
cess of oxidation by blowing air into the liquid (without oxygen, no oxi-
dation). Direct the air jet in such a way that the solution of ammonia is
rotated evenly.
The time required for dissolving the residues depends on the …

• ammonia concentration of the solution,
• availability of oxygen,
• temperature as well as
• thickness and
• surface porosity of the residues.
5. Replace the solution of ammonia after 3 to 4 hours by fresh solution.

As a rule, cleaning should be finished within 12 hours.
6. Dry cylinder; remove remaining residues (alloys) by means of a wire
brush.

Cylinder
8.9.4 Piston Clearance Measurement

Measure 1. The piston clearance of each individual stage must be measured in the
Piston Clearance Top Dead Center (TDC) as well as in the Bottom Dead Center (BDC)
position.
Always measure simultaneously with two opposite feeler gauges (see
Fig. 8-40).
Record measured values. If required, you can order templates for mea-
surement log sheets from our Service Division (see section 1.6 Contact
Address).
The clearance measured at the same place in the BDC and TDC must
be practically the same. Should doubts arise concerning measurement,
please contact our Services Division.
1 2 3 4
7 6 5
A E
D CH G
LA_C1_0006b_05
B F
Fig. 8-40 Measure piston clearance
1 Feeler gauge no. 1 5 Measuring points BDC (E with F,

2 Feeler gauge no. 2 G with H)
3 Piston 6 Piston rod
4 Cylinder 7 Measuring points TDC (A with B,
C with D)

Cylinder
8.9.5 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).
Cylinder Clearance with Spacer Ring
1 2 3 4
LA_C0_0011b_02
a
Fig. 8-41 Spacer ring
1 Cylinder 4 Spacer ring

2 Cylinder cover a Cylinder clearance (TDC)
3 Piston
The 1st stage cylinder covers are equipped with spacer rings. The height of
the spacer rings on top of the cylinder is as follows:
Cylinder cover Height in mm

1st stage 5
Tab. 8-5 Spacer ring
Measure
Cylinder Clearance

Check cylinder clearances and record measured values. If required, you

can order templates for measurement log sheets from our Service Division
(see section 1.6 Contact Address).

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.
A
a
LA_C0_0002b_02
b
Fig. 8-42 Measure cylinder clearance
A Piston diameter
a Top dead center (TDC)
b Bottom dead center (BDC)
Stage Diameter A in mm Clearance a in mm Clearance b in mm
Min. Max. Min. Max.

1st 400 7.0 7.5 1.5 2.0
st
1 a + b shall not exceed 9.5 mm (with spacer ring)
Tab. 8-6 Cylinder clearance measurements of 1st stage
1. Check the bottom dead center (BDC) cylinder clearance with a feeler
gauge through the valve openings (see Fig. 8-40).
Repeat this procedure in the top dead center (TDC).
2. Compare the cylinder clearances you have measured with the table of
clearances in section “Compressor” in chapter 13 Appendix.
 You have installed the piston correctly if the measured values of the
cylinder clearance correspond with the table of clearances.
3. If necessary, adjust the cylinder clearance.
Admissible Tolerances not Achieved?

If the values are not within the given tolerances, there might be a mix-up of
parts (e.g. wedges, piston rods or crosshead).
If there is no mix-up with the assembly, the cylinder clearance must be ad-
justed with distance washers of 0.5 mm thickness between the lower piston
crown and piston rod (Fig. 8-42).

Cylinder
In case the piston must be disassembled, mark skirt, upper and lower
crown.
1 2 3
LA_C0_0020b_01
Fig. 8-43 3-piece piston
1 Piston skirt
2 Piston rod
3 Upper piston crown
4 Lower piston crown
5 Washer 0.5 mm
8.9.6 Piston Nut SUPERBOLT®
Fig. 8-44 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 Burck-
taminated gas) hardt Lubrication Grease BLG05
4 Hardened washer 8 Piston nut SUPERBOLT®

Cylinder
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,
• 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.

Cylinder
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. 8-45 Loosening of pressure

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

pressure screws!
Tightening Procedure Required Tools

• Piston nut wrench
• Torque wrench
• Hexagonal socket
• Square insert for socket
• Lubricant “Burckhardt Lubrication Grease BLG05”
The marked tightening torque is the maximum permitted value. For appli-
cable tightening torques: see section “Compressor” in chapter 13 Ap-
pendix.
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.

Cylinder
9
5 4
6 3 10
2
7 1
1 7
2
3 6
XA_T9_0014b_01
4 5
Fig. 8-46 Piston nut wrench for piston nut SUPERBOLT® (position 1–7 = SUPER-
BOLT® size)
1 G 1" 6 G 2 1/2"
2 G 1 1/4" 7 G 3"
3 G 1 1/2" 8 Piston nut wrench
4 G 1 3/4" 9 Pin (dia. 6 mm/dia. 8 mm)
5 G 2" 10 Hexagon 22 mm
3. If the piston is multi-part, tighten the nut to eliminate the pretension of

the piston halves:
4. Screw the pins (9) into the piston nut wrench (8) at the position which
corresponds with the SUPERBOLT® size.
– Pin with diameter 6 mm, up to SUPERBOLT® size G 2"
– Pin with diameter 8 mm, from SUPERBOLT® size G 2 1/2"
5. Attach piston nut wrench.

Cylinder
6. Tighten the piston nut with the piston nut wrench to a perceptible in-
creasing resistance.
X
LA_T9_0025b_01
6 5 4 3
Fig. 8-47 X = Gap approx. 1 mm
1 Groove for O-ring 4 Piston rod

(with contaminated gas) 5 Pressure screw
2 Piston nut SUPERBOLT® 6 Piston
3 Hardened washer
7. 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.
2. Tighten the same 4 pressure screws crosswise with 50 %.
1 1
8 2
3 4 7 3
XA_T9_0019a_01
XA_T9_0020a_01
6 4
2 5
Fig. 8-48 Tighten 4 pressure screws Fig. 8-49 Tighten all pressure
screws

Cylinder
4. Tighten the remaining pressure screws crosswise with 50 % of the rec-

ommended tightening torque.
5. Repeat step 4 with 100 %.
6. Now change to circular tightening and tighten all pressure screws with
100 % until all pressure screws are equally tightened.
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. 8-50 Tighten 3 pressure screws Fig. 8-51 Tighten all pressure
screws
4. Tighten the remaining pressure screws with 50 % of the recommended

tightening torque.
5. Repeat step 4 with 100 %.
6. Now change to circular tightening and tighten all pressure screws with
100 % until all pressure screws are equally tightened.
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.

Cylinder
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 our Services Division (address see section 1.6 Contact Ad-
dress).

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
specialists on site or in one of our Burckhardt Compression licensed
Service Centers.
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
Incorrect modification 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 9.5 Suction Valves
and Discharge Valves.

Complete Maintenance
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
• Gas pulsations
• Significant change of process conditions
Incorrect valve assembly:

• Loose pressure screws  loose valve lantern (broken valve guard)
• Loose nut of center bolt
• Valve seat of Burckhardt Poppet Valve™ or Burckhardt Plate Valve™
has been re-machined too much  pinhole has not sufficient depth
(see section 9.5 Suction Valves and Discharge Valves).
• Valve springs for Burckhardt Plate Valve™ not fitted correctly (see sec-
tion 9.5 Suction Valves and Discharge Valves).
• Center cuts of metallic valve plate and damper plate for Burckhardt
Plate Valve™ plate do not coincide (see section 9.5 Suction Valves and
Discharge Valves).
8.11 Complete Maintenance

Commissioning.

Dismantle and Assemble Compressor Components
9 Dismantle and Assemble Compressor

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

9.2 Switch Off Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.3 Switch Off Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.4 Non-Return Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.4.1 Status and Special Tools. . . . . . . . . . . . . . . . . . . . 9-7
9.4.2 Dismantle Non-Return Valve . . . . . . . . . . . . . . . . 9-7
9.4.3 Assemble and Install Non-Return Valve . . . . . . . . 9 - 10
9.5 Suction Valves and Discharge Valves. . . . . . . . . . . . . . . . . 9 - 10
9.5.1 Status and Special Tools. . . . . . . . . . . . . . . . . . . . 9 - 10
9.5.2 Dismantle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 12
9.5.3 Disassembly and Repair of Burckhardt Plate
Valve™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 13
9.5.4 Assembly of Burckhardt Plate Valve™ . . . . . . . . . 9 - 16
9.5.5 Installing a Valve with Pressure Screws . . . . . . . . 9 - 21
9.6 Cylinder Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 24
9.6.2 Dismantle and Install Cylinder Cover . . . . . . . . . . 9 - 24
9.7 Frame Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 26
9.7.2 Dismantle and Assemble Frame Covers . . . . . . . 9 - 26
9.8 Drain Lubricating Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 27
9.8.2 Drain and Refill Lubricating Oil . . . . . . . . . . . . . . . 9 - 27
9.9 Components of Lubricating System . . . . . . . . . . . . . . . . . . 9 - 28
9.9.1 Oil Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 28
9.9.2 Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 30
9.9.3 Oil Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 31
9.9.4 Oil Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 32
9.9.5 Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 32
9.10 Piston and Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 33
9.10.2 Dismantle Piston and Piston Rod . . . . . . . . . . . . . 9 - 34
9.10.3 Dismantle Piston. . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 37
9.10.4 Assemble and Install Piston . . . . . . . . . . . . . . . . . 9 - 40
9.10.5 Assemble and Install Piston and Piston Rod . . . . 9 - 40
9.11 Internal Leak Gas Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 50
9.11.2 Dismantle and Assemble Internal Leak Gas Pipes 9 - 50
9.12 Piston Rod Gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 51
9.12.2 Dismantle Piston Rod Gland . . . . . . . . . . . . . . . . 9 - 51
9.12.3 Assemble Piston Rod Gland. . . . . . . . . . . . . . . . . 9 - 52

9.13 External Gas Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 54

9.14 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 55
9.14.1 Status and Special Tools . . . . . . . . . . . . . . . . . . . . 9 - 55
9.14.2 Dismantle Cylinder . . . . . . . . . . . . . . . . . . . . . . . . 9 - 55
9.14.3 Assemble Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . 9 - 56
9.15 Oil Scraper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 57
9.15.2 Dismantle and Assemble Oil Scrapers . . . . . . . . . 9 - 57
9.16 Guide Bearing Bush. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 58
9.16.2 Dismantle Guide Bearing Bush . . . . . . . . . . . . . . . 9 - 58
9.17 Guide Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 61
9.17.2 Dismantle Guide Bearing. . . . . . . . . . . . . . . . . . . . 9 - 61
9.18 Connecting Rod Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 62
9.18.2 Dismantle the Connecting Rod Bearing . . . . . . . . 9 - 62
9.18.3 Assemble the Connecting Rod Bearing. . . . . . . . . 9 - 64
9.19 Crosshead and Connecting Rod . . . . . . . . . . . . . . . . . . . . . 9 - 65
9.19.2 Dismantle Connecting Rod and Crosshead . . . . . 9 - 66
9.19.3 Assemble Connecting Rod and Crosshead. . . . . . 9 - 66
9.20 Crosshead Pin Bearing (with Cylinder Removal). . . . . . . . . 9 - 67
9.20.2 Dismantle the Crosshead Pin Bearing. . . . . . . . . . 9 - 67
9.20.3 Assemble the Crosshead Pin Bearing. . . . . . . . . . 9 - 67
(without Cylinder Removal) . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 69
9.21.2 Dismantle the Crosshead Pin Bearing. . . . . . . . . . 9 - 69
9.21.3 Assemble the Crosshead Pin Bearing. . . . . . . . . . 9 - 70
9.22 Gear Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 71
9.22.2 Dismantle Gear Oil Pump . . . . . . . . . . . . . . . . . . . 9 - 71
9.22.3 Assemble Gear Oil Pump . . . . . . . . . . . . . . . . . . . 9 - 72
9.23 Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 72
9.23.2 Dismantle Electric Motor . . . . . . . . . . . . . . . . . . . . 9 - 72
9.23.3 Assemble Electric Motor . . . . . . . . . . . . . . . . . . . . 9 - 72
9.23.4 Place Electric Motor. . . . . . . . . . . . . . . . . . . . . . . . 9 - 72
9.23.5 Align Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . 9 - 74
9.23.6 Check Crankshaft Deflection . . . . . . . . . . . . . . . . . 9 - 75
9.24 Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 76
9.24.2 Dismantle Coupling . . . . . . . . . . . . . . . . . . . . . . . . 9 - 76
9.24.3 Assemble Coupling . . . . . . . . . . . . . . . . . . . . . . . . 9 - 76

9.24.4 Install Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 76

9.25 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 78
9.25.2 Transport and Lifting of the Flywheel . . . . . . . . . . 9 - 78
9.25.3 Dismantle the Flywheel . . . . . . . . . . . . . . . . . . . . 9 - 79
9.25.4 Assemble the Flywheel. . . . . . . . . . . . . . . . . . . . . 9 - 79
9.25.5 Check Crankshaft Deflection . . . . . . . . . . . . . . . . 9 - 81
9.26 Oil Trap and Crankshaft Seal . . . . . . . . . . . . . . . . . . . . . . . 9 - 82
9.26.2 Dismantle and Assemble Oil Trap and Crankshaft
Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 82
9.27 Bearing Bracket and Main Bearing . . . . . . . . . . . . . . . . . . . 9 - 83
9.27.2 Dismantle and Assemble Bearing Bracket and
Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 83
9.28 Dismantle Crankshaft Sidewards . . . . . . . . . . . . . . . . . . . . 9 - 84
9.29 Switch On Compressor After Assembly . . . . . . . . . . . . . . . 9 - 84


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
Prerequisites before
Assembly
DANGER
Fire hazard!
Important Markings
Compressor parts which must always be fitted in the same position are
numbered. Please refer to section 8.7.2 Marking of Compressor Compo-
nents.
Lubricants, Tightening
Torques and Methods
For applicable lubricants, mandatory tightening torques as well as appro-

priate tightening methods: see sections “Lubricating System” and “Com-

Switch Off Compressor
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.
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!

Non-Return Valve
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 following figure:
2 3 4 5 6 7
Fig. 9-1 Non-return valve (typical view) XA_L2_0002b_01
1 Flow direction 5 Housing

2 Threaded bolt 6 Non-return valve
3 Flange 7 Nut
4 Gasket
Contrary to the assembly of plate valves installed in the compressor, the

non-return valve is assembled without springs (elimination of whistling
noises).

Non-Return Valve
Required Checks Check the marking “X5”:
HS 1
2
HS 2
HS 3
3
XA_CX_0027b_01
HS
Fig. 9-2 X5 Marking
1 Valve guard 4 Valve seat

2 Damper plate 5 Marking X5
3 Valve plate HS Lift washer
Assemble New
or Used Parts
For installation of NORD-LOCK® washer pairs see section 8.7.5 NORD-

LOCK® Securing System.
1 2
XA_CX_0030b_02
Fig. 9-3 Positioning of damper plate and valve plate
1 Correct position
2 Incorrect position

Non-Return Valve
1
2
8
4
XA_L2_0006b_02
Fig. 9-4 Components of non-return valve
1 Nut 5 Valve plate

2 Washer 6 Valve seat
3 Valve guard 7 Center bolt
4 Damper plate 8 Lift washer
Thread size Center bolt Torque for nut in Nm

torque in Nm
M8 8 15
M10 15 29
M12 26 51
M14 40 81
M16 63 126
M18 87 174
M20 123 247
M22 168 336
M24 213 426
Tab. 9-1 Tightening torques, only valid if “Burckhardt Lubrication Grease” BLG05
is used

9.4.3 Assemble and Install Non-Return Valve

Assemble and install the non-return valve according to Fig. 9-1.
• 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.
9.5 Suction Valves and Discharge Valves

Special Tools Valve Dismantling and Assembling Device for Lightweight Valves
with Pressure Screws
1 2 3
LA_T9_0027b_01
Fig. 9-5 Valve dismantling and assembling device for lightweight valves with
pressure screws
1 Cylinder
2 Valve
3 Dismantling and assembling device
Burckhardt Compression recommends this tool for handling of smaller size

valves and lanterns with moderate weight (valve size  202mm).
Recommended Tools Recommended: valve service device (for assembly and disassembly)
(Not Delivered with
Compressor)

Fig. 9-6 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

9.5.2 Dismantle Valve
DANGER
Fire hazard!
Powerful oxidizing power! Process gas residues in cylinders and
piping!
become highly flammable. Residues of process gas can cause fire.
 Before you dismount valves, discharge the process gas from cylinders
and piping.
 Purge the compressor plant with dry nitrogen before opening the com-
pressor.
Removal of
Lightweight Valves
DANGER
Falling machine parts!
Serious injury or death
 Heavy equipment may only be lifted according to manufacturer’s in-
structions.
 Do not stand underneath suspended loads.
 Protect carrying ropes against sharp edges!
1. If applicable: remove cap nut for pressure screws and gaskets.

2. Remove valve cover nuts.
3. Remove valve cover.
4. Remove gasket.
5. Remove lantern.
6. Remove valve using the removal and assembling device according to
Fig. 9-5.

9.5.3 Disassembly and Repair of Burckhardt Plate Valve™

Disassembly
of Valves This compressor is equipped with
original Burckhardt Plate Valves™.
Fig. 9-7 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 1.6 Contact Address.
XA_T9_0029a_02
Fig. 9-8 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 1. Clean all components. Use a cleaning fluid and a soft brush, taking par-
after 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 are
damaged due to hammering, etc., they can be machined on a lathe ac-
cording to Tab. 9-2 and Fig. 9-9.
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. 9-9 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
All dimensions in 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. 9-2 Re-machining limits
Re-machining quality of surface (3): N6 fine-machined. Check pinhole (1)

for sufficient depth. Drill deeper if necessary.
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.
9.5.4 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. 9-10 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
The valves shall be fitted with the following lift washers and springs:

Number Valve type Size of Lift washer Lift Spring Wire dia.
thread for
per stage center bolt piece x mm in mm piece in mm

1st Stage
Suction 8 181-BC M16 3 x 0.55 1.65 22 0.5
Discharge 8 181-BC M16 3 x 0.55 1.65 22 0.6
Tab. 9-3 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 our Services Division, address see 1.6 Con-
tact Address.
General Remarks
Clean all parts according to chapter 10 Clean and Degrease Plant and
Compressor Components.
DANGER
Fire hazard!
become highly flammable. Oil and grease are particularly hazardous in the
presence of oxygen as they can ignite spontaneously and burn with explo-
sive violence.
 Degrease and clean all valve components to required cleanliness stan-
dard (oxygen service).
 Use “Burckhardt Lubrication Grease BLG05” lubricant only (BAM ap-
proved for use with oxygen).
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.
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.

Assemble New
or Used Parts 1 2
3
4
XA_CX_0022b_02
Fig. 9-11 Valve assembly
1 Suction valve
2 Discharge valve
3 Nut
4 NORD-LOCK® washer pair
For installation of NORD-LOCK® washer pairs see section 8.7.5 NORD-

LOCK® Securing System.

Check the marking “X5”:
HS 1
2
HS 2
HS 3
3
XA_CX_0027b_01
HS
Fig. 9-12 X5 Marking
1 Valve guard 4 Valve seat

2 Damper plate 5 Marking X5
3 Valve plate HS Lift washer
Instruction for Fitting of Valve Springs

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. 9-13 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. 9-4 – For tightening torques
Fig. 9-13 – For fitting of the valve springs

The nuts must be tightened thoroughly.

The center slanting cuts on valve and damper plates must coincide (see
Fig. 9-3).
1 2
XA_CX_0030b_02
Fig. 9-14 Positioning of damper plate and valve plate
1 Correct position
2 Incorrect position
Thread size Center bolt Torque for nut in Nm

torque in Nm
M8 8 15
M10 15 29
M12 26 51
M14 40 81
M16 63 126
M18 87 174
M20 123 247
M22 168 336
M24 213 426
Tab. 9-4 Tightening torques, only valid if “Burckhardt Lubrication Grease” BLG05
is used

9.5.5 Installing a Valve with Pressure Screws

Special Tools For special tools please refer to section 9.5.1 Status and Special Tools.
Transport and For transport and lifting of valves, please refer to section “9.5.1 Status and
Lifting of Valves Special Tools”.
Fit Valves The sealing surfaces between the valves and the cylinders are lapped in.
into Cylinder 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. 9-15 Correct installation of valves
WARNING
Wrongly installed valves can lead to compressor damage.
Lanterns for the suction side are shorter than those for the discharge side.
In suction valves, the center bolt is threaded into the guard. In discharge
valves, the center bolt is threaded into the seat.
 Make sure that all suction and discharge valves are installed in the cor-
rect direction. See Fig. 9-15 for correct position.
 Read the following instructions carefully.
A suction valve cannot be inserted in a valve cavities on the discharge side

because its diameter is larger than the diameter of a valve cavity on the dis-
charge side.
A discharge valve, however, can be inserted into a valve cavity on the suc-
tion side because its diameter is smaller than the diameter of a valve cavity
on the suction side. Nonetheless it can not be properly installed because
its lantern can then not be moved into its correct position.

S D
1
ø> ø<
5
LA_CX_0002b_01
G G
Fig. 9-16 Suction valve diameter > discharge valve diameter,

example of a Burckhardt Plate Valve™ with metallic valve plates
S Installed suction valve 3 Pressure screw

D Installed discharge valve 4 Gasket
G Gas flow 5 Lantern
Ø Valve diameter 6 Suction valve
1 Cap nut for pressure screw 7 Discharge valve
2 Valve cover

Install Suction and Installed valves and their lanterns are pressed to their seating surfaces by
Discharge Valves pressure screws (1). There is a gap between valve covers and installed lan-
terns/valves.
1 Pressure screw
2 Cap nut
1 3 Valve cover
4 Cap nut gasket
2 5 Nut
6 Cover gasket
X Gap
3
4
XA_CX_0032b_02
5
6
X mm
Fig. 9-17 Valve cover
1. Insert valves with their lanterns into the correct valve cavities (use eye
bolts). The inserted lantern must fit properly. The inserted lanterns must
stand approx. X mm (12–16 mm) back from the cylinder face.
2. Turn back pressure screws (1) 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.
3. Put gasket (6) and valve cover (3) on cylinder and tighten the nuts (5)
slightly.
4. Tighten the nuts diagonally, applying specified torque.
5. Tighten pressure screws (1), applying specified torque.
6. Fit gaskets for cap nuts.
7. Fit cap nuts (2) and tighten them firmly.
For mandatory tightening torques: see section “Compressor” in chapter 13

Appendix.

Cylinder Cover
9.6 Cylinder Cover

• 9.3 Switch Off Cooling System
Special Tools
LA_T9_0009a_01
Fig. 9-18 Eye bolt
9.6.2 Dismantle and Install Cylinder Cover

Spacer Ring
1 2 3 4
LA_C0_0011b_02
Fig. 9-19 Spacer ring
1 Cylinder 4 Spacer ring

2 Cylinder cover a Cylinder clearance (TDC)
3 Piston
The 1st stage cylinder covers are equipped with spacer rings.
For spacer ring details see Tab. 8-5 Spacer ring.
Dismantle and Checks Before dismantling a cylinder cover check cylinder clearances.

Cylinder Cover
CAUTION
pressor failure.
clearance.
1. Dismantle one of the upper and one of the lower valves.

 The cylinder clearance is now accessible
2. Check the cylinder clearance according to section 8.9.5 Cylinder Clear-

ance Measurement.
3. Record measured values. If required, you can order templates for mea-
Address).
Dismantle Cylinder Cover
4. Remove all nuts of the cylinder cover.

5. Fit eye bolts to cylinder cover.
6. Remove cylinder cover.
Required Checks 1. Check cylinder cover surface for cleanliness.
2. Check if the O-ring is in perfect condition.
Assemble New 1. Replace O-ring if required.

or Used Parts
Installation takes place in reverse order to dismantling.

Frame Covers
9.7 Frame Covers

Special Tools none
9.7.2 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.
LD_M0_0049a_02
Fig. 9-20 Frame cover removal

Drain Lubricating Oil
9.8 Drain Lubricating Oil

• 9.7 Frame Covers
Special Tools none
9.8.2 Drain and Refill Lubricating Oil

Drain For details about the draining procedure, please refer to section 8.7.6 Oil
Change.
Refill For details about the refilling procedure, please refer to section 8.7.6 Oil
Change.
Check for proper lubricating oil quality and quantity see Fig. 8-24 and sec-
tions 8.7.6 Oil Change and 8.7.7 Lubricating Oil Specifications.

Components of Lubricating System
9.9 Components of Lubricating System
9.9.1 Oil Drain

• 9.8 Drain Lubricating Oil
Special Tools none
Dismantle and Assemble Dismantle and assemble according to the following figure:
LA_M2_0010b_01
4 3 2 1
Fig. 9-21 Oil drain
1 Plug 3 Coupling
2 Ball valve 4 Crankgear

9.9.2 Oil Heater

Special Tools none
Dismantle and Assemble The oil heater is located in the crankgear:
LK_M1_0016c_03
1 2 3 4 5
Fig. 9-22 Dismantle oil heater and strainer
1 Cover
2 O-ring
3 Oil strainer
4 Crankgear
5 Oil heater

9.9.3 Oil Strainer

• 9.9.2 Oil Heater
Special Tools none
Dismantle and Assemble The oil strainer is located in the crankgear:
LK_M1_0016c_03
1 2 3 4 5
Fig. 9-23 Dismantle oil heater and strainer
1 Cover
2 O-ring
3 Oil strainer
4 Crankgear
5 Oil heater

9.9.4 Oil Sight Glass

Special Tools none
Dismantle and Assemble The oil sight glass is installed in the crankcase.
Dismantle and assemble according to the following figure:
4
LA_M2_0006b_02
Fig. 9-24 Oil sight glass
1 Sight glass holder

2 Sight glass
3 Gasket
4 O-ring
9.9.5 Relief Valve

Special Tools none
Dismantle and Assemble For detailed illustration of the relief valve, please refer to section 5.11.7
Running in Pistons.

Piston and Piston Rod

• 9.5 Suction Valves and Discharge Valves
• 9.6 Cylinder Cover
Special Tools
1 2 3
LA_T9_0022b_02
1 Crosshead
2 Piston rod
3 Cotter key
LA_T9_0009a_01
Fig. 9-26 Eye bolt

9.10.2 Dismantle Piston and Piston Rod

Measure 1. Check the piston clearance according to section 8.9.4 Piston Clear-
Piston Clearance ance Measurement.
Address).
Measure 3. Check the cylinder clearance according to section 8.9.5 Cylinder Clear-
Cylinder Clearance ance Measurement.
Address).
CAUTION
pressor failure.
clearance.
Measure 5. Check clearance between guide bearing bush and piston rod (see sec-
Guide Bearing Clearances tion 8.8.7 Guide Bearing).

Dismantling Procedure
12
11
1
10
2
3
9
8
4
7
LA_C1_0023b_03
Fig. 9-27 Components to dismantle (typical view)
1 Guide bearing cover 7 Safety device

2 Spring plate 8 Piston rod
3 Wiper elements 9 Oil shield
4 Guide bearing 10 Piston rod gland
5 Wedge 11 Cylinder
6 Crosshead 12 Piston
6. Disconnect the piston rod (8) from the crosshead, proceeding as fol-
lows:
• Bring crosshead to TDC (top dead center).
• Loosen safety device (7) and knock out wedges (5).
• Apply lube oil to the sliding faces and insert the cotter key (see
Fig. 9-31).
• Drive in the middle wedge until the piston rod is forced out. A dull
sound can be heard.

1 2 3
LA_T9_0022b_02
1 Crosshead
2 Piston rod
3 Cotter key
Confirm that the two rounded parts of the cotter key are inserted as shown
in the figure above.
Make sure to allow the tapered center wedge to work properly (tapered
opening between rounded pieces). The arrangement is correct if the
stamped-on numbers of the three parts are facing to the same side.
7. Remove cotter key.

8. Lift piston and piston rod carefully.
9. Make sure that the gland rings, the wiper elements and the guide
bearing bush are not damaged.
10. Loosen the guide bearing cover and spring plate, and remove the wiper
elements.
For details regarding wiper elements, see section 9.15 Oil Scraper.
11. Disconnect the piston rod (11) from the crosshead (9), proceeding as
follows:
• Bring crosshead to TDC (Top Dead Centre).
• Loosen safety device (10) and wedge (8).
• Apply lube oil to the sliding faces and insert the cotter key (see
Fig. 9-31).
• Drive in the middle wedge until the piston rod is forced out; a dull
sound can be heard.

9.10.3 Dismantle Piston

Dismantle Dismantle the piston according to Fig. 9-32.
1 2 3 4 5
LA_C1_0018c_01
6
Fig. 9-29 Dismantled piston
1 Piston rod
2 Lower piston crown
3 Piston skirt
4 Upper piston crown
5 Piston nut SUPERBOLT®
6 Washer 0.5mm (one or several pieces)
For detailed information about piston nut SUPERBOLT® see section 8.9.6
Piston Nut SUPERBOLT®.
Markings on Piston and piston rod have no key. Therefore all components are match-
Piston and Piston Rod marked and precisely aligned when leaving our works. These marks define
the position of all piston components and the piston rod relative to each
other. When installing new parts, reference mark them accordingly.
This also applies to inspections, whether components are replaced or not
(e.g. when checking the piston pretension). During reassembly of the com-
ponents, these markings will help to recover the correct position of the
piston in relation to the cylinder. The marking should be stamped or en-
graved only.
In addition to the above mentioned markings, mark the piston with its Vx-
number (see section 8.7.2 Marking of Compressor Components). The
marking should be stamped or engraved only. When assembled and in-
stalled these piston markings should always be on the “V”-side (name plate
side) of the compressor.
The marks that define the position of all piston components and the piston
rod relative to each other plus the Vx-marks define the position of the piston
to the cylinder. It is very important that this relative position does not
change.
Matchmark and When new piston parts are installed or the piston rod is replaced, all com-
Align New Parts ponents must be matchmarked and precisely aligned as indicated in
Fig. 9-33.

1 2 3
LA_C1_0030b_01
Fig. 9-30 Marking of piston, piston crown and skirt
1 Piston rod 4 Marking on piston rod

2 Piston crown, upper 5 Markings on piston crown, upper
3 Piston skirt 6 Markings on piston skirt
Check the Pretension of 1. The pretension of the piston crowns to the piston skirt is measured
Piston Crowns when a 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 distance “A” as shown in Fig. 9-34 with the piston crowns
clamped together without the piston skirt.
Pretension = Dimension B - Dimension A

1 2 4
A B
LA_C1_0027b_02
5
Fig. 9-31 Check pretension of piston crowns
1 Piston crown 4 Piston skirt

2 Piston nut 5 Piston rod
3 –
Piston Diameter in mm Pretension in mm

1st stage 400 0.241 to 0.300
Tab. 9-5 Pretension of piston crowns
WARNING
Risk of piston seizure or loose piston skirt!
Check for correct pretension and tightening of piston nut.
 The measured values must be within the tolerances given above.
 Tighten piston nut in accordance with section 8.7.3 Tightening Methods
and section “Compressor” in chapter 13 Appendix.
Installation of 1. When a new piston skirt is installed, it must be matchmarked and pre-
New Piston Skirt cisely aligned with the piston rod, the top piston crown and the bottom
piston crown (see Fig. 9-33 and subsection “Markings on Piston and
Piston Rod” earlier in this section).
2. If the piston crowns need no re-machining, proceed with section 9.10.4
Assemble and Install Piston.
Re-machining of Piston crowns which have to be re-machined because of pretension loss

Piston Crowns must not be reduced more than 1.5 mm in height. Face runout must not ex-
ceed 0.02 mm.
h
LA_C1_0028b_02
Fig. 9-32 Overview

Pretension hmin Face runout (mm)

h -1.5 mm > 0.02
Tab. 9-6 Pretension loss and face runout
After facing the outer contact surface (1) and the inner contact surface (2)
of the upper and lower piston crown proceed as follows:
LA_C1_0029b_02
1 2
Fig. 9-33 Contact surfaces to be faced
1 Outer contact surface

2 Inner contact surface
1. Clamp the piston crowns together without the piston skirt, see
Fig. 9-34.
2. Compare the measured pretension with the values in Tab. 9-5.
3. Re-machine the pretension by facing the outer contact surface (1) and
the inner contact surface (2).
9.10.4 Assemble and Install Piston
1. Assemble the piston according to Fig. 9-32 in previous section 9.10.3

Dismantle Piston.
2. Observe markings on piston and piston rod (see Fig. 9-33 in section
9.10.3 Dismantle Piston) and install accordingly.
3. Tighten piston nut SUPERBOLT® according to chapter 8.9.6 Piston Nut
SUPERBOLT®.
4. Install piston and piston rod as described in section 9.10.5 Assemble
and Install Piston and Piston Rod.
9.10.5 Assemble and Install Piston and Piston Rod
Before installation of piston and piston rod, the assembly and installation of
oil scraper and oil shield is necessary.
Proceed as described in the following sections.
Required Checks Observe numbering of individual parts (see section 8.7.2 Marking of Com-
pressor Components).

1. Check all items to be fitted for possible damage.

2. Check if the piston rod surface is in good condition. Should a piston rod
be damaged, contact our Services Division.
3. Check pretension of piston crowns according to section “Check the

Pretension of Piston Crowns”.
4. The wiper elements shall not show any sign of damage and must lie
snug against the piston rod on their whole circumference. The height of
the ring surface on the piston rod (running surface) should be 1.5 mm
to max. 2 mm. The scraping edge must be as sharp as possible and
must end in a pointed angle.
The rings must have a slight pretension when pushed onto the piston
rod, even without the garter spring. With the garter spring fitted, they
must not slide off the piston rod when in a vertical position.
1
LA_M5_0037b_01
Fig. 9-34 Oil scraper with 1-piece wiper elements (set)
1 Wiper element 5 Scraping edge

2 Garter spring 6 Marking (line-up when fitting)
3 Brad 7 Top
4 Running surface 8 Bottom

Assemble New
or Used Parts
If you insert a new piston rod, please note the last part in this section: “Fur-
ther Steps for Piston Rod Replacement”.
Preparations
1. Bring crosshead to TDC (Top Dead Centre).

2. Fit eye bolt into the piston rod. Lift piston rod and piston with the hoist.
DANGER
 Heavy equipment may only be lifted according to manufacturer’s in-
structions.
DANGER
Fire hazard!
Install Oil Scraper
1. Lower the oil-free and dry piston rod through the gland to approxi-
mately 50 mm above the guide bearing housing.
2. Using the correct sequence, slide the following parts on the dry piston
rod:
• Oil shield (1)
• Guide bearing cover with O-ring installed (2)
• Spring plate (3)

6
LA_M5_0039b_01
Fig. 9-35 Install oil scraper
1 Oil shield (without garter spring) 4 Piston rod

2 Guide bearing cover 5 Wiper elements
3 Spring plate 6 Guide bearing
3. Hold these parts in the uppermost possible position and oil the piston
rod (4) underneath.

4. Mount the wiper elements in the correct order: top, middle and bottom
ring. Make sure that the diagonal cuts of the wiper elements are offset
120° to each other (they must form a triangle when viewed from above
(see figures below).
 Another indication of proper assembly are the positioning marks
(black vertical notch on each wiper element). They line up, one on
top of the other. Bottom, middle and top wiper elements have dif-
ferent code numbers.
 The two upper wiper elements have one brad each. The brads prevent
the rings to rotate against each other.
Never tilt the wiper elements on the piston rod.
2 1 2 3 2
LA_M5_0011b_01
Fig. 9-36 Wiper elements without garter spring
1 Brad (upper rings)

2 Diagonal cut: 120° staggered
3 Marking

2 1 2 3
LA_M5_0006b_01
2
Fig. 9-37 Wiper elements with garter spring
1 Brad (upper rings)

2 Diagonal cut: 120° staggered
3 Marking
5. Oil the wiper elements with compressor lubricating oil on the inside and
slide them with fitted garter springs onto the piston rod.
6. Put the spring plate and the guide bearing cover with the O-ring on top
of the wiper elements.
Install Oil Shield
1. While lowering the piston rod through the oiled guide bearing, move the
dry oil shield up along the piston rod. Make sure that the portion of the
piston rod below the oil shield always gets some oil before it moves
through the wiper elements.
2. As soon as the piston rod is positioned in the guide bearing, tighten the
guide bearing cover by hand.
3. Lower the piston rod and continue to move up the oil shield on the
piston rod until it sits in its groove on the piston rod. At the same time
clean off excess oil on the piston rod taper and crosshead.
4. Install the garter spring on the oil shield.

Connecting Piston Rod to Crosshead

Piston rod (3) and crosshead (1) are connected with two asymmetric
wedges (2). The contact patterns at the taper part of the piston rod and at
the back of the wedges (4) have to be even.
4
3
LA_M3_0007b_02
5 4
Fig. 9-38 Adjustment of wedges
1 Crosshead 4 Back of wedges

2 Wedges 5 Sliding faces
3 Piston rod
If the piston rod/crosshead connection has to be adjusted in height, cotter

keys allow loosening the connection fro adjustment (see Fig. 9-43).
Assembly of Piston Rod and Crosshead
1. Lower the piston rod completely. Fit the taper part of the piston rod (3)
into the tapered bore of the crosshead (1) (check the contact pattern,
touch up with blue ink, refer to Fig. 9-41). Apply some compressor lu-
bricating oil to all sliding surfaces.
2. Make sure the number on the wedges corresponds with the crosshead
and piston rod.
3. Fit the wedges (2) into the slot (make them move freely).
4. Slightly knock the large wedge in and adjust rounded backs of wedges.
5. Apply lube oil to the sliding faces (5) and firmly force the wedge by hand
into its slot and knock it in approx. 10 mm from this position.
6. Knock out lower wedge with a mandril, disassemble wedges and adjust
backs of wedges.

15 mm
0.4 mm
11
10
5
9
LA_M3_0003c_02
Fig. 9-39 Position of wedges
2 Wedges 10 Hexagonal screw

5 Sliding faces 11 Overlapping end
9 Locking plates
7. Apply lube oil to the sliding faces (5). Firmly force the wedges (2) by
hand into the slot again. Now use a copper punch and a hammer and
knock in the lower wedge approx. 15 mm from this position (see
Fig. 9-42). The piston rod must consequently enter into the tapered
bore by approx. 0.4mm.
8. Check contact pattern at the rear of the wedges.
9. Dismantle the piston rod again, and adjust the contact patterns of the
taper end and the rear of the wedges.
10. Repeat steps 7 to 9 until contact patterns are in order.
11. Shorten the large wedge on the two ends (11) in case it overlaps the
crosshead.
Make sure that the wedge is forced into the slot by 15 mm and the piston
rod has entered the tapered bore by at least 0.4 mm.
12. Drill the bore for the hexagonal screw (10) in the wedge in closest po-
sition to the crosshead neck when positioning the locking plates (9).
The bore in the locking plates are eccentric in order to allow 4 different
positions for clearance-free adjustment.
13. Secure the wedges with the hexagonal screw.

Measure 1. Check the piston clearance according to section 8.9.4 Piston Clear-
Piston Clearance ance Measurement.
Address).
Measure 3. Check the cylinder clearance according to section 8.9.5 Cylinder Clear-
Cylinder Clearance ance Measurement.
Address).
CAUTION
pressor failure.
clearance.
Using Cotter Keys for Removal of Crosshead and Piston Rod
1 2 3 4 5
LA_T9_0022c_02
Fig. 9-40 Cotter keys
1 Crosshead 4 Lower cotter key

2 Piston rod 5 Middle cotter key
3 Upper cotter key
The cotter keys are placed in correct order, when the stamped-on numbers
are facing to the same side
1. Remove the hexagonal screw first and then the two asymmetric
wedges.

2. Insert cotter keys, according to figure above, in such a way that the flat
middle cotter key (5) lays between the two rounded ones (3 and 4).
3. Force out piston rod (2) from crosshead (1) by driving in the middle
cotter key; a dull sound can be heard. Remove cotter keys.
Further Steps in Case of In general, proceed as mentioned in part “Assemble New or Used Parts”,
Piston Rod Replacement sequence 1 through 10 in section in this section.
Because new parts have to be fitted, the contact pattern of the tapered seat
(piston rod and crosshead) and of the wedges must be checked. The posi-
tion of the piston in the cylinder must also be checked. Proceed as follows:
1. Lower the piston rod and continue to move up the oil shield on the
piston rod until it sits in its groove on the piston rod. At the same time
clean off any oil on the piston rod taper and cross head seat with a sol-
vent. Apply some blue ink for a dye check.
2. Lower the piston rod and check the blue pattern, the cone should be
matching at its whole surface area (check contact pattern).
3. Apply some oil to the contact faces, between the wedges only, apply
blue ink to the outside (rounded side) and firmly force wedges by hand
into crosshead slot, now use a copper punch to hammer the lower
wedge in approx. 10 mm from this position. Check the clearances of the
piston to the cylinder. Compare clearances with the piston clearances
taken with the old piston rod. Clearances should not change.
4. Remove the wedges and compare the contact faces to its counter part,
i.e. the top wedge to the corresponding part of the crosshead and the
lower wedge to the corresponding part of the piston rod. File off the high
points on the wedges only, with a fine file. Repeat this procedure 3 and
4 until the wedges get contact along the entire seat-engaging surface.
5. Finally force wedges by hand firmly into crosshead slot, now use a
copper punch to hammer the lower wedge in approx. 15 mm from this
position. The piston rod must drop about 0.4 mm into the tapered bore
during this procedure. The piston rod has to have a min. of 0.5 mm
clearance measured between the lower wedge and the lowest point of
the crosshead slot. Mark the position for the locking device hole. Dis-
mantle the wedges and drill the holes for the applicable locking device
(probably the old hole has to be closed first). Fit the wedges securely
with the safety device according to the drawing (Fig. 9-41).
6. Check piston clearances and compare them with the previous mea-
surements. Record measured values in the corresponding log sheet. If
required, you can order templates for measurement log sheets from
our Service Division (see section 1.6 Contact Address).
7. Verify the proper tightening torque of the piston nut. Install the cylinder
cover and tighten the nuts (see part “Final Checks” in this section).
8. Check cylinder clearance according to section 8.9.5 Cylinder Clear-
ance Measurement. Record measured values in the corresponding log
sheet. If required, you can order templates for measurement log sheets
from our Service Division (see section 1.6 Contact Address).

Internal Leak Gas Pipes
9.11 Internal Leak Gas Pipes

Special Tools none
9.11.2 Dismantle and Assemble Internal Leak Gas Pipes

Dismantle and assemble the internal leak gas pipes according to Fig. 9-44.
1 2
LA_C5_0055b_01
Fig. 9-41 Piston rod gland leak gas pipes
1 Leak gas pipes

2 Piston rod gland

Piston Rod Gland
9.12 Piston Rod Gland

• 9.10 Piston and Piston Rod
• 9.11 Internal Leak Gas Pipes
• 9.14 Cylinder
Special Tools none
9.12.2 Dismantle Piston Rod Gland
For dismantling and installing the 1-piece gland rings, the piston and piston
rod must be removed.
1. Unfasten gland flange and carefully lower the complete piston rod
gland.
2. Dismantle piston rod gland and clean individual parts.
Required Checks 1. Inspect individual parts for possible damage. Grooves and front faces
must not be damaged.
2. Measure the radial clearance of the 1-piece rings on the piston rod (on
oil scraper area).
Minimum gland ring clearance:
Clearance Value Gland ring type

A 75 + 0.05 mm Cylindrical
(see Fig. 9-45)
Tab. 9-7 Gland ring clearance values

Piston Rod Gland
LA_C5_0042b_01
A
Fig. 9-42 Gland ring (cylindrical type)
A Minimum gland ring clearance

1 Cylindrical
3. The three-piece gland ring at the bottom has no radial clearance. When
fitted, there must be a clearance of total 2–4 mm between the three
parts of the ring. Measure the clearance on the piston rod (on scraper
area).
9.12.3 Assemble Piston Rod Gland
DANGER
Fire hazard!

Piston Rod Gland
10 1
6 3
5 4
LD_C5_0005b_02
Fig. 9-43 Piston rod gland
1 Spring 6 Gasket
2 Gland ring 7 Intermediate ring
3 3-piece gland ring 8 Gland chamber (bottom)
4 Gland flange with 2 connections 9 Gland chamber (middle)
for leak gas pipes 10 Gland chamber (top)
5 Leak gas pipe
Procedure:
1. Place gland flange (4) with 3-piece gland ring (3) and springs (1) on top
of guide bearing.
 The springs must face upwards.
2. Place intermediate ring (7) on top of the gland flange.
3. Place bottom gland chamber (8) with gland ring (2) and springs (1) on
top of the first intermediate ring.
4. Place the second intermediate ring on top of the bottom gland
chamber.
5. Then build a stack with following sequence:
• 2 gland chambers (9) with gland rings and springs
• 1 gland chamber (10) with gland ring and springs
 The springs must face upwards.
6. Place this stack on top of the intermediate ring.

External Gas Pipes
7. Install piston rod gland. Tighten flange slightly.
Screws Axial Clearance

Loose 0.050 - 0.114 mm
Tightened > 0.03 mm
Tab. 9-8 Installation requirements for piston rod gland
8. Install piston, see section 9.10 Piston and Piston Rod and check the
axial clearance requirements (see Tab. 9-8 above).
 With flange tightened, the gland rings must be movable radially.
9. Turn the flywheel several times by hand – with the bar – in running di-
rection.Verify that everything is in proper mechanical condition.
10. Tighten flange with the mandatory tightening torque, see section “Com-
11. Fit the leak gas lines.
9.13 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.

Cylinder
9.14 Cylinder

• 9.13 External Gas Pipes
Special Tools
XA_T9_0007a_01
Fig. 9-44 Flogging spanner
9.14.2 Dismantle Cylinder
1. Remove coolant pipes from cylinder.

2. Loosen the nuts of the threaded bolts.
DANGER
Suspended loads!

Cylinder
3. Attach carrying ropes in the safe manner, described and illustrated in

section 5.4 Lifting Procedure.
4. Lift off the cylinder. Be careful that the threaded bolts do not touch the
bores in the frame.
9.14.3 Assemble Cylinder
CAUTION
Contamination of process gas!
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 manufac-
turer.
1. Degrease leak gas pipes of piston rod glands according to chapter 10

2. Place them on the frame inside the distance piece.
3. Supply the contact surfaces of the cylinder and the crankcase with an
appropriate sealing compound (e. g. RHODORSIL CAF® 7037).
DANGER
Suspended loads!
4. Attach carrying ropes in the safe manner, described and illustrated in

section 5.4 Lifting Procedure.
5. When lowering the cylinder onto the frame, be careful that the threaded
bolts do not touch the bores in the frame.
6. Pay attention that the centering pins fit properly into the corresponding
bores in the cylinder.

Oil Scraper
1 2 3 4 5
LA_C0_0003c_01
Fig. 9-45 Centering pin
1 Plug 4 Epoxy resin

2 Cylinder 5 Frame
3 Centering pin
7. Tighten the nuts of the threaded bolts with the mandatory tightening
torque.
9.15 Oil Scraper

Special Tools none
9.15.2 Dismantle and Assemble Oil Scrapers

A detailed description of assembling the oil scraper see section 9.10 Piston
and Piston Rod.

Guide Bearing Bush
9.16 Guide Bearing Bush

• 9.15 Oil Scraper
Special Tools Dismantling device for bush (see Fig. 9-49); not supplied by Burckhardt
Compression.
9.16.2 Dismantle Guide Bearing Bush

Dismantle If the diametrical clearance between bush and piston rod exceed the Dia.
“B” (for applicable clearances see section “Compressor” in chapter 13 Ap-
pendix), replace the bush with the device to be made on site as shown in
Fig. 9-49.
6
LA_M5_0026c_02
Fig. 9-46 Dismantle guide bearing bush
1 Guide bearing 4 Bearing bush

2 Crown ring 5 Dismantling device
3 Allen screw 6 Crosshead

Guide Bearing Bush
Preparation
1. Dismantling device manufactured and above activities completed.

2. Unfasten and remove Allen screws (3, see Fig. 9-49) and crown ring
(2).
3. Bring crosshead (6) to BDC (Bottom Dead Centre).
4. Put the device (5) on the top part of the crosshead and center it.
5. Slowly and carefully turn the crankshaft using the bar, thus moving the
crosshead towards the TDC (Top Dead Centre).
6. By doing this, the bearing bush (4) is pushed out of the bore.
7. Remove bearing bush and dismantling device and carefully inspect
and clean the bore.
CAUTION
Contamination of process gas!
All components coming in contact with process gas must be checked for
cleanliness prior to their installation.

Guide Bearing Bush
LA_M5_0041b_01
Fig. 9-47 Guide bearing details
1 Hexagonal screw 5 Bearing housing

2 Usit ring 6 Spring plate
3 Crown ring 7 O-ring
4 Bearing bush 8 Guide bearing cover
Required Checks Before fitting the new bush, check the clearance between bush and piston
rod (see section 8.8.7 Guide Bearing).

Guide Bearing
9.17 Guide Bearing

Special Tools none
9.17.2 Dismantle Guide Bearing

Dismantle Before removal and inspection, the guide bearing clearance must be mea-
sured.
Measure the clearance with a feeler gauge.

13 Appendix.
Should doubts arise about acceptance of measured clearance, contact our

Customer Support Service that will gladly assist you.
1. Remove all coolant pipes.

If a guide bearing must be replaced, e.g. after a damage by freezing,
the coolant pipes of guide bearings must be blown out first from outlet
side. Then the guide bearing can be removed through the lateral
opening in the frame.
2. Loosen the screws and remove the guide bearing according to

Fig. 9-51.

1 2 3 4
LA_M5_0028b_01
9 8
Fig. 9-48 Guide bearing with cooling and open design (typical view)
1 Bearing housing 6 Crown ring

2 Piston rod 7 Bearing bush
3 Oil shield 8 Adjustable elbow union
4 Guide bearing cover 9 Oil syphon
5 Wiper elements
9.18 Connecting Rod Bearing

• 9.17 Guide Bearing
Special Tools none
9.18.2 Dismantle the Connecting Rod Bearing
Required checks
Turn crank to BDC and measure clearance between crankshaft journal and
connecting rod lower bearing shell with a feeler gauge.

For applicable clearances see section “Compressor” in chapter 13 Ap-

pendix.
6
LA_M4_0004b_02
Fig. 9-49 Connecting rod bearing
1 Connecting rod 5 Connecting rod bolt

2 Crosshead pin bearing 6 Connecting rod bearing
3 Crosshead pin 7 Connecting rod cover
4 Circlip for crosshead pin bearing 8 Locking plate
Dismantle the connecting rod bearing as follows:

1. Measure bearing clearance and record it (see section Required
Checks).
2. Remove bolt locking device.
3. Slacken bolts.
4. Turn respective crank to TDC (Top Dead Centre).
5. Lower connecting rod cover by unscrewing the bolts.

9.18.3 Assemble the Connecting Rod Bearing

Assemble After removal for inspection, refitting of bearing is generally carried out in
reverse sequence to removal.
1. Turn respective crank to TDC.

2. Fit connecting rod cover with bearing shell.
3. Tighten bolts according to the following instruction.
L1
L
∆L
3
4
LA_M4_0005b_03
Fig. 9-50 Instructions for fitting of connecting rod bolts
1 Connecting rod bolt L Length of bolt before tightening

2 Locking plate L1 Length of bolt when tightened
3 Bearing shell
4 Connecting rod cover
The bolt is properly tightened when ∆L is between the following tolerances:
Expansion Tolerance
∆L min. + 0.30 mm
∆L max. + 0.36 mm
Tab. 9-9 Bolt tolerance
4. Measure bearing clearance.

13 Appendix.
5. Only if necessary, re-punch marks on the connecting rod.
6. Fit locking plate (2).

Crosshead and Connecting Rod
9.19 Crosshead and Connecting Rod

• 9.18 Connecting Rod Bearing
Special Tools
3
LA_T9_0018b_01
Fig. 9-51 Support (not supplied by Burckhardt Compression)
1 Crosshead
2 Support
3 Connecting rod

Crosshead and Connecting Rod
XA_T9_0003a_01
XA_T9_0004a_01
Fig. 9-52 Circlip pliers
9.19.2 Dismantle Connecting Rod and Crosshead
The crosshead may be removed through the bore of the guide bearing.
1. Lift crosshead with hoist.Take care that the connecting rod is hanging
freely, i.e. not damaging the crosshead guide while lifting.
2. Remove crosshead pin.
9.19.3 Assemble Connecting Rod and Crosshead

Installation is done in reverse order to dismantling.

Crosshead Pin Bearing (with Cylinder Removal)
9.20 Crosshead Pin Bearing (with Cylinder Removal)

• 9.14 Cylinder
• 9.19 Crosshead and Connecting Rod
Special Tools • Press, freezer, oven
9.20.2 Dismantle the Crosshead Pin Bearing

Dismantle Push the used crosshead pin bearing out of the connecting rod bore with a
press.
9.20.3 Assemble the Crosshead Pin Bearing
1. Clean the connecting rod bore and the crosshead pin.

2. Check the crosshead pin and the crosshead pin bearing diameter. The
diameter of the crosshead pin and the crosshead pin bearing must cor-
respond to the set values given in the table of clearances, see section
“Compressor” in chapter 13 Appendix.
CAUTION
Risk of connecting rod deformation!
Check all components for cleanliness prior to their installation.
 Never use a burner or a blower for heating-up the connecting rod.
3. The crosshead pin bearing must be cooled down to approximately

-20°C before it can be installed. Therefore, cool it in a freezer for about
12 hours.
4. The connecting rod must be heated-up evenly to 60°C–80°C (e.g. in
hot oil). Never use a burner or a blower for heating-up. Risk of con-
necting rod deformation!

Crosshead Pin Bearing (with Cylinder Removal)
5. Insert the new crosshead pin bearing quickly. Make sure that the posi-
tioning pin in the bearing and the groove of the connecting rod are in
line.
Due to thermal expansion of the crosshead pin bearing, thermal
shrinkage of the connecting rod the position of the crosshead pin
bearing cannot be corrected anymore after a few seconds!
Final Checks Check the diameter of the crosshead pin bearing when the crosshead pin
bearing and the connecting rod have reached ambient temperature. Table
of clearances, see section “Compressor” in chapter 13 Appendix.

Crosshead Pin Bearing (without Cylinder Removal)

(without Cylinder Removal)

Special Tools • Press, freezer, oven

• Support according to Fig. 9-54.
3
LA_T9_0018b_01
Fig. 9-53 Support (not supplied by Burckhardt Compression)
1 Crosshead
2 Support
3 Connecting rod
9.21.2 Dismantle the Crosshead Pin Bearing
1. Lift crosshead with hoist and fix connecting rod with support according
to Fig. 9-56.
2. Turn the crosshead secured with the hoist. Remove crosshead pin with
pull-off device.
3. Remove crosshead through frame opening.

Crosshead Pin Bearing (without Cylinder Removal)
4. Remove connecting rod through frame opening.

5. Push the used crosshead pin bearing out of the connecting rod bore
with a press.
9.21.3 Assemble the Crosshead Pin Bearing
1. Clean the connecting rod bore and the crosshead pin.

2. Check the crosshead pin and the crosshead pin bearing diameter. The
diameter of the crosshead pin and the crosshead pin bearing must cor-
respond to the set values given in the table of clearances, see section
“Compressor” in chapter 13 Appendix.
3. The crosshead pin bearing must be cooled down to approximately

-20°C before it can be installed. Therefore, cool it in a freezer for about
12 hours.
4. The connecting rod must be heated-up evenly to 60°C–80°C (e.g. in
hot oil). Never use a burner or a blower for heating-up. Risk of con-
necting rod deformation!
5. Insert the new crosshead pin bearing quickly. Make sure that the posi-
tioning pin in the bearing and the groove of the connecting rod are in
line.
Due to thermal expansion of the crosshead pin bearing, thermal
shrinkage of the connecting rod the position of the crosshead pin
bearing cannot be corrected anymore after a few seconds!
Final Checks Check the diameter of the crosshead pin bearing when the crosshead pin
bearing and the connecting rod have reached ambient temperature. Table
of clearances, see section “Compressor” in chapter 13 Appendix.

Gear Oil Pump
9.22 Gear Oil Pump

Special Tools Eye bolts
9.22.2 Dismantle Gear Oil Pump
1. Remove external oil pipes.

2. Dismantle the oil pump according to figure Fig. 9-57.
19
18
17
16
15
14
12 13
10 11
5 9
4 8
3 6 7
2
1
20
22 21
23
LD_M2_0042b_01
24
Fig. 9-54 Dismantled crankshaft driven gear oil pump (typical view)
1 Hexagonal screw 13 Washer

2 Throttle valve 14 Hexagonal screw
3 Pressure gauge, (Lube Oil) 15 Main bearing non-drive end
4 Pressure gauge, (Crankcase) 16 Cylindrical pin
5 Housing 17 O-Ring
6 Driven gearwheel 18 Crankshaft
7 Driving gearwheel 19 Frame
8 O-Ring 20 Nylon bush
9 Cover 21 Circlip
10 Conical pin 22 Driving flange
11 Spring washer 23 O-Ring
12 Hex nut 24 Relief valve

Electric Motor
The gear oil pump is fitted to the frame (19) at the non-drive end of the com-
pressor. Bearing bracket (15) and housing (5) are sealed with O-rings (8
and 23).
The gear oil pump consists of a driven gearwheel (6) and a driving gear-
wheel (7) attached to the driving flange (22), which is driven by the crank-
shaft (18). The two gearwheels are of the same size and fit snugly in the
pump body. The lubricating oil is carried from the inlet to the delivery side
of the pump by both gearwheels.
9.22.3 Assemble Gear Oil Pump

Assemble New Assemble the gear oil pump in reverse order of dismantling procedure.
or Used Parts
9.23 Electric Motor

Special Tools none
Installation of electrical parts must be performed by professionals.

Please refer to manufacturer’s instructions.
9.23.2 Dismantle Electric Motor

The electric motor is coupled to the compressor with a flexible coupling.
Crankshaft and motor shaft have to be coupled so that they are stressfree
and the axial clearance is evenly distributed. In this way, both shafts attain
free thermal expansion. The axial float of the motor shaft must be mea-
sured at a suitable point and the end positions must be marked. Clearances
need to be checked after alignment and installation of coupling.
1. Remove flywheel guard.

2. Release electric motor from coupling.
9.23.3 Assemble Electric Motor

Installation takes place in reverse order to dismantling.
9.23.4 Place Electric Motor

Check Runout Before the electric motor can be placed, check the runout of the motor cou-
pling flange:

Electric Motor
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 0.05 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 4 5
LP_L1_0034b_01
Fig. 9-55 Radial- and face runout
1 Dial gauge 4 Key

2 Motor shaft 5 Motor
3 Motor coupling flange
Install Motor on 3. To enable vertical realignment of the electric motor (after maintenance/
Sole Plates 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. Place the motor onto the sole plates.

5. Fix the sole plates to the motor.

Electric Motor
Place Motor
DANGER
 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.
6. In the same way as for the compressor, place electric motor.
7. Approximately line up the electric motor.
9.23.5 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 1. Prior to starting the assembly, the coupling parts must be cleaned thor-
Coupling Parts oughly.
 The rubber parts of the coupling should not come into contact with
cleaning solvents!
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.
2. In relation to the flywheel/intermediate piece, carefully align the electric

motor.

Electric Motor
1 2 3 4 5
LD_L1_0020b_01
Fig. 9-56 Align electric motor, coupling, and flywheel
1 Flywheel 4 Dummy
2 Motor coupling flange 5 Motor coupling flange
3 Dial gauges
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. After fitting of coupling, measure crankshaft deflection on the drive end

crank in 5 positions. Record all measured values as well as the mea-
suring position (i.e. offset from crankweb) of the dial indicator.
For details and values see 8.8.1 Check Crankshaft Deflection.

Coupling
9.24 Coupling

Special Tools none
9.24.2 Dismantle Coupling

Dismantle coupling according to manufacturer’s instructions (see Technical
Documentation).
9.24.3 Assemble Coupling

For assembly of the coupling, follow the instructions in section 9.24.4 Install
Coupling.
9.24.4 Install Coupling
For coupling installation and operating instructions refer to manufacturer’s

instructions.
For coupling drawings see section “Drive System” in chapter 13 Appendix.
1 2 3
LA_L1_0053b_01
f h
Fig. 9-57 Coupling
1 Flywheel f Clearance
2 Coupling h Clearance
3 Electric motor

Coupling
For detailed description of flexible coupling see manufacturer’s instructions

in the Technical Documentation.
For exact drawing of flexible coupling see section “Drive System” in chapter
13 Appendix.
1. Re-check the alignment of motor and flywheel in accordance to section

9.23.5 Align Electric Motor.
2. Check contact surfaces on motor coupling flange for possible damage

or unevenness. Correct any unevenness by using a fine file or a
scraper.
3. Check contact surfaces on intermediate piece for possible damage or

unevenness. Correct any unevenness by using a fine file or a scraper.
4. Prior to starting the assembly, the coupling parts must be cleaned thor-
oughly. The rubber parts should not come into contact with cleaning
solvents!
5. Check bores of coupling bolts for cleanliness and for damages. The
bores of the coupling bolts must be absolutely clean and free of any
damages.
6. The permissible axial displacement of the shaft system must be taken

into account during installation. Push crankshaft towards drive end.
Clearance Value in [mm]

f 2
h 1
(also see Fig. 9-60 Coupling)
Tab. 9-10 Permissible axial displacement
7. Assemble the coupling according to manufacturer’s instructions.

Flywheel
9.25 Flywheel

• 9.24 Coupling
Special Tools none
9.25.2 Transport and Lifting of the Flywheel

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
LA_XX_0044c_01
Fig. 9-58 Transport and lifting of flywheel

Flywheel
9.25.3 Dismantle the Flywheel
1. Dismantle coupling.
2. Attach flywheel in the safe manner as described and illustrated above

to a lifting device, carefully strapping the ropes.
3. Take off flange (Fig. 9-62).
1 2 3 4 5 6 1 2 3 4 6
LA_L1_0018b_02
LA_L1_0017b_02
Fig. 9-59 Pulling-off flywheel
1 Crankshaft 4 Threaded bolt

2 Key 5 Bolt
3 Flywheel 6 Flange
4. Turn over flange (6), attach on crankshaft such that bossed side of
flange faces towards crankshaft (1).
5. Tighten outer bolts until flywheel is pulled off from taper (Fig. 9-62).
6. Drain the lube oil from the seal housing through the drain plug before
opening the bearing bracket.
9.25.4 Assemble the 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 fine file or a scraper.
3. Use a light oil with corrosion inhibitor to slightly lubricate flywheel hub
and conical part of crankshaft.
4. Attach carrying ropes in the safe manner as illustrated in this section
and lift flywheel.

Flywheel
DANGER
Suspended loads!
 Lift flywheel only in the correct manner as described and illustrated in
3
8
7 5
6
LA_L1_0007b_02
Fig. 9-60 Fitting of flywheel
1 Flywheel 5 Nut
2 Bolt 6 Bolt
3 Feeler gauge 7 Crankshaft
4 Flange 8 Key
5. Carefully slide flywheel (1) onto the conical part of crankshaft.

6. Mount flange (4) with its flat side facing the crankshaft. Slightly tighten
nuts (5) of the inner bolts (6), until flywheel is correctly positioned.
7. Remove nuts and flange once again.
8. Measure clearance between key and flywheel with a feeler gauge (3).
The clearance must be approx. 0.2mm.
9. Refit flange, then tighten nuts crosswise with the mandatory tightening
torque.
Final Checks 1. Check radial and face runout as illustrated in Fig. 9-64.

Flywheel
1 2 3 4 5 6
LA_L1_0009b_02
Fig. 9-61 Radial and face runout
1 Crankshaft 4 Outer bolt

2 Flywheel 5 Measuring head
3 Inner bolt 6 Dial gauge
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.
1. Measure crankshaft deflection on the drive end crank in 5 positions ac-

cording to following figures. Record all measured values as well as the
measuring position (i.e. offset from crankweb) of the dial indicator.
For details and values see 8.8.1 Check Crankshaft Deflection.

Oil Trap and Crankshaft Seal
9.26 Oil Trap and Crankshaft Seal

• 9.24 Coupling
• 9.25 Flywheel
Special Tools none
9.26.2 Dismantle and Assemble Oil Trap and Crankshaft Seal
CAUTION
Leaking crankshaft seal!
Rough handling of the rings for the crankshaft seal may lead to damages
of the lapped rings and therefore to excessive leakage of the crankshaft
seal.
 Handle all rings with greatest care!
Dismantle or assemble the crankshaft seal according to Fig. 9-65.

For mandatory tightening torques see section “Compressor” in chapter 13
Appendix.
1 2 3 4 5
LD_M1_0039b_01
Fig. 9-62 Pulling-off oil trap and crankshaft seal
1 Bearing bracket 4 Cover

2 Crankshaft 5 Lip seals
3 Gasket

Bearing Bracket and Main Bearing
9.27 Bearing Bracket and Main Bearing

• 9.24 Coupling
• 9.25 Flywheel
Special Tools none
9.27.2 Dismantle and Assemble Bearing Bracket and Main

Bearing
Dismantle or assemble the bearing bracket and main bearing according to
Fig. 9-66.
1 2 3 4 5
LA_M1_0019b_01
Fig. 9-63 Removal of bearing bracket and main bearing
1 Crankgear
2 Crankshaft
3 Main bearing
4 Bearing bracket
5 Cover

Dismantle Crankshaft Sidewards
CAUTION
Risk of crankshaft drop!
Damage on crankshaft and bearings.
 Dismantle only the respective bearing bracket, never both sides!
Required Checks Measure clearance with feeler gauge at the upper circumference between
crankshaft and main bearing.

13 Appendix.
9.28 Dismantle Crankshaft Sidewards

We strongly recommend that crankshaft dismantling is carried out by our
specialists on site. We assume no liability for damage caused by inexpert
crankshaft dismantling.
For on-site support please contact our Services Division, address see sec-
tion 1.6 Contact Address.
9.29 Switch On Compressor After Assembly

Status Compressor assembly completed
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 Please see section 5.11.2 Cooling System.

Cooling System
Switch On 1. Re-insert the safety switch.

Compressor
2. Start the compressor according to section “Control Description” in
Final Checks See section “Control Description” in chapter 13 Appendix.

Switch On Compressor After Assembly

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 - 4
10.1.3 Required Level of Cleanliness . . . . . . . . . . . . . . . 10 - 4
10.1.4 Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 5
10.1.5 Safety Measures. . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 5
10.1.6 Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 5
10.2 Working Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 6
10.2.1 Workplace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 7
10.2.2 Tools and Facility . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 7
10.2.3 Materials and Auxiliary Supplies. . . . . . . . . . . . . . 10 - 7
10.3 Select Cleansing Agent . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 8
10.4 Cleaning Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 11
10.4.1 Mechanical Cleaning . . . . . . . . . . . . . . . . . . . . . . 10 - 11
10.4.2 Chemical Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 10 - 12
10.4.3 Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 12
10.4.4 Immersion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 12
10.4.5 Wiping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 12
10.4.6 Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 12
10.4.7 Degreasing with Solvent Vapor . . . . . . . . . . . . . . 10 - 13
10.4.8 Ultrasonic Cleaning . . . . . . . . . . . . . . . . . . . . . . . 10 - 13
10.5 Inspection Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 13
10.5.1 Direct Visual Inspection . . . . . . . . . . . . . . . . . . . . 10 - 13
10.5.2 Inspection with Mirror and Endoscope . . . . . . . . . 10 - 13
10.5.3 Ultraviolet Light (Black Light) Inspection . . . . . . . 10 - 14
10.5.4 Wipe Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 14
10.5.5 Solvent Discoloration Test . . . . . . . . . . . . . . . . . . 10 - 14
10.6 Preserve Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 15


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 be used for:
• oxygen service or
• process gases with an oxygen content of > 23.5 % or
• air under a very high pressure
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.
The main contaminants to be avoided and/or eliminated are hydrocarbon
oils and greases, which are easily combustible and particulate matter,
which can easy ignite or cause ignition.
DANGER
Fire hazard!
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 5.8.4 Pickle and Pas-
sivate Piping.
service”.

DANGER
Fire hazard!
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.
Oxygen For purposes of the cleaning specification, any gas containing more than
23.5 % of oxygen by volume or air under a very high pressure.
Cleaned for Means that significant surfaces must be free of contaminants or any other
Oxygen Service matter not admissible for oxygen service.
10.1.3 Required Level of Cleanliness
The level of cleanliness must comply with the requirements stated in sec-
tion 10.5 Inspection Methods.
It is the superior authority’s responsibility to ensure safe working condi-

tions.
Significant surfaces must be dry and free of contaminants including – but
not restricted to:
• hydrocarbon oils or greases,
• unapproved thread or gasket sealing compounds (see section 10.2.3
Materials and Auxiliary Supplies),
• conventional paints, varnishes, fluxes or organic rust preventatives,
• loose or potentially loose parts such as slag, rust, weld spatter, abra-
sive particles (e.g shot peening remains),
• any other matter not admissible for oxygen service.

The following are not considered objectionable contaminants and may be

allowed to remain:
• light stain or discoloration of the surface e.g. due to strongly attached
mill scale or light rust film.
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

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.

Working Environment
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.
10.2.3 Materials and Auxiliary Supplies

BAM Oxygen Approval BAM = Bundesanstalt für Materialprüfung in Berlin.
Only materials which meet the BAM-guidelines may be used for cleaning,
testing or assembly. Other materials require our specific approval for such
use. For all materials and utilities ask your supplier for a written oxygen ap-
proval.

Select Cleansing Agent
A list of BAM oxygen approved gasket materials as well as lubricants may

be requested from Burckhardt Compression (address see section 1.6 Con-
tact Address). The use of the listed materials (including methods of appli-
cation) must be limited to the specified applications.
Gaskets Only BAM oxygen approved products may be used.
Pipe Thread Sealant As a thread sealant only Teflon tape is acceptable. If Teflon tape is used,
apply two threads back from the end of the pipe or fitting to prevent shred-
ding.
Lubricants To facilitate the fitting and removal of some specially indicated screw con-
nections, e.g. piston rod nut, or all screw connections on outdoor plants in
general, some specially approved lubricants are permitted. These lubri-
cants must be used sparingly.
Only the following lubricants may be used for parts coming in contact with
oxygen or process gas:
• Burckhardt Lubrication Grease BLG05
• Fomblin (Montedison)
• Krytox (DuPont)
• Fluorolube (Hooker)
• Halocarbon
• or other BAM oxygen approved products
Cleaning Tissues Cleaning tissues used for wiping components or small areas of equipment
surfaces must be clean, lint-free and free from traces of oil or grease.
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.
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 generates residues containing oils and greases.
The solvent contained in these residues can be recovered to a certain de-
gree by distillation either in house or by a licensed recycler. The remaining,
highly concentrated final waste should be disposed of by a licensed con-
tractor in accordance with local regulations.
Cleaning in an aqueous system generates effluent, which contains chemi-
cals and may be contaminated with oils and greases. This residue must be
treated in a waste water treatment 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.
The specific guidelines of the IGC-document (Industrial Gas Committee)

“Cleaning of Equipment for Oxygen Service”, IGC Doc 33/06/E give more
detailed information about alternatives to CFCs or VOCs and are valid for
oxygen compressor plants. These guidelines are also of avail for com-
pressor plants used with Univation process.
Due to the potential hazard caused by solvents in contact with oxygen, after
completion of any method of solvent cleaning, all residual cleaning fluid
must be totally removed from the components. An assessment of the com-
ponent system to be cleaned shall be made to ensure there are no pipe or
other dead ends or pockets present from which it will be difficult to com-
pletely drain or blow out the solvent. If not, this method shall not be used.
After cleaning, the component must be thoroughly drained, purged, and
dried with warm, dry, oil-free air or nitrogen. A method of checking that re-
sidual solvents have been eliminated is using a commercially available
vapor detector/analyzer.

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 The manufacturer’s specification for application of the cleansing agent
Cleansing 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

service”.
DANGER
Fire hazard!
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 5.8.4
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.

Inspection Methods
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 Inspection Methods

Various methods exist for determining the cleanliness of the cleaned parts.
Items cleaned for oxygen service must be inspected by a method which ap-
plies to the particular component and shows whether the acceptance cri-
teria are achieved.
If an inspection reveals the presence of non-acceptable contamination with
oil or grease, residues of cleansing agent or particles, the component must
be cleaned again. Usually, wiping the contaminated area with a clean
tissue moistened with a solvent will adequately clean the area. Persistent
rejection requires a re-evaluation of the cleaning methods used.
10.5.1 Direct Visual Inspection

This is the most simple inspection method used to verify the cleanliness of
a component with easily accessible surfaces. It shall be used in conjunction
with other methods.
Look at or in the component under bright white light to detect the presence
of visible grease or oil films and in particular filings, chips, loose or loosely
adhered rust or mill scale. If any contamination is observed, the component
must be cleaned again.
10.5.2 Inspection with Mirror and Endoscope

Inaccessible significant surfaces must pass indirect inspection such as vi-
sual inspection with mirror and endoscope.

Inspection Methods
Parts which will be inaccessible to inspection after assembly must be in-

spected prior to assembly.
10.5.3 Ultraviolet Light (Black Light) Inspection

Many common but not all hydrocarbons or organic oils and greases fluo-
resce under ultraviolet light even though they may be invisible under bright
light. Apply this method in addition to direct visual inspection to detect
common oils or greases.
Inspect in darkness or subdued light using ultraviolet light of 320–380 nm
(3200–3800 Å) wavelength. If a bluish-white fluorescent smear is present,
clean the component again.
Fluorescent specks due to lint and mildly fluorescent stains from detergent
residues are acceptable except when in excess.
WARNING
Harmful ultraviolet rays!
Excessive exposure to direct or reflected ultraviolet light can cause eye and
skin damage.
 Protected skin and eyes.
 Strictly follow lamp manufacturer’s safety instructions.
10.5.4 Wipe Test

This method should be used to check the cleanliness of inaccessible sur-
faces or to verify the cleanliness of a component with a large surface area.
Wipe the component or at least 1000 cm2 (one sq. ft.) of the surface, which-
ever is smaller, with white filter paper or with clean lint-free cotton or linen
cloth. Examine this paper or cloth under white light and/or ultraviolet light
to find traces of contamination. If excessive discoloration or any bluish-
white fluorescence appears, the surface must be cleaned again.
10.5.5 Solvent Discoloration Test

This method is based on the comparison of used and unused solvent. It
should be used to check the cleanliness of inaccessible surfaces which
have been flushed with a solvent.
Thoroughly flush the component with solvent and collect a sample of the
draining in a clear glass jar. Compare a half liter (pint) jar filled with used
solvent with a half liter (pint) jar of unused solvent by holding both to the
light and simultaneously viewing them from the side. There should be few
suspended particles and little, if any, difference in color between the two. If
contamination is present, the component should be reflushed with solvent.

Preserve Cleanliness
10.6 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 Waste Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Standstill damage possible!
Due to the numerous possibilities of installation and employment of our
compressors, instructions on preservation depend on application.
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.
compressed air (if an antifreeze solution is used, drainage is not nec-
essary under certain circumstances).
3. Fill crankgear with lubricating oil.

A special corrosion protecting oil from a reputable supplier may be
used during the standstill period.
4. Oil the piston rods well by hand up to the oil shield. Turn the flywheel
several times by hand – with the bar – in running direction.
Generally, the gas conducting compressor and plant components should

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

through continuously with nitrogen, or kept under a slight overpressure of
0.20 bar g/0.02 MPa g/0.20 kg/cm2 g.
DANGER
Plant/compressor under nitrogen pressure.

Preserve Compressor Plant
system.
DANGER
Health hazard!
symptoms.
6. Alternative solution:
To prevent corrosion in the vicinity of the cylinder and down to the guide
bearings, insert moisture absorbent agent – e.g. VCI mats (Volatile
Corrosion Inhibitor) – in the cylinder, 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.

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.
Address.
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 generates residues containing oils and greases.
The solvent contained in these residues can be recovered to a certain de-
gree by distillation either in house or by a licensed recycler. The remaining,
highly concentrated final waste should be disposed of by a licensed con-
tractor in accordance with local regulations.
Cleaning in an aqueous system generates effluent, which contains chemi-
cals and may be contaminated with oils and greases. This residue must be
treated in a waste water treatment 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.: 102609
• Compressor type: 2D200B-1A_1
• Spare part designation
• Code no.
Stage Dependent When ordering stage dependent spare parts, consider the following ex-
Code 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.
Code Numbers for Tools Standard tools and special tools are not enclosed in the spare parts list. For
ordering tools please refer to the corresponding code numbers listed in
section 8.3 Tools.
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

A40000 Set of gaskets/O-rings complete, per compressor X 1
C01620 O-ring for cylinder cover 1st stage X 4
C11110 Piston skirt 1st stage X 1
C11500 Piston rod 1st stage X 1
C11520 Washer for piston rod 1st stage X 4
C11700 Oil shield for piston rod, complete 1st stage X 2
C21015 Gasket for suction valve cover 1st stage X 8
C21200 Suction valve, complete 1st stage X 4
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 176
C41015 Gasket 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 176
C51124 Gland ring no. 1 1st stage X 8
C51127 Gland ring no. 1, with garter springs 1st stage X 2
C51134 Spring for gland ring 1st stage X 24
L20580 Self locking hexagonal nut for non-return valve X 1
M00432 Gasket for plexiglas frame cover fold-away X 1
M10200 Crankshaft bearing X 1
M10755 Lip-seal for shaft seal M10700 X 2
M30600 Crosshead pin X 1
M40310 Connecting rod bearing half (2 pcs.= 1 bearing) X 2
M40410 Crosshead pin bearing X 1
M50060 Bearing bush X 2
M50095 Strain washer USIT X 12
M50510 Wiper element upper, complete X 2

Spare Parts
Order Spare Parts
Code No Designation W C Qty

M50515 Wiper element middle, complete X 2
M50520 Wiper element lower, complete X 2
M50545 Spring plate X 2

Spare Parts
Spare Parts List
12.2 Spare Parts List
Code No Designation W C
A00200 Instrumentation of gas system
A00210 Throttle valve for pressure gauge, complete
A00215 Gasket for pressure gauge connection
A00260 Pipe union for throttle valve
A00270 Reduction piece for throttle valve
A00275 Gasket for reduction
A00295 Pressure gauge connecting piece
A00710 Pressure gauge, oil pressure
A01410 Pressure gauge, gas discharge side 1st stage
A10100 Internal pipes for guide bearings
A10110 Gasket for guide bearing cooling
A10115 Pipe union for guide bearing, (Inlet)
A10125 Pipe union, complete guide bearing
A10130 Gasket for A10125
A10150 Pipe union with pipe for guide bearing (Outlet)No.2
A10155 Pipe union
A10160 Pipe union with oil syphon, complete
A10165 Gasket for A10160
A30510 Gasket for leak gas return pipe for p. rod gland
A30515 Gasket no.2, leak gas return pipe for p. rod gland
A40000 Set of gaskets/O-rings complete, per compressor X
A40101 Gasket for water pipe no. 1
A40102 Gasket for water pipe no. 2
A40201 Gasket for gas pipe no. 1
A40301 Gasket for oil pipe no. 1
A40401 O-ring for oil pipe no. 1
C0*001 Cylinder
C0*200 Threaded bolts for cylinder/frame, distance piece
C0*205 Nut for cylinder/frame
C0*210 Threaded bolts for cylinder cover
C0*215 Hexagonal nut for cylinder cover
C0*220 Threaded bolt for suction valve cover
C0*225 Threaded bolts for discharge valve cover
C0*230 Hexagonal nut for valve cover
C0*240 Threaded bolt for piston rod gland
C0*245 Hexagonal nut for piston rod gland

Spare Parts
Spare Parts List
C0*605 Cylinder cover, complete
C0*620 O-ring for cylinder cover X
C0*630 Cleaning cover
C0*635 Gasket for cleaning cover
C0*645 Screw plug for cylinder cover
C0*650 Gasket for screw plug
C0*660 Spacer ring for cylinder cover
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
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
C01161 Gasket for small cylinder cleaning cover no. 2 1st stage
C01180 Screw plug, small 1st stage
C01181 Screw plug No. 2, small 1st stage
C01270 Threaded bolts for connection suction-/discharge line 1st stage
C01275 Hexagonal nut for pipe connection suction-/discharge line 1st stage
C01510 Pipe union suction-/discharge side, complete 1st stage
C01513 Stub end, suction-/discharge side 1st stage
C01519 Gasket for suction-/discharge pipe 1st stage
C1*100 Piston, complete
C1*110 Piston skirt X
C1*120 Upper piston crown
C1*130 Lower piston crown
C1*500 Piston rod X
C1*520 Washer for 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*000 Installation of suction valve
C2*005 Valve cover, suction valve without actuator
C2*015 Gasket 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*096 Screw plug for valve cover, suction valve
C2*097 Gasket for screw plug, suction valve
C2*200 Suction valve, complete X

Spare Parts
Spare Parts List
C2*310 Hexagonal nut for suction valve body
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
C4*000 Installation of discharge valve
C4*005 Valve cover, discharge valve
C4*015 Gasket for discharge valve cover X
C4*020 Valve lantern for discharge valve
C4*025 Pressure screw, discharge side
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*001 Gland complete, per piston rod
C5*106 Gland flange
C5*108 Intermediate ring no. 1
C5*115 Gland chamber no. 1
C5*116 Gland chamber no. 2
C5*124 Gland ring no. 1 X
C5*127 Gland ring no. 1, with garter springs X
C5*134 Spring for gland ring X
C50900 Leak gas return pipe for piston rod gland
C50910 Pipe union, no. 1, complete for gland flange

Spare Parts
Spare Parts List
C50911 Gasket for pipe union C50910
C50940 Tee union, No. 1
C50982 Reduction union, No. 2
L10000 Drive
L10010 Flywheel
L10110 Coupling bolts with guide, complete
L10130 Hexagonal nut
L10170 Coupling bolt, without guide
L10350 Bracket
L10370 Threaded bolt
L10380 Flange
L2*001 Non-return valve standard discharge side, comp.
L2*100 Housing for L21001, complete
L2*500 Discharge valve, complete for non-return valve
L2*510 Valve seat for non-return valve
L2*520 Lift washer, non-return valve
L2*530 Valve disc, non-return valve
L2*550 Damper disc for non-return valve
L2*560 Non-return valve guard
L2*570 Center bolt for non-return valve
L2*580 Self locking hexagonal nut for non-return valve X
L2*590 Washer for non-return valve
L2*600 Cylindrical pin for non-return valve
L20001 Non-return valve standard discharge side, comp.
M00000 Crankgear
M00015 Crankcase
M00199 Bearing bracket, non-drive end, complete
M00200 Bearing bracket, non-drive end
M00205 O-ring for bearing bracket, non-drive end
M00259 Bearing bracket, drive end, complete
M00260 Bearing bracket, drive end
M00265 O-ring for bearing bracket, drive end
M00410 Frame cover, large
M00412 Frame cover with breather
M00415 Gasket for large frame cover
M00426 Plexiglas frame cover
M00428 Plexiglas frame cover fold-away
M00432 Gasket for plexiglas frame cover fold-away X
M00455 Frame cover
M00460 Gasket for frame cover

Spare Parts
Spare Parts List
M00470 Cleaning cover for frame
M00475 Gasket for cleaning cover
M00830 Centering pin between frame and cylinder
M00900 Breather for crankgear/distance piece
M10010 Crankshaft, complete with counter-weight
M10015 Crankshaft without counterweights
M10020 Sunk key for crankshaft
M10040 Threaded bolt for crankshaft/counterweight
M10045 Counterweight for crankshaft
M10071 Hexagonal nut for counterweight
M10090 Rollpin for crankshaft/counterweight
M10095 Cylindrical pin for crankshaft/counterweight
M10106 Locking disc
M10110 Threaded bolt for flywheel fastening (L10010)
M10115 Hexagonal nut for M10110
M10200 Crankshaft bearing X
M10610 Oil trap
M10620 O-ring for oil trap
M10755 Lip-seal for shaft seal M10700 X
M20000 Gear oil pump complete
M20010 Housing for M20000
M20030 O-ring No. 1 for oil pump
M20040 Driving flange, complete
M20050 Nylon-bush for driving flange
M20060 Driving gearwheel
M20070 Sunk key
M20090 Driven gearwheel
M20100 Cover for M20000
M20400 Throttle valve for pressure gauge, complete
M20401 Valve housing
M20402 O-ring for throttle valve
M20403 Gasket for throttle valve
M20404 Valve spindle, complete
M20406 Pressure ring for throttle valve
M20407 Packing ring, inner
M20408 Cap nut for M20400
M20409 Hand wheel for throttle valve
M20410 Pressure gauge connection 3-pieces for M20400
M20411 Gasket for pressure gauge connection
M20412 Gasket for pressure gauge

Spare Parts
Spare Parts List
M20417 Packing ring, outer
M20423 Pressure gauge connecting piece
M20500 Relief valve, complete
M20510 Screw plug
M20515 Gasket for screw plug
M20535 Valve body
M20545 Spring
M20550 Washer for spring (gasket)
M20700 Sight glass for oil level, complete
M20710 Sight glass holder
M20715 Sight glass
M20720 Gasket for sight glass
M20725 O-ring for sight glass
M20805 Oil strainer, complete
M20815 O-ring for oil strainer
M20910 Oil drain screw
M3*000 Crosshead-piston rod connection
M3*006 Crosshead body
M3*065 Set of wedges (set per piston rod)
M3*090 Locking plate for wedges
M3*095 Dowel bolt for wedges, complete
M3*600 Crosshead pin X
M3*620 Circlip for crosshead pin
M30000 Crosshead-piston rod connection
M4*000 Connecting rod, complete with bearings
M4*410 Crosshead pin bearing X
M4*420 Circlip for crosshead pin bearing
M40000 Connecting rod, complete with bearings
M40010 Connecting rod, without bearings
M40020 Connecting rod bolt
M40060 Lock for connecting rod, complete
M40310 Connecting rod bearing half (2 pcs.= 1 bearing) X
M50000 Guide bearing and oil scraper
M50020 Guide bearing housing
M50030 Screw plug guide bearing
M50040 Gasket for screw plug guide bearing
M50060 Bearing bush X
M50080 Crown ring
M50090 Cover for guide bearing
M50095 Strain washer USIT X

Spare Parts
Spare Parts List
M50100 O-ring for cover of guide bearing
M50501 Set of wiper elements, complete (set per piston rod)
M50510 Wiper element upper, complete X
M50515 Wiper element middle, complete X
M50520 Wiper element lower, complete X
M50545 Spring plate 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 126003706
Drive System
Title Drawing No.

Drive 126002074
Gas System
Title Drawing No.

Non-return valve 126000556
Lubricating System
Title Drawing No.

Gear oil pump 126001955
Pressure gauge and throttle valve, oil pump 126000033
Oil relief valve 126001118
Oil sight glass 126001089
Crankgear
Title Drawing No.

Crankgear 126003164
Crankshaft, complete with counterweight 126001080
Bearing bracket, drive end, complete 126001082
Bearing bracket, non-drive end complete 126001083
Connecting rod 126001143
Crosshead-piston rod connection 126001077
Guide bearing and oil scrapers 126001113
Internal pipe for guide bearings 126003193

Spare Parts
Spare Parts Drawings
Cylinder
Title Drawing No.

Cylinder 126001110
Labyrinth piston 126000985
Piston rod gland 126002755
Leak gas return pipe for piston rod gland 126003585
Instrumentation of gas system 126001116
Installation of suction valve 126000011
Assembly of suction valve 126000087
Installation of discharge valve 126000015
Assembly of discharge valve 126000089

A40101
C01001 C01140
C01145
C01156
C01161 C01156
C01161
C01181
C01181
M00428
M00432
M00426 M00455
M00460
M00410
M00900 A40102
M00415
M00900
M00412 M00426 M00000

M00415
A40102
M00470 M00470
M00475 M00475
A40102
M00410 M00410
M00415 M00415
A40302
A40302 A40303
A40303 A40301
A40301
A40301
L10000
A40401
A40401 M20815 M20700
C01155
C01160
C01155
C01180 A40102 C01160
A40102
A40201
M00455
C01270 C01270 M00460
A01410
C01275 C01275
C01510 C01510
C01513 C01513 A00200
C01519 C01519 M00470
M00475 NRV: L20001
C01270 C01270
C01275 C01275 A00710
Compressor layout
A40302 A40302
Kompressor Ansicht
A40102 C01155 A40102
C01160 A40303 A40303 2D200B-1A_1
A40301
A40301
M20910 A40401
CO20/rmi Original 120 714 407 199 12.12.2016 Rev. 0 126 003 706
Drive
Antrieb L10000
L10010
L10110
L10350
L10130
M10020
L10370
L10380
M10115
M10110
L10170
CO20/gw Original 122 845 414 002 30.05.2013 Rev. 0 126 002 074
Non-return valve
Rückschlagventil L2*001
Stage*
Stufe Code No. * * select stage as applicable,
e.g.: Non-return valve, complete 2nd stage L22001
1 L21001 entsprechende Stufe auswählen,

z. B. Rückschlagventil, komplett 2. Stufe L22001
2 L22001
3 L23001
4 L24001
5 L25001 L2*001
6 L26001
L2*100
L2*500
L2*570 L2*510 L2*560
L2*550
L2*560
L2*530
L2*510
L2*600 L2*590
L2*580
L2*520
L2*570
Use only ORIGINAL gaskets

Nur ORIGINAL Dichtungen einbauen
CO20/ADK 14.11.2014 Rev. 6 126 000 556

Gear oil pump
Zahnradölpumpe M20000
M20030
M20410
M20500
M20100
M20400
M20050
M20060
M20070
M20040
M20090
M20010
CO20/gw Original 122 847 571 24.01.2013 Rev. 0 126 001 955
Pressure gauge and throttle valve, oil pump M20400
Manometer und Drosselventil, Ölpumpe M20410
Optional
(M20423)
M20410
M20412
M20411
M20401
M20406
M20400
M20409 M20404 M20408 M20417 M20403 M20402

M20407
CO20/kw Original 006 003 573 21.06.2010 Rev. 10 126 000 033
Oil relief valve
Überströmventil M20500
M20510 M20550 M20545
M20515
M20535
CO20/gw Original 106 034 509 200 17.11.2015 Rev. 1 126 001 118
Oil sight glass
Ölstand-Schauglas M20700
M20710
M20715
M20720
M20725
CO20/bk Original 6 000 545 01.03.2010 Rev. 0 126 001 089

Crankgear
Kurbeltrieb M00000
A10160
A10165
M00830
M50000
A10100
M30000
M00199 M00259
M40000
M20000
M00015
M10755
M20815 M10010 M20805 M10610
M10620
CO20/rmi Original 122 890 425 21.10.2015 Rev. 0 126 003 164
Crankshaft, complete with counterweight
Kurbelwelle mit Gegengewicht, komplett M10010
A–A
M10040
M10090 M10071
M10106
M10095
M10045
M10015
Bearing bracket, drive end, complete
Lagerschild, Antriebseite, komplett M00259
M00260
M00265
M10200
Bearing bracket, non-drive end, complete
Lagerschild, Nichtantriebseite, komplett M00199
M00205
M10200
M00200
Connecting rod
Schubstange M4*000
Stage*
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*420
M4*410
M40010
M40310
M40020
M40060
CO20/ae Original 106 109 289 13.04.2010 Rev. 0 126 001 143
Crosshead-piston rod connection
Kreuzkopf-Kolbenstangenverbindung
M3*000
Stage *
e.g.: Crosshead pin, 1st stage M31600

1 M31600
z. B.: KK-Zapfen, 1. Stufe M31600
2 M32600
3 M33600
4 M34600
5 M35600
6 M36600
M3*090 M3*006
M3*095
M3*065
M3*600
M3*620
CO20/wgl Original 122 848 127 11.08.2011 Rev. 2 126 001 077
Guide bearing and oil scrapers
Führungslager und Ölabstreifer M50000
Stage *
e.g.: Oil shield for piston rod 1st stage C11700

1 C11700
z. B. Ölschirm zu Kolbenstange 1. Stufe C11700
2 C12700
3 C13700
4 C14700
5 C15700
6 C16700
M50090
M50501
M50545
M50095
M50100
M50510
M50515
M50080 M50520
M50060
M50020
M50030
(M50040)
Internal pipe for guide bearings
Rohrleitung zu Führungslagern A10100
A10115 A10115
A10110 A10110
A10125
A10130
A10150
A10110
A10155 A10150
A10110
Cylinder
Zylinder C0*001
Stage*
e.g.: Piston, complete 1st stage C11100

1 C01001
z. B. Kolben, komplett 1. Stufe C11100
2 C02001
3 C03001
4 C04001
5 C05001 Variant
6 C06001 C0*645
C0*650
Option
C0*660
Option
C0*620
C0*630 C0*605 C0*620
C0*210 C0*635
C0*215
C4*000 C2*000
C1*100
C5*001
C50900
C0*200
C0*205
C1*700
C1*500
Labyrinth piston
Labyrinthkolben C1*100
Stage
e.g.: Labyrint piston 1st stage C11100
1 C11100 entsprechende Stufe auswählen,

z. B. Labyrinthkolben 1. Stufe C11100
2 C12100
3 C13100
4 C14100
5 C15100
6 C16100
C1*550 (C1*610)
Optional
C1*120
C1*110
C1*100
C1*130
C1*520
CO20/bk 07.04.2011 Rev. 1 126 000 985

Piston rod gland
Kolbenstangenstopfbüchse C5*001
Stage
Stufe * Code No. *
* entsprechende Stufe auswählen,
z. B. Stopfbüchsring 2. Stufe C52124
1 C51124
select stage as applicable,
2 C52124 e.g.: Gland ring 2nd stage C52124
3 C53124
4 C54124
5 C55124
6 C56124
C5*001
C5*134
C5*115
C5*124
C5*116
C5*108
(C0*240)
C5*127
C5*106
(C50911)
C0*245
(C50910)
C5*134
C5*124
Leak gas return pipe for piston rod gland
Stopfbüchs-Leckgasrückführung C50900
C50910
(C50911)
A30515
A30510
A30515
C50982 C50940
Instrumentation of gas system
Instrumentierung Gassystem A00200
Optional
(A00295)
A00215
A00210
A00270
A00275
A00260
Installation of suction valve
Saugventil, Einbau C2*000
Stage *
e.g.: Suction valve 2nd stage C22200

z. B. Saugventil 2. Stufe C22200
2 C22200
3 C23200
4 C24200
5 C25200
6 C26200
Option
C2*096
(C2*097)
C2*045
C0*220
C2*050 C0*230
C2*025
C2*005
C2*015
C2*020
C2*200
CO20/gw 08.11.2016 Rev. 7 126 000 011

Assembly of suction valve
Saugventil, Zusammenbau C2*200
Stage *
e.g.: Suction valve 2nd stage C22200

1 C21200
z.B. Saugventil 2. Stufe C22200
2 C22200
3 C23200
4 C24200
5 C25200
6 C26200
C2*200
C2*330
C2*310
C2*350
C2*320
C2*380
C2*390
C2*400
C2*370 C2*430
C2*360
CO20/ae 28.03.2010 Rev. 8 126 000 087

Installation of discharge valve
Druckventil, Einbau C4*000
Stufe *
stage Code No. * * select stage as applicable,
e.g.: Discharge valve 1st stage C41200

z. B. Druckventil 1. Stufe C41200
2 C42200
3 C43200
4 C44200
5 C45200
6 C46200
Option
C4*096
(C4*097)
C4*045 C0*225
C4*050 C0*230
C4*025 C4*005
C4*015
C4*020
C4*200
CO20/gw 08.11.2016 Rev. 7 126 000 015

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 125500755 E01
P & I Diagram Lube Oil System 125500756 E01
P & I Diagram Coolant System 125500757 E01
Technical Data

Orifice Plates 2054304 E01
Compressor Summary 2052997 S01
Utility Consumption List 2053459 E01
General Arrangement

General Arrangement Skid Baseframe 125501041 E01
General Arrangement Gas System 125500830 E01
General Arrangement 125500830 E02
General Arrangement Firewall 125501140 E01
Control Description

Control Description 2054690 E01
Foundation

Foundation 125500837 E01
Foundation 125500837 E02
Drive System

Main Motor 122F81229 E01
Coupling 122F82075 E01

Appendix
Lubricating System

Lubrication of BCA Piston Compressors VBCA546005
(VSB)
Lubrication of Closed (Pressure-Resis- 1001300 (VSB)
tant) Labyrinth Compressors
Crankgear Lubrication Mineral Oil 1001132 (VSB)
Lubricating Oils ISO VG 150 Categories 1001135 (VSB)
C/CL
Laby® Polyalkylene Glycol Lubricants 1001301 (VSB)
Laby® Polyalkylene Glycol Lubricants 1001302 (VSB)
Instrumentation

List of Instruments 2053936 000
Compressor

Compressor Outline 120714407 D01
Compressor Sectional View 120714468 D01
Table of Clearances 2054510 D01
Tightening Torques (List) 2054572 E01
Tightening Torques 2D200B-1A_1
(Drawing)

GDANSK
VPSA UNIT
Linde Project No.: 2210BDCW Customer P/O No.: 2001904
Linde Project Code : GDANSK Customer Project Code.: 2001904
Linde Doc. No.: 0012KD9950-P-FP 2015.001 Customer Doc. No.: 125 500 755
Linde Item No.: 3250-K2 Page 1 of 1

GDANSK
VPSA UNIT

GDANSK
VPSA UNIT

Kennwort
LINDE GDANSK
TSP for Orifice Plates
Projektauftrag_Nr.
2001904
All orifices shall be provided with:

- 3.1 certificate in accordance to EN 10204
- Imprinted charge number
- Imprinted material designation
- Imprinted Tag number
- Imprinted Pipe size and rating
- Imprinted ID diameter
Gasket thicknesses [G]:

1st stage suction: 4.5 mm
2nd stage discharge: 4.5 mm
Orifice thickness [C]:

10 mm for mole weight higher 12 g/mol
30 mm for mole weight smaller 12 g/mol
Note: Ø ID of the orifices will be added after final report of the pulsation study.
Rev. Index B
erstellt / prepared 30.09.2016 MANFREDINI_S
2054304
geprüft / reviewed Seite 1
Freigabe DVS / Release DVS 30.09.2016 MANFREDINI_S von 2
Kennwort
LINDE GDANSK
TSP for Orifice Plates
Projektauftrag_Nr.
2001904
Orifice TAG Ø ID ØA L Material of Rev

Location Size Rating
No. [mm] [mm] [mm] orifice
Suction Strainer S1501, outlet FO-1501 8” 150lbs (*) 276 110 SS316
Suction Damper D1531, outlet FO-1502 12” 150lbs (*) 406 110 SS316
Discharge Damper D1532,

FO-1503 12” 150lbs (*) 406 110 SS316 C
inlet
Discharge Damper D1532,
FO-1504 8” 150lbs (*) 276 110 SS316 C
outlet
Nitrogen line to crankcase FO-1598 1½” 150lbs (*) 82 110 SS316 C
(*) To be defined after Pulsation Study
 Orifice plates which have been cleaned for Oxygen service to be separately packed,
wrapped and marked “CLEAN FOR OXYGEN SERVICE”. 
Rev. Index B
erstellt / prepared 30.09.2016 MANFREDINI_S
2054304
geprüft / reviewed Seite 2
Freigabe DVS / Release DVS 30.09.2016 MANFREDINI_S von 2
RecipCalc™
Compressor Performance Summary
Customer Linde AG
Project Linde Gdansk
Job Site Gdansk, Poland
Item No. C 1561
Compressor Type 2D200B-1A_1
Units 1
Customer Reference 001 2KD9950 Sup.000
Burckhardt Compression Ref. No. 2001904
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 6
1.6 Summary auxiliary data 7
1.7 Compressor sketch 8
1.8 Torque diagrams 9
1.9 Starting torque 11
1.10 Unbalanced forces and moments 13
1.11 Sound pressure level 14
REV.INDEX: 02 DOK.NR.:
PREPARED 26.05.2016 KIRCHHOFF_T (TDO) 2052997-S01
APPROVED 22.08.2016 BOTTA_F PAGE 1
2001904/LINDE/GDANSK[02]&ORDER RecipCalc V 04.00.00 OF 14
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: Linde AG BCA Tender No.: Q-003394-A-01-SZ03

Project: Linde Gdansk BCA Contract No.: 2001904
Application: IG BCA Equipment No.: 102609
Compressor type: 2D200B-1A_1 Customer Reference: 001 2KD9950 Sup.000
1.1 Summary operation data
Min, Min,
Design_m Ts_max_ ps_high_
Operating Case Design Min Max
ax_T_CW max_T_C max_T_C
W W
ts_max_fo ps_min_fo
Operating conditions at battery limit Design Min Max Design
r_ps_min r_ts_max
Type of control
Suction pressure at battery limit bar a 1.23 1.17 1.54 1.23 1.17 1.28
Suction temperature °C 38 50 20 38 38 50
Rel. humidity (inlet H2O) % 0.00 0.00 0.00 0.00 0.00 0.00
Discharge pressure at battery limit bar a 4.10 4.10 4.10 4.10 4.10 4.10
Discharge temperature °C 45 45 45 52 52 52
Capacity wet kg/h 3501 3195 5068 3447 3219 3586
Capacity dry kg/h 3501 3195 5068 3447 3219 3586
Standard volume flow (0°C/1.013bar a) Nm3/h 2439 2226 3531 2402 2243 2498
Inlet volume flow m3/h 2299 2282 2493 2264 2214 2341
Specified standard volume flow Nm3/h 2333
Shaft power (coupling) kW 162 157 181 163 159 165
Recommended motor power kW 220 220 220 220 220 220
Speed rpm 595 595 595 595 595 595
Operating conditions at cylinder flange 1 1 1 1 1 1

Active compression chambers/stage % 100 100 100 100 100 100
Clearance pockets active (yes/no/-) - - - - - -
Mole weight kg/kmol 32.1 32.1 32.1 32.1 32.1 32.1
Suction pressure at cylinder flange bar a 1.21 1.16 1.52 1.21 1.16 1.27
Suction temperature °C 38 50 20 38 38 50
Discharge pressure at cylinder flange bar a 4.26 4.26 4.26 4.26 4.26 4.26
Adiabatic discharge temperature °C 171 193 120 171 176 182
Predicted discharge temperature °C 169 182 131 179 184 184
Capacity wet (inlet) kg/h 3501 3195 5068 3447 3219 3586
Capacity dry (inlet) kg/h 3501 3195 5068 3447 3219 3586
Standard volume flow (0°C/1.013bar a) Nm3/h 2439 2226 3531 2402 2243 2498
Inlet volume flow m3/h 2322 2305 2519 2286 2236 2364
Volumetric efficiency % 65.9 65.4 71.5 64.9 63.5 67.1
Condensate flow upstream stage kg/h 0 0 0 0 0 0
Delta temp. to dew point °C 220 232 200 220 220 231
Bypass flow across stage kg/h
Side stream kg/h
Shaft power kW 162 157 181 163 159 165
RecipCalc™
Max_max
Operating Case
_T_CW
Operating conditions at battery limit Max
Type of control
Suction pressure at battery limit bar a 1.54
Suction temperature °C 20
Rel. humidity (inlet H2O) % 0.00
Discharge pressure at battery limit bar a 4.10
Discharge temperature °C 52
Capacity wet kg/h 5002
Capacity dry kg/h 5002
Standard volume flow (0°C/1.013bar a) Nm3/h 3485
Inlet volume flow m3/h 2461
Specified standard volume flow Nm3/h
Shaft power (coupling) kW 181
Recommended motor power kW 220
Speed rpm 595
Operating conditions at cylinder flange 1

Active compression chambers/stage % 100
Clearance pockets active (yes/no/-) -
Mole weight kg/kmol 32.1
Suction pressure at cylinder flange bar a 1.52

Suction temperature °C 20
Discharge pressure at cylinder flange bar a 4.26
Adiabatic discharge temperature °C 120
Predicted discharge temperature °C 139
Capacity wet (inlet) kg/h 5002
Capacity dry (inlet) kg/h 5002
Standard volume flow (0°C/1.013bar a) Nm3/h 3485
Inlet volume flow m3/h 2486
Volumetric efficiency % 70.5
Condensate flow upstream stage kg/h 0
Delta temp. to dew point °C 200
Bypass flow across stage kg/h
Side stream kg/h
Shaft power kW 181
Manufacturer capacity including API618 requirements with tolerances as follows: specified capacity +3/-0 %
shaft power +3/-3 %
RecipCalc™
Gas-Library: PPDS2 Model: 10 (LKP/LKP)
1.2 Gas properties
Min, Min,
Operating conditions Chem. Design Min Max
W W
ts_max_fo ps_min_fo
formula Design Min Max Design
r_ps_min r_ts_max
Stage 1 1 1 1 1 1
Gas comp. at cyl. inlet flange [mole %]:
Oxygen O2 90.00 90.00 90.00 90.00 90.00 90.00
Argon Ar1 4.50 4.50 4.50 4.50 4.50 4.50
Nitrogen N2 5.50 5.50 5.50 5.50 5.50 5.50
Max_max_
Operating conditions Chem.
T_CW
formula Max
Stage 1
Gas comp. at cyl. inlet flange [mole %]:
Oxygen O2 90.00
Argon Ar1 4.50
Nitrogen N2 5.50
1.3 Summary loading data
Min, Min,
Operating conditions Design Min Max
W W
ts_max_fo ps_min_fo
Design Min Max Design
r_ps_min r_ts_max
Stage (cylinder flange) 1 1 1 1 1 1
Max. allowable gas rod load kN 114 114 114 114 114 114
Max. allowable gas rod load at psv kN 132 132 132 132 132 132
Max. allowable combined rod load (C/T) kN 110 110 110 110 110 110
Gas rod load compression kN 45 46 43 45 46 45
Gas rod load tension kN 43 43 40 43 43 42
Combined rod load compression kN 42 41 46 42 41 43
Combined rod load tension kN 41 40 45 41 40 41
Combined rod load at relief valve set C kN 38 37 43 38 37 39
Combined rod load at relief valve set T kN 33 33 38 33 33 34
Rod reversal at normal op. condition deg 175 175 165 175 175 170
Rod reversal at safety valve setting deg 140 140 145 140 140 145
RecipCalc™
Max_max_
Operating conditions
T_CW
Max
Stage (cylinder flange) 1
Max. allowable gas rod load kN 114
Max. allowable gas rod load at psv kN 132
Max. allowable combined rod load (C/T) kN 110
Gas rod load compression kN 43
Gas rod load tension kN 40
Combined rod load compression kN 46
Combined rod load tension kN 45
Combined rod load at relief valve set C kN 43
Combined rod load at relief valve set T kN 38
Rod reversal at normal op. condition deg 165
Rod reversal at safety valve setting deg 145
1.4 Compressor design data
Running Dry
Stage 1
No. of cylinders per stage 2
Acting (single=s/double=d) d
Piston diameter mm 400
Piston rod diameter mm 75
Stroke mm 200
Average piston speed m/s 3.97
Piston displacement m3/h 3526
Spacer ring height mm 5/5
Clearance volume (average) % 17.0
Valve type plate
No. of suction valves per cylinder - 4
Suction valve size BCAG-181
Suction valve pressure class 8/16
Suction valve lift mm 1.65
Suction valve gas velocity (average) m/s 31.15
No. of discharge valves per cylinder - 4
Discharge valve size BCAG-181
Discharge valve pressure class 8/16
Discharge valve lift mm 1.65
Discharge valve gas velocity (average) m/s 31.15
Unloader type -
No. of clearance pockets per stage - n.a.
RecipCalc™
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 (60%Water/40% Glycol) Min 20 26 6.15 37.3
Min VR1.1 1.52 9.2
Min VR1.2 1.55 9.4
Min VR2.1 1.52 9.2
Min VR2.2 1.55 9.4
Design PF1
Design PF2
Gas (60%Water/40% Glycol) Min, ps_high_max_T_CW 41 47 20.1 122
Min, ps_high_max_T_CW KL1 20.13 121.6
Oil (60%Water/40% Glycol) Design 20 25 1.97 9.9
Design oil cooler 1.97 9.9
Remarks:
VR: compression chamber (cylinder pos./ compression chamber)
PF: piston friction (cylinder position)
KL: gas cooler
RecipCalc™
1.6 Summary auxiliary data
Relief valve setting
Suction side 1st stage bar g

Discharge side 1st stage bar g 4.5
Cooling water system bar g
RecipCalc™
1.7 Compressor sketch
Crank C1 C2
Stage 1/1 1/1
Stroke [mm] 200 200
Piston diameter [mm] 400 400
Number of suction valves 2/2 2/2
Number of discharge valves 2/2 2/2
Valve size 181 181
Valve manufacturer BC BC
Clearance volume [%] 15.5/18.5 15.5/18.5
Stage 1
Piston displacement m3/h 3526
RecipCalc™
1.8 Torque diagrams
Maximum torque
Max_max_
T_CW
Max
Torque diagram (compressor excitation torque before flywheel)
Mt0 [kNm] -2.908 Fourier-Analysis

Mtmax [kNm] 1.287 Mt=Mt0+SUM[Mt(j)*COS[j*ABS(w)*t-phi(j)]]
Mtmin [kNm] -6.937 ord. j amp. Mt(j) [kNm] phi(j) [deg]
Delta A/A [-] -0.21769 1 0.000 138.5
Inertia compr. [kgm2] 4 2 3.938 133.6
Inert. flywheel [kgm2] 163 3 0.000 311.0
Inert. motor [kgm2] 34 4 0.387 308.6
Irregularity* [1/...] 194 5 0.000 13.9
Pad [kW] 145.4 6 0.378 304.3
Shaft power
[kW] 181.2 7 0.000 49.2
(coupling)
Speed [rpm] 595 8 0.048 303.0
9 0.000 352.3
10 0.017 354.5
11 0.000 353.6
12 0.026 98.2
*Considering compressor, motor and flywheel (if available). The whole train is assumed fully rigid.
RecipCalc™
Maximum irregularity
Max_max_
T_CW
Max
Torque diagram (compressor excitation torque before flywheel)
Mt0 [kNm] -2.908 Fourier-Analysis

Mtmax [kNm] 1.287 Mt=Mt0+SUM[Mt(j)*COS[j*ABS(w)*t-phi(j)]]
Mtmin [kNm] -6.937 ord. j amp. Mt(j) [kNm] phi(j) [deg]
Delta A/A [-] -0.21769 1 0.000 138.5
Inertia compr. [kgm2] 4 2 3.938 133.6
Inert. flywheel [kgm2] 163 3 0.000 311.0
Inert. motor [kgm2] 34 4 0.387 308.6
Irregularity* [1/...] 194 5 0.000 13.9
Pad [kW] 145.4 6 0.378 304.3
Shaft power
[kW] 181.2 7 0.000 49.2
(coupling)
Speed [rpm] 595 8 0.048 303.0
9 0.000 352.3
10 0.017 354.5
11 0.000 353.6
12 0.026 98.2
*Considering compressor, motor and flywheel (if available). The whole train is assumed fully rigid.
RecipCalc™
1.9 Starting torque
Operating conditions Max

Max
Starting torque with open bypass valve(s)

Valid for direct-coupled compressor
n/n0 [%] 0 10 20 30 40 50 60 70 80 90 100

M/MN [%] 28.9 15.2 12.2 13.6 16.4 20.3 25.1 30.8 37.0 43.6 50.4
Recommended motor power 220 kW

Nominal speed n0 of compressor and motor 595 rpm
Nominal motor torque MN 3.531 kNm
Momentum of inertia (J) of compressor and flywheel (if available) 167 kgm2
Crank case pressure at start up 1.013 bar a
The acceleration torque of the revolving parts (flywheel, rotor) are not included in the curve as they are determined by the starting
time
RecipCalc™
Operating conditions Max_max_T_CW

Max
Starting torque with open bypass valve(s)

Valid for direct-coupled compressor
n/n0 [%] 0 10 20 30 40 50 60 70 80 90 100

M/MN [%] 28.9 15.2 12.3 13.7 16.4 20.3 25.2 30.9 37.1 43.7 50.6
Recommended motor power 220 kW

Nominal speed n0 of compressor and motor 595 rpm
Nominal motor torque MN 3.531 kNm
Momentum of inertia (J) of compressor and flywheel (if available) 167 kgm2
Crank case pressure at start up 1.013 bar a
The acceleration torque of the revolving parts (flywheel, rotor) are not included in the curve as they are determined by the starting
time
RecipCalc™
1.10 Unbalanced forces and moments

Related to point Z = 462 mm from 1st bearing
Q = time * angular velocity
Q = t(sec) * (360/60 * 595) (deg/sec)
Speed = 595 rpm
Mt = Motor torque
Resulting forces
Horizontal FH [kN] = 0.000 1st order
+ 0.000 2nd order
Vertical FV [kN] = 0.000 1st order
+ 23.330 * cos(2 * Q + 0.0) 2nd order
Resulting moments
Horizontal MH [kNm] = 7.298 * cos(Q - 180.0) 1st order
+ 0.000 2nd order
Vertical MV [kNm] = 37.322 * 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 23.330 0.000 23.571
Moments
Horizontal, MH [kNm] 7.298 0.000 7.298 7.298
Vertical, MV [kNm] 37.322 0.000 7.298 37.322
(*) 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 = 595.0 rpm
According ISO 2151
Lp = 84.3 dB(A)
Octave spectrum of sound pressure level
f [Hz] 63 125 250 500 1000 2000 4000 8000

Lp [dB] 75.8 80.8 84.3 80.3 79.8 77.3 73.3 66.3
f: frequency, Lp: sound pressure level
Plant Code: Project No.: Compressor Type:
2001904 LINDE GDANSK 2D200B-1A_1
Client Order No: Item No.: Serial No.:
Reciprocating Compressor
001 2KD9950 Sup.000 3250-K2 102609
Process utility consumption Client: LINDE AG
QUANTITY PER ONE MACHINE

CONNECTION
NO. OF SIZE (in)
SERVICE
NO. UTILITY SYMBOL
(EQUIPMENT AND/OR PART)
NORMAL NORMAL MAXIMUM
WORKING UNIT
SUPPLY SUPPLY
IN OUT RETURN RETURN
(m3/h) (m3/h)
1 H2O Compressor 1 NOTE 1 m3/h 5.72 5.72 6.6 6.6

3
2 H2O Gas Aftercooler 1 3" 3" m /h 19.8 19.8 22.8 22.8
3
4 N2 Purge Distance Piece 1 1 1/2" NOTE 2 kg/h 25 0 28.75 0
5
6 IA Valve Actuators 1 12x1,5 12x1,5 m3/h 0.1 per stroke
7
8
9
10
NOTE 1: Compressor cooling water connections are multiple. Please refer to P&ID N°125500757.
NOTE 2: No Outlet connection in BC design. Purge N2 will be discharged in atmosphere through the partially opened plexiglass
cover on the compressor Distance Piece
UTILITY DESCRIPTON
SUPPLY CONDITION RETURN CONDITION
UTILITY
NO.
SYMBOL
UTILITY NAME TOTAL FLOW
PRESSURE TEMPERATURE (°C) PRESSURE TOTAL FLOW
TEMP. (°C)
(bar g) normal/ min. (m3/h) (bar g) (m3/h)
1 H2O Cooling water 4÷6 20 25.5 3÷5 26 25.5
2 N2 Purge Nitrogen 6.0 Ambient 25 kg/h - - -
3 AI Instrument Air 6÷7 Ambient 0.1 - - -
Rev. Index A
erstellt/prepared 18.04.2016 MANFREDINI_S
DOK.-No. 2053459
geprüft/reviewed 16.09.2016 SEMERARO_D Seite / Page 1
Utility consumtion list...
Freigabe DVs / Release DVS 16.09.2016 MANFREDINI_S VON / OF 3
Reciprocating Compressor Client Order No.: Item No.: Serial No.:
001 2KD9950 Sup.000 3250-K2 102609
Power consumption list Client: LINDE AG
Bus Equip. Power Volt PH Hz RPM F.L.A. Eff. PF

Description Remarks
No. No. (kW) (V) (A) % %
01 Main motor 230 10'000 3 50 ±2% 596 560 96.3 0.82

Item: 3250-MK2
02 Space heater E-mot. 0.25 230 3 50 NA 0.85
E1571
03 Oil heater on compr. 0.8 400 3 50 NA 1.2
E1564
04 Oil pump motor 2.2 400 3 50 1455 4.65 84.3 0.81
3250-MP2
Rev. Index A
DOK.-No. 2053459
Freigabe DVS/Release DVS 16.09.2016 MANFREDINI_S VON / OF 3
Client Order No.: Item No.: Serial No.:
Reciprocating Compressor
001 2KD9950 Sup.000 3250-K2 102609
Lubricating list Client: LINDE AG
REPLACE MAKE UP
NO. LUBRICANT SPECIFICATION INITIAL CONSUMPTIO
EQUIPMENT LUBE LUBE
OF (ISO # / VISCOCITY NO.) CHARGE N REMARKS
ITEM NO. PART METHOD
UNIT RECOMMENDED BRAND QTY. INTERVAL QUTY. INTERVA QUTY. ( year )
(hours) (unit) L (month) (unit)
As per oil list 6311138 Viscosity at 100°C in Information will be

Compressor Bearing 1 Lube Oil 120 8000 120 -
mm2/s ( cSt) approx 14.0 to 15.0 included in the IOM
AGIP Radula 150

AGIP Acer 150
BP Amoco Energol CS 150
Castrol Magna 150
Chevron (Texaco) Regal R&O 150
ExxonMobil Mobil DTE 10 Excel 150 BC recommended
ExxonMobil Mobil Vacuoline 128 Lubricants
Shell Morlina S1 B 150

Shell Morlina S2 B 150
Total Cirkan RO 150
Total Dacnis 150
Strub Vulcobase P
Rev. Index A
DOK.-No. 2053459
Freigabe DVS/Release DVS 16.09.2016 MANFREDINI_S VON / OF 3
GDANSK
VPSA UNIT
Linde Doc. No.: 0012KD9950-L-ZP 2015 (EN) Customer Doc. No.: 125 500 830
Linde Item No.: Page 1 of 1

Kennwort / Project Name
LINDE GDANSK
Control Description Projektauftrag Nr. / Project No.
2001904
The control description Client Information:

Name & Logo: Service Type: Plant Location: Reference No.:
Oxygen Grupa LOTOS S.A. 001 2KD9950
Linde AG / Dr.-Carl-von-Linde- Sup.000
Compressor Gdansk - Poland
Strasse 6-14 / DE-82049
Pullach bei München
TAG or Item No.: Project Contractors: Project No.:
3250-K2 Linde AG 2210BDCW
Vendor Information:
Project Name, Plant Code: Project No.: Compressor Type: Serial No.:
LINDE GDANSK 2001904 2D200B-1A_1 102609
FINAL
2016-09-13
Burckhardt Compression AG, CH-8404 Winterthur, Switzerland
Revision Index B
erstellt prepared 13.09.2016 KOHLER_P
2054690
geprüft reviewed 14.09.2016 MANFREDINI_S Seite / Page 1
freigegeben released 14.09.2016 KOHLER_P von / of 19
LINDE GDANSK
2001904
Table of Contents
Introduction .............................................................................................................................. 3
1. Project Information .............................................................................................................. 4
1.1. Project Data ............................................................................................................................. 4
1.2. Related Documents .................................................................................................................. 4
1.3. General Compressor Unit Function .......................................................................................... 4
2. Operating Procedures & Instructions ................................................................................ 5
2.1. Flow Chart acc. DIN 66001 / ISO 5807..................................................................................... 5
2.1.1. Compressor Start .............................................................................................................. 5
2.1.2. Compressor Normal Stop, Process Trip (SD) or ESD ....................................................... 6
2.2. Preparations of the Compressor Unit ....................................................................................... 7
2.2.1. Mechanical Check Points: ................................................................................................. 7
2.2.2. Instrumentation Check Points: .......................................................................................... 7
2.3. Start Procedures ...................................................................................................................... 8
2.3.1. Start Sequence (Step 1) .................................................................................................... 8
2.3.2. Compressor Start Interlocks SI (Step 2) ............................................................................ 8
2.3.4. Main motor start up (Step 3).............................................................................................. 9
2.3.5. Main motor running (Step 4).............................................................................................. 9
2.4. Stop Sequences & Procedures............................................................................................... 10
2.4.1. Manually issued Normal Stop.......................................................................................... 10
2.4.2. Stop by Process Trip Conditions ..................................................................................... 10
2.4.3. Automatic Compressor Trips (SD)................................................................................... 10
2.4.4. Stop by Emergency Stop (ESD) ...................................................................................... 11
2.4.5. Equipment Conditions after Compressor Stop................................................................. 11
3. System Description ........................................................................................................... 12
3.1. Process Gas System .............................................................................................................. 12
3.1.1. Isolation valve on suction side (XV-1530)........................................................................ 12
3.1.2. Isolation valve on delivery side (XV-1550)....................................................................... 12
3.1.3. Vent valve to atmosphere (PCV-1513) ............................................................................ 13
3.1.4. Fast open valve (XX-1513).............................................................................................. 13
3.2. Compressor Capacity Control System .................................................................................... 14
3.2.1. Recycle Valve (PCV-1545).............................................................................................. 14
3.2.2. Fast close valve (XX-1545) ............................................................................................. 15
3.4. Compressor Lubricating System............................................................................................. 16
3.4.1. Electrical Oil Heater E1564 (I-1013) ............................................................................... 16
3.4.2. Electrical External Oil Pump 3250-P2 (I-1011) ............................................................... 17
3.4.3. Lubricating Oil Filter ........................................................................................................ 17
3.5. Coolant System ...................................................................................................................... 18
3.6. Main Motor 3250-MK2 ............................................................................................................ 18
3.6.1. Anti-Condensation Heater ............................................................................................... 18
3.7. Compressor............................................................................................................................ 19
3.7.1. Temperature monitoring on piston rod packing ............................................................... 19
3.7.2. Distance piece purging with nitrogen............................................................................... 19
3.7.3. Compressor maintenance operation ............................................................................... 19
Revision Index B
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2001904
Introduction
The purpose of this technical document is to provide a basic understanding of the plant
application and the service needed of the supplied compressor unit(s). In addition this document
serves as a control philosophy and control-function description of the supplied compressor and
associated auxiliaries.
This document, together with the documents listed below, shall all provide at minimum a basic
understanding of the control system functions and features. These documents are thought as
guidelines for process engineers as well as for system operators.
This document is organized in three main chapters and a reference section at the end, listing
other technical documents which complement the project specific documents, or provide special
in-depth knowledge.
Abbreviations
Interfaced Systems Instrumentation & Control
CCR Central Control Room CP Control Panel
DCS Distributed Control System ES Emergency Stop
ESD Emergency Shutdown System HMI Human Machine Interface
HVS High Voltage System I/O Inputs / Outputs (Analog & Digital)
MCC Motor Control Centre JB Junction Box
MMS Machine Monitoring System LCP Local Control Panel
SIS Safety Instrumented System LIB Local Instrument Board
SI Start Interlock
Auxiliary Systems Additional Abbreviations
CW Cooling Water BC Burckhardt Compression
CS Coolant System BN Bently Nevada
GS Gas System PSG Prognost System Germany
OS Oil System IOM Instruction and Operation Manual
Revision Index B
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2001904
1. Project Information
1.1. Project Data
Client: Linde AG
Client Reference No.: 001 2KD9950 Sup.000
Plant Location: Grupa LOTOS S.A., Gdansk - Poland
Project Name: LINDE GDANSK
Project No.: 2001904
Item No.: 3250-K2
Compressor Type: 2D200B-1A_1
Compressor Serial No: 102609
Gas Type: O2+
Ambient Conditions:
Hazardous Area: -
Installation: Indoor, heated
Temperature: +5…+45°C
Special Applications: Oxygen application
1.2. Related Documents
Document Name BC Document No. Clients Document No.

P&I Diagram Gas System 0-125.500.755 0012KD9950-P-FP 2015.001 A
P&I Diagram Oil System 1-125.500.756 0012KD9950-P-FP 2015.002 A
P&I Diagram Coolant System 1-125.500.757 0012KD9950-P-FP 2015.003 A
General Arrangement Gas System 0-125.500.830 0012KD9950-L-ZP 2015 (EN) A
Interface Diagram ELD 122597246 0012KD9950-J-ZW 2015 (EN) A
(an overview of the electrical & data connections)
List of Instrumentation TSP 2053936 0012KD9950-J-LJ 2015 (EN) A
(includes alarm & control set points)
1.3. General Compressor Unit Function

The Laby® Compressor of type 2D200B-1A_1 is used at the Grupa LOTOS S.A plant in
Gdansk, Poland.
The unit compress the gas over one stage from a suction pressure of 0.23 bar g at 38°C to a
delivery pressure of about 3.1 bar g at 45°C.
The delivery pressure is controlled by an overall bypass (a recycle) valve.
The unit includes the compressor and an electric main motor, a skid mounted lube oil system
and open coolant system.
The compressors are controlled and monitored by the client’s DCS.
Revision Index B
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2001904
2. Operating Procedures & Instructions

This chapter includes operating procedures and tasks for the safe operation of the compressor
and associated utilities. In the procedure descriptions reference is given to instrument TAG
numbers for the operator.
2.1. Flow Chart acc. DIN 66001 / ISO 5807

2.1.1. Compressor Start
Compressor Off
Ready for start
when no shut down
are active
- Start External Oil Pump 3250-P2 (for 2 min.)

After 2 min.:
Step 1
Start Command - Open suction isolation valve XV-1530
Compressor Start Sequence
from DCS - Close delivery isolation valve XV-1550
- Open vent valve PCV-1513
- Open Recycle Valve PCV-1545
Step 2
Start Interlocks (SI)
Stop start sequence Conditions

No
OK
Yes
Step 3
Main Motor Start Command to MCC
Main Motor Start-up
As soon as main motor is running

- Switch off the main motor anti condensation
Main Motor Running Feedback
AND heater
from MCC active
- Enable controller for recycle valve PCV-1545
(after 30 sec.)
- Close vent valve PCV-1513
Step 4 - Enable controller vent valve PCV-1513
Main Motor Running (after 30sec.)
- Open delivery isolation XV-1550 (after 30sec.)
- Stop external oil pump P-1567 (after 30 sec.)
Compressor
Running
Compressor Run
Warning: This normal starting mode shall only be used for compressors that have been
run-in and purged. For initial start (commissioning) of the compressor see IOM.
Revision Index B
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2.1.2. Compressor Normal Stop, Process Trip (SD) or ESD
Compressor Run
Stop Command from

DCS
Process Trip (SD) OR
ESD Command
Step 10 - Main Motor Stop Command to MCC

Main Motor Stop - Anti-Condensation Heater On
- Start External Oil Pump (for 5min.) 1)

Main Motor Running Feedback - Recycle Valve PCV-1545 forced close
not active AND
- Suction Isolation valve XV-1530 close
- Delivery Isolation valve XV-1550 close
- Vent valve PCV-1513 opens (for 30sec.) 2)
Step 11
Main Motor Off
Compressor Off
Compressor Off
1) In case of an emergency stop or shut down caused by PALL-1566 (low oil pressure) the
external oil pump will not start for post lubrication.
2) Time to set during commissioning.
Revision Index B
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2.2. Preparations of the Compressor Unit

During commissioning, after maintenance or after a long stand still period, the following checks
shall be executed to ensure the full functionality of installed equipment.
It is not allowed to run the compressor with defective / malfunctioning equipment or
instrumentation.
2.2.1. Mechanical Check Points:

Additionally to the checks mentioned in the IOM of the compressor following checks have to be
performed after maintenance work or if the compressor unit was not in operation for long period.
Gas System:
 Check gas suction strainer in the main suction line for cleanliness.
 Check all damper/separators, gas-coolers, piping low-points for accumulated liquids and
drain as required.
 All safety devices shall be operational
 Check instrument air pressure for control valves
Lubricating System:
 Open the isolation valves on the external oil pump.
 Check the sight glass at the lube oil tank and make sure that the level is at least 75% for
starting.
 Perform operational test prior to compressor start to ensure trouble free operation of the
lube oil system and check the differential pressure indicator on the duplex oil filter for the
selected cartridge and change over if necessary.
 Check the local temperature gauge that the oil temperature is above the minimum
allowed starting temperature, declared by the pump manufacturer.
 Make sure the drain valves are closed
Coolant System:
 Open isolating valves on supply and return header of the fresh-water system.
 Check coolant supply to compressor indicated by sight glasses.
 Open hand valves if required.
 Open hand valves if required.
Compressor:
 Check all manual valves to be in the correct position.
 Turn the compressor manually at the flywheel making sure that everything is
mechanically in order. Ensure that the flywheel – coupling guard is closed after the
mechanical check. An open cover will activate the limit switch ZSO-1598, which will not
allow the compressor to start.
2.2.2. Instrumentation Check Points:
 All valves to process instruments must be open.

 Drain impulse lines of gas measuring instruments from likely collected liquids.
 All instruments and their loops must be functioning correctly.
 Check that all pneumatically controlled devices are supplied with control medium..
Revision Index B
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2.3. Start Procedures

2.3.1. Start Sequence (Step 1)
When no shutdowns are activated, the READY TO START indication, located on DCS, is
switched on. The entire package can be started up by COMPRESSOR SEQUENCE START
push button, located on DCS.
The following tasks are executed automatically:
 Start External Oil Pump 3250-P2 for pre lubrication (2 min.)
After 2min.
 Open suction isolation valve XV-1530
 Close delivery isolation valve XV-1550
 Open vent valve PCV-1513
 Open Recycle Valve PCV-1545.
2.3.2. Compressor Start Interlocks SI (Step 2)

TAG-No Interlock condition Corrective measures
Remedy all existing shut downs and
CMP-SD General shut down active
reset the system
Remedy existing ESD and reset the
CMP-ESD Emergency shutdown active
system
ZAH-1530 Suction isolation valve is not open Check if valve operates correctly. B
The suction pressure is lower than Check suction valve/line and
PAL-1514
the set point. increase pressure.
ZAH-1513 Vent valve is not open Check if valve operates correctly. B
ZAH-1545 Recycle valve is not open Check if valve operates correctly. B
ZAL-1550 Delivery isolation valve is not closed Check if valve operates correctly. B
The pressure in the compressor Check for indications of insufficient
PAL-1566 lubricating system is lower than the oil flow or air in the lubricating
set point. system.
Pre lube time Pre-lubrication timer for crank gear Make sure the external oil pump is
not elapsed oil system has not elapsed. running.
The temperature of the lubricating oil Start of the external oil pump and
TAL-1566
is lower than the set point. start of the oil heater is necessary.
The flow of the coolant through the Check coolant supply from the plant.
FAL-1572 open cooling circuit is lower than the Check for valve open positions and
set point. any leaks in the coolant system
The purge gas pressure is lower Check nitrogen supply to
PAL-1598
than the set point. compressor distance piece.
ZSO-1598 Flywheel guard cover open Close flywheel guard cover B
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2.3.4. Main motor start up (Step 3)

If no start interlock is active and the compressor is pre lubricated for two minutes the main motor
will be started automatically.
2.3.5. Main motor running (Step 4)

As soon the main motor running feedback from MCC is received, the following tasks are
executed automatically:
 Switch off the main motor anti condensation heater
 Enable controller for recycle valve PCV-1545 after 30 sec.
 Close vent valve PCV-1513
 Enable controller for vent valve PCV-1513 after 30 sec.
B
 Open delivery isolation valve XV-1550 after 30 sec.
 Stop external oil pump 3250-P2 after 30 sec.
The following alarms warn the operator of any trouble but do not cause the compressor unit to
shut off:
TAG-No Alarm description Corrective measures

PAL-15141) Low gas pressure suction side
Check if recycle valve operates correct.
PAH-1514 High gas pressure suction side
TAH-1514 High gas temperature suction side Check gas cooler function.
TAH-1515 High gas temp. discharge 1st stage Check cylinder cooling
TAH-1537 High gas temp. delivery side Check gas cooler function.
PAH-1534 High gas pressure delivery side Check if recycle valve operates correct. B
TAH-1566 High lube oil temperature

TAL-1566 Low lube oil temperature
PAL-15662) Low lube oil pressure Check if oil filter is clogged.
PDAH-1548 High diff. pressure over lube oil filter Switch over to the spare chamber
Check coolant supply from the plant.
Low flow of the coolant through the
FAL-1572 Check for valve open positions and any
open cooling circuit.
leaks in the coolant system
TAH-1581-7
High main motor bearing temp.
TAH-1581-8
TAH-1581-1
TAH-1581-3 High main motor winding temp.
TAH-1581-5
TAH-1518 Check packing/gland rings in
High rod packing temp.
TAH-1519 compressor distance piece.
The purge gas pressure is lower than Check nitrogen supply to compressor
PAL-1598
the set point. distance piece.
VAH-1561 High vibration on compressor frame B
1) The alarm PAL 1514 is inhibited at compressor start-up for 10 seconds.

2) Automatic start of external oil pump 3250-P2
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2.4. Stop Sequences & Procedures

2.4.1. Manually issued Normal Stop
When the compressor is stopped from the DCS or by a process trip function, the following stop
sequence will be executed automatically:
 Main motor STOP command to MCC.
Main motor running feedback not active

 The recycle valve PCV-1545 is forced to close position. B
 Isolation valves XV-1530 and XV-1550 are closing to isolate the compressor.
 Vent valve PCV-1513 is opening for 30 sec. to release the pressure. 2)
 START the external oil pump 3250-P2 automatically for 5min. “Post-Lubrication”.
 Main motor space heater ON command to MCC.
2.4.2. Stop by Process Trip Conditions

Process Trips of the compressor are active all the time. The compressor will be stopped
automatically, if the actual process value is at or exceeding the preset trip value for longer than
the declared delay. Important trip levels have no delay; others may have delays of up to 3
seconds to eliminate de-bouncing effects or short spikes.
The Process Trip – Sequence is identical to the Normal Stop Procedure above
2.4.3. Automatic Compressor Trips (SD)

TAG No. Trip Conditions
PALL-1514 1) Low Low gas suction pressure
TAHH-1515 High High gas discharge temperature 1st Stage
TAHH-1537 High High gas temperature on delivery side
PAHH-1534 High High gas pressure on delivery side
VAHH-1561 High High vibration on compressor frame
Low Low lubricating oil pressure
PALL-1566
(prevents also post-lubrication function after compressor shutdown)
TAHH-1566 High High oil temperature
TAHH-1581-7
High High main motor bearing temperature
TAHH-1581-8
TAHH-1581-1
TAHH-1581-3 High High main motor winding temperature
TAHH-1581-5
PALL-1598 Low Low purge gas pressure
1) The suction pressure alarm and shut down will be overridden during the first 10 sec. after compressor start.
2) Time to be set during commissioning
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2.4.4. Stop by Emergency Stop (ESD)

An Emergency Stop for the compressor unit can be activated at any time.
Emergency Stop will shut down all consumers of the compressor unit at once and makes sure
that the energy supply to these consumers is cut off.
The energy supply remains off until the emergency condition is remedied and reset.
Attention: As long as the emergency stop condition is active no other actions will
commence. It prevents also post-lubrication function after compressor shutdown.
All isolating valves and process valves drive into their desired fail-safe position.
2.4.5. Equipment Conditions after Compressor Stop

Consumer / Actuator Normal Stop Emergency
TAG-No. Process Trip Stop
Main Motor
OFF OFF
3250-MK2
Anti-Condensation Heater
ON OFF
E1571
External oil pump motor Starts for post-
OFF
3250-P2 lubrication, then OFF 2)
Electrical Oil Heater
- OFF
E1564
Isolation valve on suction side
CLOSE CLOSE
XV-1530
Isolation valve on delivery side
CLOSE CLOSE
XV-1550
Vent valve to atmosphere
OPEN OPEN
PCV-1513
Fast open vent valve
DE-ENERGIZED DE-ENERGIZED
XX-1513
Recycle Valve
CLOSE CLOSE
PCV-1545
Fast close valve
DE-ENERGIZED DE-ENERGIZED
XX-1545
2) If trip is caused by PALL-1566 (too low oil pressure) the external oil pump is switched off immediately.
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3. System Description
3.1. Process Gas System
The gas system refers to all equipment from the suction to the delivery side according to P&ID.
A conical wire mash type suction strainer is installed at the suction side. Its function is to hold
back and prevent any particles of size >300 micron to flow into the compression chambers. A
differential pressure transmitter installed over the suction strainer and is used to alarm in case
of clogging.
Temperature transmitters with compressor trip alarms are installed on the discharge side of
every stage to avoid damage to cylinders or pistons in case of too high discharge gas
temperatures.
The compressors, the unit vessels (pulsation dampers) and the piping system are protected
from unexpected overpressure conditions by means of mechanical safety relive valves
installed within the piping system. These safety pressure relieve valves are mounted on the
client’s header.
A gas cooler after the first stage is installed to cool down the process gas. The gas cooler (heat
exchanger) use coolant to cool the process gas.
3.1.1. Isolation valve on suction side (XV-1530)

An on/off valve is installed to isolate the suction side when the compressor is stopping, is off or
in case of emergency.
The valve is controlled by a solenoid valve XX-1530 and is equipped with limit switches for
open and close position. The valve is a fail close design, the solenoid valve has to be
energized to open the valve.
Function Description:
Start Preparation: When the pre-start sequence is activated the valve will open.
A compressor start is not possible as long as the valve is not in open position (start interlock). B
Compressor Stop: The valve will close and remain closed.
Emergency Stop: The valve will close and remain closed.
3.1.2. Isolation valve on delivery side (XV-1550)

An on/off valve is installed to isolate the delivery side when the compressor is stopping, is off or
in case of emergency.
The valve is controlled by a solenoid valve XX-1550 and is equipped with limit switches for
open and close position. The valve is a fail close design, the solenoid valve has to be
energized to open the valve.
Function Description: The isolation valve has following functions:
Start Preparation: The valve will open as soon the purging procedure is completed (ca. 30 sec.
after compressor start).
Compressor Stop: The valve will close and remain closed.
Emergency Stop: The valve will close and kept in that position as long as the emergency stop B
has not been released.
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3.1.3. Vent valve to atmosphere (PCV-1513)

An automatic control valve is installed to vent the gas system when the compressor is stopping.
In case of a sudden interruption of oxygen consumption, the excessive gas can be released B
through the vent valve. This is controlled by FICC-1545 (in clients scope of supply).
The valve is electrically operated by a controller and is equipped with a continuous position
feedback to indicate the actual valve position.
Function Description: The vent valve has following functions:

Start Preparation: When the pre-start sequence is activated the valve will open. After
compressor start, pipe system will be purged for 30 sec. by blowing off the gas to atmosphere.
A compressor start is not possible as long as the valve is not in open position (start interlock).
Automatic Operation: After the vent valve is fully closed, the automatic controlled operation is
enabled. The vent valve is controlled automatically by FICC-1545 (in clients scope of supply) B
Compressor Stop: The valve will open.
In order to prevent having wet air in the pipe system the valve will be closed after 30 sec.3)
automatically.
Emergency Stop: The valve will open and kept in that position as long as the emergency stop
has not been released.
When the valve is released, it will close in order to prevent having wet air in the pipe system.
3.1.4. Fast open valve (XX-1513)

A solenoid valve XX-1513 is installed on vent valve (PCV-1513) in order to move the valve
fast into the fail position (open). The solenoid valve has to be energized to operate the valve.
Function Description: The valve has following functions:
Compressor Stop: The solenoid valve will be de-energized and opens the valve fast.
Emergency Stop: The solenoid valve will be de-energized and opens the valve fast.
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3.2. Compressor Capacity Control System

The main purpose of the capacity control system is controlling the gas flow through the
compressor to the discharge line.
To achieve this, the compressor capacity control system consists of a process Interface
Controller (FIC-1545), controlling the recycle valve overall
Recycle Valve Overall
The UC controls the recycle valve continuously according to the gas discharge pressure set
point. The suction pressure is used as a guard controller.
The recycle valve overall is designed for 100% capacity and is used to maintain the gas
discharge pressure of the compressor unit and for an unloaded starting of the compressor.
FIC
Guard 1545 Primary
PT PT
SUC PCV-1545 DEL
1st Stage
1st Stage
3.2.1. Recycle Valve (PCV-1545)

An automatic control valve is installed over compressor stage to control the discharge
pressure.
When the compressor is not in operation or get stopped, the recycle valve is closed, in order
to isolate the suction and discharge side for safety reasons.
The valve is electrically operated by a controller and is equipped with a continuous position
feedback to indicate the actual valve position.
Function Description: The recycle valve control has following functions:
Start Preparation: When the pre-start sequence is activated the recycle valve will be forced to
fully open position for start-up automatically.
A compressor start is not possible as long as the valve is not in open position (start interlock).
Automatic Operation: After the recycle valve is fully closed, the automatic controlled operation
is enabled. The recycle valve is controlled automatically by FIC-1545.
Compressor Stop: The recycle valve will be forced to close position and remains closed until
the open command for start preparation.
Emergency Stop: The recycle valve will be forced to close position and remains closed until
the open command for start preparation.
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3.2.2. Fast close valve (XX-1545)

A solenoid valve XX-1545 is installed on recycle valve (PCV-1545) in order to move the valve
fast into the fail position (close). The solenoid valve has to be energized to operate the valve.
Function Description: The valve has following functions:
Compressor Stop: The solenoid valve will be de-energized and closes the valve fast in order
Emergency Stop: The solenoid valve will be de-energized and closes the valve fast in order
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3.4. Compressor Lubricating System

The compressor lubricating system is used to lubricate the moving parts of the compressor
outside the process gas wetted area, namely the crankshaft main bearing, the connecting rod
bearings, the crosshead.
The lubricating oil is stored the compressor crankcase (sump) from where it is circulated through
the oil-filter to the various lubricating points of the compressor.
During compressor operation, the compressor shaft driven gear oil pump is in operation. The
external oil pump is then at stand-by.
The external oil pump is required for start-up prior to starting the compressor (pre-lubrication)
and after stopping the compressor (post-lubrication).
During stand-by of the compressor, the lubricating system can be operated in order to maintain
the minimum start-up temperature of the oil.
This system comprises:

 A crankshaft mounted mechanical gear oil pump
 An electrical oil heater mounted into the compressor crankcase with an integrated
temperature controller & limiter (cut-out)
 A skid mounted lubricating system consisting of:
o An electrical external oil pump
o A dual oil filter with integrated differential oil pressure transmitter
o An oil temperature transmitter
o An oil pressure transmitter
3.4.1. Electrical Oil Heater E1564 (I-1013)

General Description:
An electrical oil heater is used to prevent viscosity problems of the lubricating oil.
The oil heater consists of heater elements, which extend into the medium to be heated. On
the external side is an electrical control box attached.
The operation of the heater must be interlocked with a running oil pump, since heating the oil
in the reservoir without running pump does not circulate the oil sufficient enough. Insufficient
circulation would likely cause oil overheating or damaging close to the heater elements.
The electrical oil heating control has following functions:
Thermostat as Pre-Limiter: The Internal thermostat will be used as a pre-limiter to prevent the
internal limiter to trip. It will be set to the maximum possible (e.g. 70°C) and has to be wired
separate from the limiter loop. The Alarm will reset automatically as soon as the thermostat
signals heating condition again. However, the heater will be kept off until the temperature has
dropped to the ON set point of the controller. This avoids that the limiter inside the heater has
to be reset manually.
Over Temperature Limiter: The internal temperature limiter is set at 100°C to trip a safety
contact to an open state. This contact can only be reset inside the control box manually.
No Running Oil Pump will turn off or interlock the heater. Insufficient circulation of oil will not
allow a proper temperature reading and would likely cause oil overheating close to the heater
elements.
On-Off Temperature Controller: The temperature sensor in the lubricating system will turn on
and off the heating automatically by given set points.
It will turn off also when the input from pre-limiter is active.
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3.4.2. Electrical External Oil Pump 3250-P2 (I-1011)

The external oil pump is an electrically driven oil pump and used to lubricate the vital
compressor parts before and after compressor operation. The external oil pump is used in
conjunction with the mechanical/crankshaft driven gear oil pump and is mounted on an oil
skid.
The external oil pump control has following functions:
Pre-Lubrication function is active with the oil pump start and takes place before the
compressor can be started. The pre-lubrication default time is 2 minutes. This function is
initiated by the pre-start sequence.
Parallel-Lubrication function is active right after the compressor has been started. During this
function, the external oil pump runs for approximately another 30 seconds4) in order to
maintain the pressure, while the compressor is revving-up to full RPM. Afterwards, it will be
switched off and remain in stand-by. The crankshaft driven gear oil pump will maintain
lubrication during compressor run.
Post-Lubrication function is active right after stopping of the compressor. The external oil
pump will be started after the stop command for the main motor is issued and takes over
lubrication of the compressor parts while the compressor is running down and remains on for
5 minutes.
This function is not active when an emergency stop is issued.
Low Oil Pressure Compensation Run function is needed when the lubricating oil pressure
drops to the low alarm level while the compressor is running. In such a case, the external oil
pump will be started in order to regain a healthy oil pressure. In this condition, the pump will
not switch off automatically to prevent constant on/off situations, while the low oil pressure
problem has not been solved. The 3250-P2 oil pump can be stopped by pressing the ALARM
RESET push button, located on DCS, provided that the oil pressure has returned steady
above 4 barg.
Note: In case of low low lubricating oil pressure detection, the external oil pump will be
tripped immediately and remain off also for the post-lubrication function. In such a case, it
assumed that there is a major leak in the system; hence the operation of the external oil
pump is not allowed to prevent dry running conditions.
3.4.3. Lubricating Oil Filter

Before distributing the oil to parts to be lubricated, it is filtered in a duplex type filter. One
chamber of this filter is in operation and the other is in stand-by (spare). In case the active
cartridge inside a chamber becomes clogged with particles, the filter can be manually
switched over to the spare chamber. This can be done without interrupting the oil flow and
while the compressor is running.
The filter is provided with a differential pressure indicator and a differential pressure
transmitter which generates an alarm at DCS.
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3.5. Coolant System

The open cooling circuit consumers are directly connected to the supply header from client’s
cooling system
The compressor and the heat exchangers on gas system are water cooled. The cooling water is
led to the individual elements through a supply manifold. The return flow of the cooling water
from each cooling element is individually monitored for temperature by temperature gauges.
The cooling water systems is provided with a flow switch (FSL-1572) to sense the flow quantity.
The flow switch is in the starting interlock chain. If the water flow is lower than the minimum
required the machine will not start.
3.6. Main Motor 3250-MK2

A 220 kW, three phase induction motor with squirrel cage rotor, IP 55 type is driving the
compressor at its rated speed.
Temperature sensors for bearing and winding temperatures are provided
Restart Restrictions:
During the start-up of the main motor the windings are heating up more than in the normal
running state. Therefore the time between the main motor start is monitored by the DCS and
shall also be monitored by the Customer’s HVS motor protection relay.
There is a programmable minimum wait time (Relock Time ca. 20min.) used to lock out a
restart of the main motor.
Typical motor max allowed quantity of starts per hour is 3 from cold condition and 2 from
warm condition (always check motor data sheet as the design might differ from standard).
After corresponding 2 or 3 starts of the motor the rotor and stator winding temperatures can
reach its maximum allowed values. Therefore a longer relock time is required before the next
2 starts per hour from the warm condition can be performed. Typical relock time can be
between 3-6 hours for the medium size motors. The cooling down time is counted as 4x the
cooling down constant (can be found on the motor data sheet).
The start interlock “Relock Time” is released whenever the timer has elapsed and the ready
signal from the HVS is received.
For further starting restrictions, consult the main motor manufacturer user manual
and refer also to the pre- & start interlock table.
3.6.1. Anti-Condensation Heater

The anti-condensation heater is installed to avoid condensation within the main motor during
standstill.
Control Description:
The On/Off command is dependent on the main motor run feedback status. It is important
that the anti-condensation heater is powered at all times when the compressor is not running.
The operation of the heater must be interlocked with a running main motor.
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3.7. Compressor
Additional to the vibration transmitter mounted on compressor frame, the following temperature
probes are installed.
3.7.1. Temperature monitoring on piston rod packing

The temperature monitoring will help to detect valve failures or worn out packing/gland rings in
an early stage and scheduling the compressor stop and maintenance work in accordance to the
required availability of the machine.
On each piston rod packing temperature probes (Pt100) will indicate a too high temperature.
3.7.2. Distance piece purging with nitrogen

During operation the compressor distance piece shall be continuously purged with nitrogen in
order to avoid an oxygen concentration >30%. The purge gas will be vented to atmosphere.
At the nitrogen supply line a pressure transmitter (PT-1598) is installed to monitor the pressure.
The low pressure alarm acts as starting interlock. In case the pressure drops during operation to
a too low level the compressor will be tripped.
The installed flow orifice is limiting the purge capacity to about 25 kg/h.
3.7.3. Compressor maintenance operation

For maintenance or piston running in, the compressor can be started with nitrogen
accordingly to the instructions of the responsible Burckhardt service and commissioning
engineer.
For maintenance work, the compressor is running with nitrogen in recycle mode with fully
opened by-pass valve and closed suction and delivery isolating valve.
For safety reasons the compressor shall not be operated with oxygen during
maintenance operation.
Prior to compressor start, all pneumatic operated valves have to be set to manual operation in
DCS.
This shall be done by the function key on the operator panel as follows:
 The recycle valve (PCV-1545) set manually to open position
 The suction isolation valve (XV-1530) set manually to close position
 The delivery isolation valve (XV-1550) set manually to close position
 The vent valve (PCV-1513) set manually to open position
After compressor start, the valve position shall be adjusted manually acc. to the requirements of
the operator and / or the work (eg. running-in pistons with Nitrogen).
For further details refer to the compressor Instruction and Operation Manual!
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VPSA UNIT
Linde Doc. No.: 0012KD9950-C-ZB 2015 Customer Doc. No.: 125 500 837

SPECYFIKACJA TECHNICZNA 3-FAZOWEGO SILNIKA INDUKCYJNEGO
Z WIRNIKIEM KLATKOWYM
TECHNICAL SPECIFICATION OF 3-PHASE INDUCTION MOTOR
ŻYCHLIN WITH SQUIRREL-CAGE ROTOR
1. ` Typ silnika / Motor type Sh450HV10B
2. Moc znamionowa i rodzaj pracy / Rated output and Duty 220 kW, S1
3. Prędkość znamionowa / Rated speed 595 min-1
4. Napięcie i częstotliwość znamionowe / Rated voltage and frequency 10000 V ± 5%, 50 Hz ± 2%
5. Moment znamionowy / Rated torque 3531 Nm
6. Prąd znamionowy / Rated current 18,2 A
7. Współczynnik mocy – przy 100/75/50% obciążenia /Power factor – at 100/75/50% of 0,74/0,68/0,56
8. the load – przy 100/75/50% obciążenia / Efficiency – at 100/75/50% of the load
Sprawność 94,5/94,2/92,9
9. Prąd rozruchowy / Locked-rotor current – Il/IN 5,6
10. Moment rozruchowy / Locked-rotor torque – Tl/TN 1,1
11. Moment maksymalny / Breakdown torque – Tb/TN 2,5
12. Masa / Weight 4050 kg
13. Poziom hałasu bez obciążenia / Sound pressure level at no load 80 dB(A)
14. Temperatura otoczenia / Ambient temperature -25 C ÷ +36 C
15. Wilgotność względna / Relative humidity 95 %
16. Wysokość ustawienia n.p.m / Altitude above sea level 1000 m
17. Forma wykonania mechanicznego / Mounting arrangement IM 1001 (B3)
18. System chłodzenia / Cooling system IC 411
Stopień ochrony – silnika/ skrzynek zaciskowych
19. IP55 / IP55
Degree protection - motor / terminal box
20. Połączenie stojana / Stator circuit Gwiazda / Star
21. Liczba zacisków / Number of terminals 3
22. Sposób zasilania / Method of supply DOL
23. Klasa izolacji / Insulation class F (VPI)
24. Kierunek wirowania / Direction of rotation *) Lewy / CCW
25. Izolowana komora łożyskowa / Insulated bearing chamber NDE
26. Łożyska toczne / Roller bearings:
strona napędowa DE / DE side 6324 MC3
strona przeciwnapędowa NDE / NDE side NU222 EM1
rodzaj smaru / grease Motor life 16N
27. Skrzynka zaciskowa główna / Main terminals box:
usytuowanie / situated on frame u góry kadłuba / on top
ilość wyprowadzeń / number of glands 1
kierunek wylotu kabla / direction of cable outlets *) w stronę NDE / in the NDE side
średnica dławienia / diameter of cable Ø 82,9 mm
28. Skrzynka zaciskowa pomocnicza / Auxiliary terminals box:
usytuowanie na kadłubie / situated on frame u góry kadłuba / on top
ilość otworów / number of holes 3
kierunek wylotu kabla / direction of cable outlets *) na lewą stronę / on the left side
średnica dławienia / diameter of cable Ø 10÷17 mm
29. Skrzynka zaciskowa grzałek / Heaters terminals box:
usytuowanie na kadłubie / situated on frame u góry kadłuba / on top
ilość otworów / number of holes 1
kierunek wylotu kabla / direction of cable outlets *) na lewą stronę / on the left side
średnica dławienia / diameter of cable Ø 10÷17 mm
30. Malowanie / Painting RAL 7035 - klasa/class C5-M
31. Rysunek wymiarowy / Dimensional drawing RZ-449777
32. Normy / Standards EN 60034-1
33. Czujniki temperatury uzwojenia stojana Pt100 3-przewodowe – 6szt. (2szt./fazę)
Windings thermal protection Pt100 3-wire – 6 pcs.(2 pcs./phase)
34. Czujniki temperatury łożysk Pt100 3-przewodowe – 2szt. (1 szt./węzeł łożyskowy)
Bearings thermal protection Pt100 3-wire – 2 pcs. (1 pcs./ bearing)
35. Grzałki antykondensacyjne / Anti-condensation heaters 250W 230V
36. Pomiar drgań / Vibration measurement Kołki SPM / SPM nipples
Uwagi / Note:
1. Lewy kierunek wirowania silnika (patrząc na silnik od strony napędowej), uzyskuje się przyłączając fazy do zacisków w kolejności: L1-U;
L2-W; L3-V (skrzyżowanie faz). / Anticlockwise (left) motor rotation (looking at the motor from drive end) is obtained by connecting phases to
terminals in the following sequence: L1-U; L2-W; L3-V (phase crossing).
Data/Date: Opracował/Prepared by: Sprawdził/Checked by: Zatwierdził/Approved by: Rev.

14-09-2016 r. M. Rybacki E. Jaskuła S. Wojewoda S-160365 04
STATIC AND DYNAMIC LOADS
OBCIĄŻENIA STATYCZNE I DYNAMICZNE
1. DEAD LOAD
(load caused by motor weight / obciążenie pochodzące od masy własnej silnika)
thrust / siła nacisku Fm = 22,1 kN
2. STATIC / Normal Electromagnetic Reaction

(motor’s operation at nominal supply and nominal load / praca silnika przy zasilaniu i obciążeniu
znamionowym)
thrust / siła nacisku Fs1 = 40,9 kN
lifting force / siła podrywania Fs2 = -3,2 kN
3. DYNAMIC
( including impact of electromagnetic moment and rotor imbalance at full phase oposition and 100%
residual voltage / z uwzględnieniem udarowego oddziaływania momentu elektromagnetycznego i
niewyważenia wirnika przy załączeniu na pełną opozycję faz i 100% napięcia resztkowego)
thrust / siła nacisku Fd1 = 92,7 kN
lifting force / siła podrywania Fd2 = 48,5 kN
4. SHORT – CIRCUIT ELECTRMAGNETIC REACTION

thrust / siła nacisku Fz1 = 152,1 kN
lifting force / siła podrywania Fz2 = 108,0 kN
Sh450HV10B
220 kW, 10000 V; 50 Hz; 595 rpm
REV.
E M I T S.A. Document N
o
F – 160365 01
Torque - speed curve of Sh450HV10B
220 kW; 595rmp, 10000V
compressor type: 20200B-1A_1 - starting torque with open bypass valve
T/Tn
2,6
2,4
2,2
1,8
1,6 U=Un
1,4
1,2
0,8 U=80%Un
0,6
0,4
compressor
0,2
0
0 50 100 150 200 250 300 350 400 450 500 550 600
n [rmp]
Prepared by: A. Głowacka Date: 11-05-2016 Sh450HV10B

Checked by: E. Jaskuła Date: 11-05-2016 220 kW; 10000 V ( ); 595 obr/min
EMIT S.A. Dokument No RT-160365A \ Rev. 01
Current - speed curve of Sh450HV10B
220kW; 595rpm; 10000V
compressor type: 20200B-1A_1 - starting torque with open bypass valve
I/In
7
6,5
6 U=Un
5,5
4,5 U=80%Un
3,5
2,5
1,5
0,5
0
0 50 100 150 200 250 300 350 400 450 500 550 600
n [rpm]

EMIT S.A. Dokument No RI-160365A / Rev.01
Speed-time curve of
Sh450HV10B, 220kW, 10000V, 595 rpm motor
n [rpm]
(compressor type: 20200B-1A_1 - starting torque with open bypass valve)
700
600
500
U=Un U=0,8Un
400
300
200
100
0
0 1 2 3 4 5 6 7 8 9
t [s]

EMIT S.A. Dokument No NT-160365
EFFICIENCY-RATED OUTPUT OF
Sh450HV10B, 220kW, 10000V, 595rpm motor
96
95
94
93
EFFICIENCY [%]
92
91
90
89
88
87
0 100 200 300
Pn [kW]

EMIT S.A. Dokument No OE-160365
Schemat zastępczy silnika typu Sh450HV10B /
Equivalent circuit diagram of Sh450HV10B motor
1. Parametry znamionowe silnika Sh450HV10B / Rated motor parameters Sh450HV10B :

PN = 220 kW, UNS = 10000 V (Y), nN = 595 rpm, INS = 17,9 A, cosϕ = 0,75, η = 94,7 %,
Tb/TN=2,5.
2. Parametry schematu zastępczego silnika/ Parameters of the equivalent diagram:
- Rezystancja uzwojenia stojana w temperaturze 20ºC/

Stator winding resistance at 20°C R1 = 4,05 Ω,
- Reaktancja stojana w stanie nasycenia znamionowego/
Stator reactance at rated saturation X1 = 39,87 Ω,
- Rezystancja uzwojenia wirnika w temperaturze pracy, sprowadzona/
Rotor winding resistance at operating temperature, reduced R2’ = 2,543 Ω,
- Reaktancja wirnika w stanie nasycenia znamionowego, sprowadzona/
Rotor reactance at rated saturation, reduced X2’ = 38,71 Ω,
- Rezystancja gałęzi poprzecznej przy obciążeniu znamionowym/
Resistance of transverse branch at rated load RFe= 28590 Ω,
- Reaktancja gałęzi poprzecznej przy obciążeniu znamionowym/
Reactance of transverse branch at rated load Xµ = 584,3 Ω.
11-05-2016
Time constants of Sh450HV10B motor
Parameter
PN UN IN nN Il/IN τ1↑ τ2↑ τ1↓ τ2↓ tr max t z max
Type kW V A rpm - min min min min s s
Sh450HV10B 220 10000 17,9 595 5,6 120 11 450 115 24 6
PN -rated output,
UN -rated voltage
IN - rated current,
nN - rated speed,
Il/IN - starting current,
τ1↑ - heating thermal time constant (for I < 2IB),
τ2↑ - heating thermal time constant of the motor stator windings (for I > 4IB),
τ1↓ - cooling thermal time constant of motor at stationary rotor,
τ2↓ - cooling thermal time constant of motor at coasting,
tr max - permissible starting time,
tz max - maximum time of inhibition of the rotor.
Permissible number of starts: - from cold state 2 / hour,

- from hot state 1 / hour.
Maximum settings for the stator winding protection system
- alert - 140 °C (corresponds to the sensors resistance 153.6 Ω),

- shut-down - 150 °C (corresponds to the sensors resistance 157.3 Ω).
Maximum setting limits for bearings thermal protection:
- alarm - 95 °C ( corresponds with sensor resistance = 136,6 Ω),

- switch off - 100 °C ( corresponds with sensor resistance = 138,5 Ω)
Recommended settings for the stator winding/bearings protection system
- alert - T + 5 °C
- shut-down - T + 10°C
Where T – specified stator winding/ bearings temperature at rated conditions.

MOTOR EQUIPMENT
Connection diagram
The temperature sensor leads are introduced to the auxiliary terminal box and connected to
the terminal strip as per the diagram.
The temperature sensors should be connected with the control wires of the outside diameter
as per the purchase, order entering inside the box through the cable glands.
The temperature sensor connection diagram is placed on the inside of the terminal box cover.
Designation of the terminals:
1 – 2,3
- leads of the U phase Pt100 sensors
4 – 5,6
7 – 8,9 - leads of the V phase Pt100 sensors
10 – 11,12
13 – 14,15 - leads of the W phase Pt100 sensors
16 – 17,18
19 – 20,21 - leads of the Pt100 sensor for the DE side bearing
22 – 23,24 - leads of the Pt100 sensor for the NDE side bearing
R–N - anticondensation heaters
The temperature sensors shall be connected to the system cutting off the power to the motor
when the temperature limit values are exceeded.
The motor manufacturer shall not be liable under the warranty for any motor damage caused
by failure to observe the above requirement.
Page: 1/1 S144/A

Linde Project No.: 2210BDCW Customer P/O No.:
Linde Project Code : GDANSK Customer Project Code.:
Linde Doc. No.: 0012KD9950-E-DE 2015 (EN) Customer Doc. No.:
Linde Item No.: 3250-MK2 Page 1 of 1

Linde Doc. No.: 0012KD9950-E-DE 2015 Customer Doc. No.:
(EN) Linde Item No.: 3250-MK2 Page 1 of 1

Linde Doc. No.: 0012KD9950-E-DE 2015 Customer Doc. No.:
Linde Item No.: 3250-MK2 Page 1 of 1

Linde Doc. No.: 0012YYZZZZ-X-YY ZZZZ Customer Doc. No.:

Produktions-Stückliste
Fert.-Artikel 1X30110792-B Datum 29.07.2016

VULASTIK L Seite 1
Zeichnung 1X30100792 gedruckt von SEEGER
Pos. Menge Materialnummer Bezeichnung Abmessungen Werkstoff Bemerkung LV
1 1 4X3004003M-B Mantel FM 470 X 406.5 X 101 G-AlSi7Mg-T64/VS-07-0603
4 1 4X3020336M-B Nabe FM 220 X 110 X 210 42CrMo4+QT
6 1 2X3011A004 VULASTIK L Element 3011 St/Gummi
7 16 7010416050 Zylinderschraube M 16 X 50 10.9 912M
8 16 7033616000 Unterlegscheibe FM 27 X 16.2 X 4.5 10.9
12 1 3X3016030M-B Tellerflansch FM 475 X 160 X 38 C45+N
13 1 4X3031043M-B Doppelflansch FM 220 X 135 X 296 42CrMo4+QT
15 12 7000112150 Sechskantschraube M 12 X150 10.9 931M
16 12 7020112000 Sechskantmutter M 12 10 934
17 24 3X26210000 Scheibe FM 26 X 12.1 X 4 42CrMo4V EN 10083-1 EN 10083-1
19 1 4X3031044M-B Anschlussflansch FM 380 X 135 X 33 42CrMo4+QT

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)
Allocation Table Crankgear Lubrication 1001300
Lubrication of Closed (Pressure-Resistant) Labyrinth Piston

Compressors
Area of Application
®
This specification applies to the lubrication of closed BCA labyrinth piston compressors (Laby ).
General
Due to solubility and/or chemical reaction issues, certain gases necessitate the application of especially suited types of
lubricating oils. These interactions depend on the temperature and the pressure. For the temperature, a value of 40–50 °C
(typical oil sump temperature) is assumed, the usual pressures are covered by the allocation table below.
Allocation Table
MO Mineral oil according to “Lubrication Oil Specification” (VSB) 1001132.
PAG Polyalkylene glycol according to “Lubrication Oil Specification” (VSB) 1001301.
! Refer to Burckhardt Compression AG (Dept. TSi).
X Not admissible
Suction pressure 1 2 3 4 6 10 Remarks

[bar a]
Gas
Methane CH4
MO MO MO MO MO MO
Ethane C2H6
PAG PAG PAG PAG PAG PAG
Ethylene C2H4
MO MO MO For refrigeration applications use special propane
Propane C3H8 PAG X X
PAG PAG PAG refrigeration oils
MO MO
Butane C4H10 PAG X X X
PAG PAG
MO MO MO MO
Propylene (Propene) C3H6 PAG X
PAG PAG PAG PAG
Butylene C4H8 PAG PAG X X X X
MO
Butadiene C4H6 PAG X X X X
PAG
MO
Vinyl chloride (VCM) PAG X X X X
PAG
Dimethyl ether (DME) MO MO
MO X X X No operation experience (02/2003)
(CH3)O(CH3) PAG PAG
Reacts with certain additives
Ammonia NH3 ! ! ! ! ! !
Check suitability of the product used
Carbon monoxide CO MO MO MO MO MO MO
Carbon dioxide CO2 MO MO MO MO MO MO
Air, nitrogen, noble gases MO MO MO MO MO MO
Sulphur dioxide SO2 ! ! ! ! ! !
Hydrogen sulphide H2S ! ! ! ! ! ! Special oils available (corrosion protection)
Chlorine Cl2 ! ! ! ! ! !
Helium He MO MO MO MO MO MO
Gases and pressures not listed: Check with Burckhardt Compression AG or oil manufacturers.
Rev. Dat. Sig. Ersatz für

Erstellt / Prepared 29.06.2016 ARZTMANN_R Replacement for Seite 1 von 1
Überprüft / Reviewed C 29.06.2016 KAUFMANN_W Revision Page 1 of 1
Freigabe / Approval DVS 29.06.2016 CRUZ_R vom / date
Revision
(VSB)
Crankgear Lubrication Mineral Oil 1001132
This specification applies to BCA compressors with the crankgear lubricated with mineral oil.
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 containing additives to increase
corrosion protection and aging resistance.
Note: There are no corresponding ISO standards to these categories.
Other lubricating oil categories (VBL, VCL, VDL, L-TD, HL according to DIN 51 502 or L-DAB, L-DAC, L-DAG, L-DAH, L-TSA,
L-TGA, L-TGB, L-HH, L-HL, L-HM, L-HR, L-HV according to ISO 6743-X) are admissible if they meet the following requirements
stated below.
Only lubricating oils FREE of zinc dialkyl dithiophosphate (ZDDP, ZDTP, ZDP) may be used!
Requirements
Parameter Value Unit DIN ISO

Viscosity class VG 150 (kin. Viscosity 150mm²/s ± 10% at 40 °C) - 51 519 3448
Density at 15 °C Report kg/m³ 51 757
The sump and/or inlet temperature must be between +5 °C and +60 °C.
The use of lubricating oils that differ in particular points from these requirements must be cleared with Burckhardt
Compression AG.
Burckhardt Compression AG does not assume any responsibility for the quality and properties of the sub-
supplied lubricating oils.
Further relevant BCA specifications etc.:
MI-76en Safe Handling of Lubricants
VSB 1001135 Selection List
Rev. Dat. Sig. Ersatz für 1001132

Erstellt / Prepared 16.10.2014 KAUFMANN_W Replacement for Seite 1 von 1
Überprüft / Reviewed B 17.10.2014 CRUZ_R Revision 0 Page 1 of 1
Freigabe / Approval DVS 25.11.2014 ARZTMANN_R vom / date 07.05.2004
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 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
Castrol Magna 150 150 C
Castrol Magna CT 150 150 CL
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
Further relevant BCAG specifications etc.:
Rev. Dat. Sig. Ersatz für 1001135

Überprüft / Reviewed H 06.10.2016 ARZTMANN_R Revision G Page 1 of 1
Freigabe / Approval DVS 06.10.2016 CRUZ_R vom / date 08.01.2015
Revision
(VSB)
Laby® Polyalkylene Glycol Lubricants 1001301
®
This specification applies to BCAG labyrinth compressors (Laby ) that are lubricated with polyalkylene glycol (PAG) according
to “Lubricating Oil Specifications” (VSB) 1001300.
General
Hydrocarbons and other process gases dissolve to an appreciable degree in mineral oils. The resulting drop in viscosity and the
formation of foam with fluctuating suction pressures can cause operating failures. For polyalkylene glycol, the solubility is much
lower and, therefore, lubricating oils on polyalkylene glycol basis are preferably used to compress these gases.
Lubricant Category
Synthetic lubricating liquids on polyalkylene glycol basis (PAG, polyglycol), especially formulated for the use in gas
compressors.
Note: There are no DIN or ISO standard for these lubricants
Caution!
Gear lubricants on a polyalkylene glycol basis have different properties and must not be used in BCAG gas compressors!
Polyalkylene glycol based lubricants are hygroscopic, i.e. they attract humidity from the air. Therefore, contact with ambient air
should be kept to a minimum.
Requirements
Parameter Value Unit DIN ISO

Viscosity at 40 °C 120 – 200 mm²/s 51 519 3448
Density at 15 °C Report kg/m³ 51 757
The sump and/or inlet temperature must be between +5 °C and +60 °C.
The use of lubricating oils that differ in particular points form these requirements must be cleared with Burckhardt
Compression AG.
Further relevant BCA specifications etc.:
VSB 1001302 Selection List

Überprüft / Reviewed C 06.10.2016 ARZTMANN_R Revision Page 1 of 1
Revision
(VSB)
Laby® Polyalkylene Glycol Lubricants 1001302
General
This list contains a selection of lubricants on polyalkylene glycol basis (PAG) for compressors. The order is according to
manufacturer’s and/or brand names. It is intended for the use with the “Lubricating Oil Specification” (VSB) 1001301.

Synthetic lubricants on polyalkylene glycol basis (PAG, polyglycol), especially formulated for the use in hydrocarbon
compressors, with additives to increase the corrosion protection and the aging resistance.
Note: There are no DIN or ISO standards for these lubricants
Kinemat.
Brand Name Remarks
viscosity
at 40 °C
[mm²/s]
Anderol ROYCO 889 132.6

®
BASF SE Plurasafe CL Gas 9 185 ex Cognis
Castrol Aircol PG 185 185
Chevron/Texaco LPG Compressor Oil 185
ExxonMobil Gas Compressor Oil 175
Fuchs Renolin LPG 185
®
GEOlube LPG9 185
Gulf Marine GulfSea Synth LPG Compressor Oil 150
Klüber Summit PGS-2 150
Setral COVA-setral-PGB/G 190 185
Shell Gas Compressor Oil S4 PV 190 190
®
Shrieve Progiline LPG-WS 164
Total DACNIS LPG 150 141
Total Lubmarine PRIMERIA LPG 150 141
Further relevant BCAG specifications etc.:

Überprüft / Reviewed H 30.09.2016 ARZTMANN_R Revision Page 1 of 1
Plant
LINDE GDANSK
List of Instruments Project No.
2001904
It must not be copied, reproduced, or in any way communicated, or made accessible to third parties, without our written consent!
This drawing is entrusted to the recipient personally, but the copyright remains with us!
Contract Engineer Tel. No. Dept. Client

S. Manfredini +390399636808 BCIT Linde AG
Ex-Protection
Safe Area
I&C Engineer Tel. No. Dept. Item No.
P. Kohler 2 55 83 CO30 Final 3250-K2
Compressor Type Gas
2D200B-1A_1 O2+
Serial No.
102609
P&I DIAGRAMS
2053936
REV. INDEX C GAS SYSTEM 0-125.500.755

PREPARED 13.09.2016 KOHLER_P OIL SYSTEM 0-125.500.756
REVIEWED 14.09.2016 MANFREDINI_S COOLANT SYSTEM 0-125.500.757
Doc No. 2053936
APPROVED 14.09.2016 KOHLER_P CAPACITY SYSTEM Page 1 of 11
Compressor Type Plant
2D200B-1A_1
List of Instruments LINDE GDANSK
Serial No. Item No. Client Project No.
102609 3250-K2 Linde AG 2001904
Function Code Function Description

IND Indication
HH HH-Alarm
H H-Alarm
L L-Alarm
LL LL-Alarm
SI Startinterlock Compressor
SD Process Trip Compressor
I-1011 Interlock Oil Pump
I-1076 Suction Isolation Valve Open/Close
I-1077 Delivery Isolation Valve Open/Close
I-1056 Controlled Bypass Valve overall
I-1057 Fast Close Bypass overall
I-1058 Control of Vent Valve
I-1059 Fast Open of Vent Valve
REV. INDEX C
PREPARED 13.09.2016 KOHLER_P Function Index
REVIEWED 14.09.2016 MANFREDINI_S Page 2 von 11
APPROVED 14.09.2016 KOHLER_P 2053936
2D200B-1A_1
102609 3250-K2 Linde AG 2001904
X) Primary Destination
Description of Kind of Operating Electrical Data Sheet
SIL (Instr.)
Delivered
Scale Range Signalisation and Setpoints x) Advanced Destination Manufacturer
Footnotes
Measuring Point Instrument Value (O2+) Connection Document No.
Revision
#) Common Signal
Tag No
Location of Input/Output Operating Value Value Instrument
Ex-Protection Function LOP DCS ESD Type Comments
Instrument Signal Value (-) (O2+) (-) Connection
0 = not IND open X
Open Position
Limit Switch Opened SI not open X TOP WORX M20x1.5 122F81985
Separator Drain Valve
ZSH-1530 1 = Opened C
on Valve - SPDT DXP-L21GSMB
Close Position 0 = not Closed IND close X

Limit Switch TOP WORX M20x1.5 122F81985
Suction Isolating Valve 1 = Closed
ZSL-1530 C
Suction Isolating 0 = De-Energ. SD / I-1076 operation X

Solenoid Valve Asco M20x1.5 122F81985
Valve 1 = Energized
XX-1530 C
on Valve - 24V DC 8316G4MB ¼" NPT (F)
Control I-1056 operation X

I-P Converter 0 ... 100% METSO M20x1.5 122F81985
Bypass Overall
PY-1545 C
on Valve - 4..20mA ND9106HNT -
Position Feedback Feedback I-P IND 0 ... 100 X

0 ... 100% SI <95 X METSO M20x1.5 122F81985
Bypass Overall Converter
ZT-1545 C
on Valve - 4..20mA ND9106HNT -
Fast Close 0 = De-Energ. I-1057 operation X

Bypass Overall 1 = Energized
XX-1545 C
on Valve - 24V DC NF8327B211 ¼" NPT (F)
Suction Pressure Pressure IND -1 ... 2 X

-1 ... +2 bar g 0.1 ... 0.5 bar g H 0,75 X Emerson Process M20x1.5 TSP 2054520
1st Stage Transmitter
PT-1514 L / SI 0,1 X A
on Gas Pipe - 4..20mA LL / SD 0,05 X x 2051T G ½" (F)
Suction Temperature IND -50 ... +250 X

Pt100 -50 ... +250 °C 25 ... 55 °C H 56 X Emerson Process M20x1.5 TSP 2054525
1st Stage
TE-1514 B
on Gas Pipe - Ohm Series 65 G ½" (M)
REV. INDEX C Footnotes

PREPARED 13.09.2016 KOHLER_P Suction 1st Stage
REVIEWED 14.09.2016 MANFREDINI_S Page 3 of 11
2D200B-1A_1
102609 3250-K2 Linde AG 2001904
SIL (Instr.)
Delivered
Footnotes
Revision
#) Common Signal
Tag No
0 = not IND open X
Open Position
Suction Pressure Limit Switch
Pressure Gauge -1Opened
... +3 bar g 0.1 ... 0.5 bar g TOP WORX
Nuova Fima M20x1.5
- 122F81985
TSP 2054523
Separator Drain Valve
1st Stage
PI-1516 A
on Compressor - - MGS20 G ½" (M)

PREPARED 13.09.2016 KOHLER_P Suction 1st Stage
2D200B-1A_1
102609 3250-K2 Linde AG 2001904
SIL (Instr.)
Delivered
Footnotes
Revision
#) Common Signal
Tag No
Discharge Pressure
Pressure Gauge 0 ... 6 bar g 3.1 ... 4.1 bar g Nuova Fima - TSP 2054523
1st Stage
PI-1517 A
Discharge Temp. IND -50 ... +250 X

Pt100 -50 ... +250 °C 132 ... 186°C HH / SD 200 X Emerson Process M20x1.5 TSP 2054525
1st Stage
TE-1515 H 194 X x B

PREPARED 13.09.2016 KOHLER_P Discharge 1st Stage
2D200B-1A_1
102609 3250-K2 Linde AG 2001904
SIL (Instr.)
Delivered
Footnotes
Revision
#) Common Signal
Tag No
IND -50 ... +250 X
Delivery Temperature Pt100 -50 ... +250 °C 45°C HH / SD 65 X x Emerson Process M20x1.5 TSP 2054525
TE-1537 H 60 X B
Pressure IND 0 ... 10 X

Delivery Pressure 0 ... 10 bar g 3.3 bar g HH / SD 4,2 X x Emerson Process M20x1.5 TSP 2054520
Transmitter
PT-1534 H 3,7 X A
on Gas Pipe - 4..20mA 2051T G ½" (F)
Position Feedback Feedback I-P IND 0 ... 100 X

0 ... 100% METSO M20x1.5 122F81985
Vent Valve Converter
ZT-1513 C
on Valve - 4..20mA ND9106HNT
Control I-1058 0 ... 100 X

I-P Converter 0 ... 100% METSO M20x1.5 122F81985
Vent Valve
PY-1513 C
on Valve - 4..20mA ND9106HNT
Fast Open 0 = De-Energ. I-1059 operation X

Vent Valve 1 = Energized
XX-1513 C
on Valve - 24V DC 8316G4MB ¼" NPT (F)
0 = not IND open X
Open Position
Limit Switch Opened TOP WORX M20x1.5 122F81985
Delivery Isolating Valve
Close Position 0 = not Closed IND close X

Limit Switch TOP WORX M20x1.5 122F81985
Delivery Isolating Valve 1 = Closed
ZSL-1550 C
Delivery 0 = De-Energ. I-1077 operation X

Isolating Valve 1 = Energized
XX-1550 C
on Valve - 24V DC 8316G4MB 2 x ½" NPT (F)

PREPARED 13.09.2016 KOHLER_P Delivery
2D200B-1A_1
102609 3250-K2 Linde AG 2001904
SIL (Instr.)
Delivered
Footnotes
Revision
#) Common Signal
Tag No
Ex-Protection Function Type Comments
Instrument Signal Value (###) (O2+) (###) Connection
Pressure IND 0 ... 10 X

Purge Gas Pressure 0 ... 10 bar g 5 ... 7 bar g L / SI 4,5 X Emerson Process M20x1.5 TSP 2054520
Transmitter
PT-1598 LL / SD 4,0 X A
on Purge Pipe - 4..20mA 2051T G ½" (F)

PREPARED 13.09.2016 KOHLER_P Purge Gas System
2D200B-1A_1
102609 3250-K2 Linde AG 2001904
SIL (Instr.)
Delivered
Footnotes
Revision
#) Common Signal
Tag No
Packing Temperature IND -50 ... +250 X

Pt100 -50 ... +250 °C 20 ... 50°C H X BCAG Direct Cabling TSP 2054526
Cylinder 1
TE-1518 B
on Compressor - Ohm A-1044/26e G ¼" (M)
Packing Temperature IND -50 ... +250 X

Pt100 -50 ... +250 °C 20 ... 50°C H X BCAG Direct Cabling TSP 2054526
Cylinder 2
TE-1519 B
on Compressor - Ohm A-1044/26e G ¼" (M)
Vibration IND 0 ... 10 X Cabling

Frame Vibration 0 ... 10 g rms < 3 g peak HH / SD 4 X Holthausen TSP 2054524
Transmitter with Plug
VT-1561 H 3 X C
on Compressor - 4..20mA ESW-small-Ex2241 M8x1.25 (M)
Flywheel Guard 0 = Uncovered IND / SI OPEN X

Limit Switch Pepperl + Fuchs Direct Cabling TSP 2054528
Position 1 = Covered
ZSO-1598 C
on Compressor - NAMUR NCB10 M30x1,5 (M)

PREPARED 13.09.2016 KOHLER_P Instruments on Compressor
2D200B-1A_1
102609 3250-K2 Linde AG 2001904
SIL (Instr.)
Delivered
Footnotes
Measuring Point Instrument Value (Oil) Connection Document No.
Revision
#) Common Signal
Tag No
Instrument Signal Value (-) (Oil) (-) Connection
Level in Crankcase Level Gauge - BCAG -

LG-1561
Manufacture
on Compressor - -
Standard
Pressure after
Pressure Gauge 0 ... 10 bar g 3.5 bar g Nuova Fima - TSP 2054523
Main Oil Pump
PI-1568 A
Pressure after
Pressure Gauge 0 ... 10 bar g 3.5 bar g Nuova Fima - TSP 2054523
el. Oil Pump
PI-1569 A
on Oil Pipe - - MGS20 G ½" (M)
Differential Pressure Differential

Boll & Kirch - 2054919
Oil Filter Pressure Gauge
PDI-1548 C
on Filter - - BF G ½" (F)
Pressure IND 0 10 X
Pressure Oil System 0 ... 10 bar g 3.5 bar g L / SI / I-1011 2,5 X Emerson Process M20x1.5 TSP 2054520
Transmitter
PT-1566 LL / SD 2 X x A
on Oil Pipe - 4..20mA 2051T G ½" (F)
Temperature after IND -50 ... +250 X

Pt100 -50 ... +250 °C 45 ... 55 °C H 55 X Emerson Process M20x1.5 TSP 2054525
Oil Filter
TE-1566 L / SI 15 X B
on Oil Pipe - Ohm Series 65 G ½" (M)
Oil Temperature Temperature H 1 X

- FATI M20x1.5 122F82077
Control Controller
TSH-1564 C
inside Heater - 24V DC TG-200 -
Oil Temperature Temperature HH 1 X

- FATI M20x1.5 122F82077
Control Limiter
TSHH-1564 C
inside Heater - 24V DC TG -

PREPARED 13.09.2016 KOHLER_P Lube Oil System
2D200B-1A_1
102609 3250-K2 Linde AG 2001904
SIL (Instr.)
Delivered
Footnotes
Measuring Point Instrument Value (Water) Connection Document No.
Revision
#) Common Signal
Tag No
Instrument Signal Value (-) (Water) (-) Connection
Coolant Return Temperature

0 ... 80 °C 30 ... 33 °C Nuova Fima - TSP 2054529
Temperature Gauge
TI-1572 A
on Water Pipe - - TB8 G ½" (M)

0 ... 80 °C 30 ... 33 °C Nuova Fima - TSP 2054529
Temperature Gauge
TI-1573 A

0 ... 80 °C 30 ... 33 °C Nuova Fima - TSP 2054529
Temperature Gauge
TI-1574 A

0 ... 80 °C 30 ... 33 °C Nuova Fima - TSP 2054529
Temperature Gauge
TI-1577 A
L / SI 1 X
Coolant Return Flow Flow Switch 0/1 Endress + Hauser M20x1.5 TSP 2054523
FSL-1572 C
on Water Pipe - SPST (NO) ATT 11 ¾" NPT (M)

PREPARED 13.09.2016 KOHLER_P Cooling System
2D200B-1A_1
102609 3250-K2 Linde AG 2001904
SIL (Instr.)
Delivered
Footnotes
Measuring Point Instrument Value (-) Connection Document No.
Revision
#) Common Signal
Tag No
Instrument Signal Value (-) (-) (-) Connection
Main Motor Bearing IND -50 ... +250 °C X

Pt100 -50 ... +250 °C HH / SD 120 X x Cantoni -
NDE Temperature
TE-1581-8 H / SI 110 X C
on Motor Bearing
- Ohm TOP-PKbm-32 -
NDE
Motor Winding IND -50 ... +250 °C X
Temperature
TE-1581-1 H / SI 135 X B
inside Motor - Ohm TOP-OP-30 -

Temperature
TE-1581-3 H / SI 135 X B

Temperature
TE-1581-5 H / SI 135 X B
Main Motor Bearing IND -50 ... +250 °C X

DE Temperature
TE-1581-7 H / SI 110 X C
on Motor Bearing
- Ohm TOP-PKbm-32 -
DE

PREPARED 13.09.2016 KOHLER_P Main Motor
A No further submission.
Document accepted as final.
P Incorporate comments and

resubmit document.
X Document is rejected.
Requirements of purchase
order are not fulfilled.
Permission to proceed does not constituate acceptance or
approval of design details, calculations, analysis, test methods
or materials developed or selected by the supplier and does not
relieve supplier from full compliance with specifications and
contractual obligations.
Linde Engineering
Date Dept.
Signature
GDANSK
VPSA UNIT

A No further submission.
Document accepted as final.
P I ncorporate comments and

resubmit document.
X Document is rejected.
Requirements of purchase
order are not fulfilled.
Permission to proceed does not constituate acceptance or
approval of design details, calculations, analysis, test methods
or materials developed or selected by the supplier and does not
relieve supplier from full compliance with specifications and
contractual obligations.
Linde Engineering
Date Dept.
Signature
GDANSK
VPSA UNIT

Spieltabelle
Clearance table
Stufe **) Alle Masse in mm
clearance after
Projektauftrag Nr. 2001904 Stage All dimesnions in mm
operation at
Etage Position Toutes dimensions en mm
Stadio Tutte le dimensione en mm
site
Kompressor-Typ 2D200B-1A_1 Etapa Todas las dimenciones en mm
ø Min. Total Max. Total Max. Allow.
1) I A1+A2 400 0.4 0.537 1.2
1) II - - - - -
1) III - - - - -
1) IV - - - - -
*) B 75 0.05 0.089 0.15
***) C 100 0.08 0.137 0.2
***) - - - - - -
*) D 250 0.07 0.128 0.17
*)
Konus
E 150 0.09 0.17 0.23
2)/3) V1+V2 a 7 7.5
- a - -
- a - -
- a - -
b 1.5 2
c 0.05 0.135 0.2
- - - - -
e - - -
*) F 150 0.095 0.145 0.21
*) G - - - -
I I *) H 150 0.095 0.145 0.21
K - - - -
f 2 - -
g - - -
h 1 - -
k - - -
1.) -If pistons are not run-in in our shop
piston clearances can be less as follows:
A1+A2 min. allow. = 0.25 mm
- min. allow. = - mm
-Max piston clearance after running in procedure:
A1+A2 max. allow. = 0.70 mm
- max. allow. = - mm
(material and discharge temp. Considered)
2.) Min. allow. for b = 1.4 mm
a+b shall not exceed for
V1+V2 Stage = 9.50 mm
- Stage = - mm
- Stage = - mm
- Stage = - mm
a,b = highest resp. Lowest part is relevant
(piston plate, skirt, rod, nut)
3.) mit Schadraumring / with Spacer Ring
*) Wenn Spiele mit Fühlerlehre gemessen, können obige Spiele wie folgt kleiner sein:
min. < 0.1 mm = 0.01 mm und min. > 0.1 mm = 0.015 mm
If clearances measured by feeler gauges, the above values can be less as follows:
min. < 0.1 mm = 0.01 mm and min. > 0.1 mm = 0.015 mm
KW-Lager Schubst.-Lager offen **) Bemerkungen und Beschreibungen siehe im Bedienungshandbuch

Dünnwandlager X Remarks and descriptions see Instruction Manual
Dickwandlager X ***) Mit Fühlerlehre gemessen
Galvanisiertes Lager Measured by feeler gauges
Gestell X
KK-Zapfenlager gasdicht druckfest Spieltabelle für ölfreie Laby-Kompressoren (Zeichnungsmasse)
Dünnwandlager Clearance table for oilfree laby-compressor (Dimensions on drawing)
Dickwandlager X Tableau des jeux de compresseur a piston sec (Dimensions du dessin)
Galvanisiertes Lager Tavola die giochi del compressore a pistone secco (Dimensioni di disegno)
Gestell Tabla de juegos del compresor de piston seco (medidas sequn dibujo)
REV. INDEX DOK.-No.
2054510
ERSTELLT / PREPARED 24.03.2016 DUX_P (TDO)
GEPRUEFT / REVIEWED 17.05.2016 MAURER_S SEITE / PAGE 1
FREIGABE DVS / RELEASE DVS 17.05.2016 MAURER_S ST / 14.01.2014 / rev. 0 VON / OF 1

TIGHTENING TORQUES 2D200B-1A_1
Projekt-No: 2001904
Pos Bolt / Location Dimension Material Method Torque Angle

001* Cylinder cover
st
-1 1 stage M20 x 99 A193 B16 II 240 - 270 Nm 20 - 30°
002* Pipe connection gas piping

st
-1 1 stage M20 x 109 A193 B16 II 240 - 270 Nm
003* Valve cover

st
-1 1 stage M16 x 77 A193 B16 II 120 - 150 Nm
-11 pressure bolt suction R3/8” x 80 34CrMo4 II 30 Nm
-12 pressure bolt discharge R3/8” x 80 34CrMo4 II 20 Nm
004* Piston nut G1 ¾” 1.7225-B7 V 37Nm

005* Piston rod packing M20 x 99 A193 B16 II 240 – 270 Nm
006* Frame - Cylinder M24 x 124 A193 B16 II § 400 - 450 Nm 20 - 30°
007** Piston rod - crosshead - - - -
008** Connecting rod M36 x 3 x 265 34CrNiMo6 IV § ∆l =0.30 – 0.36 mm
009** Main bearing cover - - - -
010** Frame - base plate - - - -
011** Foundation bolt - - - -
012** Cover plate pumpside M20 x 70 8.8 II 240 - 270 Nm
013** Cover plate flywheelside M20 x 65 8.8 II 240 - 270 Nm
014** Coupling bolts M24 x 280 34CrMo4+QT II 300 - 400 Nm
015** Tensioning bolts M20 x 144 A193 B16 II 150 - 200 Nm
016** Counterweight M30 x 123 A193 B16 VI 750 – 800Nm
017** Frame cover plate
-1 Frame cover M12 x 30 8.8 II 50 - 60 Nm
-2 Plexiglas frame cover M12 x 25 8.8 II 25 - 28 Nm
018** Guide bearing M16 x 40 8.8 II 120 - 150 Nm
§= The proper tightness of the bolt connections marked with § must be checked periodically. Lubricate all bolt connections.
* Lubricate the bolts at the cylinder with Burckhardt Lubrication Grease BLG05.
** Lubricate the bolts at the frame and at the base plate with Molykote® G-N PLUS.
*** To obtain specified pretension tightening procedure must be repeated 3 times.
Lubricate all the other bolt connections according to the instructions, stated in data sheet MBN 0707.
# After tightening - an even, measurable gap around the entire periphery of the cylinder - cylinder cover connection must
be present
DOK.-NR.:
REV. INDEX
(TDO)
2054572
ERSTELLT / PREPARED 29.03.2016 DUX_P
UEBERPRUEFT / REVIEWED 13.05.2016 STUDER_A Design-Version: 21 SEITE / PAGE 1

GENEHMIGT / APPROVED 13.05.2016 STUDER_A SW / 11-04-00 / rev. 0 VON / OF 1
Tightening torques
Anzugsdrehmomente 2D200B-1A_1
001-1 003-12
003-1
002-1
003-11
005
006
018
017
013
014
012 017
015
008
016
CO20/gvs 01.12.2016 TIM-ID 59730 Rev. 001

Index
14 Index
3 chemical cleaning 10-12

3-piece pistons 4-23 degreasing with solvent vapor 10-13
flushing 10-12
A
immersion 10-12
Absorbent agent 5-82, 11-4
mechanical cleaning 10-11
Acids 2-9
spraying 10-12
Actuator 4-6, 4-28, 4-29
ultrasonic cleaning 10-13
Address 1-6
wiping 10-12
Algae 8-22
Cleaning methods 10-11
Align electric motor 9-73
Cleaning of compressor plant 2-12
API 618 4-26
Cleaning specification 10-3
API standard 1-6
Cleansing agent 10-8
Argon 2-17
Clearance pocket control 4-30
Assemble compressor components 9-1
Commissioning 6-4
Assemble coupling 9-75
Commissioning after maintenance 2-14
Assemble cylinder 9-55
Compressor
Assemble electric motor 9-71
design data 6-3
Assemble gear oil pump 9-71
overview 4-3
Assess vibrations 5-77
Compressor designation 1-5
B Compressor maintenance 2-13
BAM oxygen approval 10-7 Compressor operation 2-11
Bearing Compressor skid
center 4-13 unload 5-7
main 4-9, 4-11, 4-13 Connecting rod 4-14, 9-64
Bearing bracket 9-82 Connecting rod bearing 4-15, 8-37, 8-38, 9-61
Black light inspection 10-14 Control elements 3-10
Brands 1-10 Controlled suction valves 4-29
Breather 3-12 Cooling system 3-6, 8-21
Burckhardt Plate Valve™ 4-25, 4-26, 9-13 Copyright 1-3
Burckhardt Poppet Valve™ 4-25, 4-27 Counterweights 4-12
Bypass 3-5 Coupling 9-75, 9-75
Bypass control 4-30 Crankcase 4-8
C Crankgear 4-7, 8-35
Calcium carbonate deposits 8-22 Crankshaft 4-12
Capacity control 4-28 rotating masses 4-12
CE conformity 2-3 Crankshaft main bearing 8-37
Check crankshaft deflection 8-35, 9-74, 9-80 Crankshaft seal 4-9, 8-38, 9-81
Check fabrication 5-35 Crosshead 4-14, 4-15, 8-40, 9-64
Checks after liquid knock 8-42 lubrication 4-15
Chemical handling 2-8 reciprocating movement 4-7, 4-12
Clean compressor plant 8-8 Crosshead pin bearing 4-15, 8-41, 9-66, 9-68
Clean piston rod 6-9, 8-43 Crosshead seizure 3-6
Cleaned for oxygen service 10-4 Crosshead-piston rod connection 8-40
Cleaning Cylinder 4-19, 8-43, 9-54
inspection methods 10-13 configuration 4-19
materials and auxiliary supplies 10-7 water cooled 4-19
tools and facility 10-7 Cylinder clearance 4-24
working environment 10-6 measurement 8-52
workplace 10-7 Cylinder cover 9-24
Cleaning method Cylinder head 4-19

Index
D check cleanliness 5-70

Definitions for this document 1-1 Gear oil pump 4-10, 9-70
Deposits 3-7 General design and function of compressors 4-1
Deposits of sand 8-23 Gland ring
Depressurize plant 8-7 1-piece 4-20
Dimensions 5-10, 8-27 3-piece 4-20
Direct visual inspection 10-13 Grounding wire 5-66
Discharge pressure 6-3 Grout Foundation Bolts 5-25
Discharge valve 4-25 Grout supporting surface of skid 5-29
Discharge valves 8-61, 9-10 Grouting Material 5-20
Disclaimer 1-3 Guide bearing 4-16, 8-42, 9-60
Dismantle and assemble bearing bracket and main bearing bush 4-16
bearing 9-82 crown ring 4-16
Dismantle and assemble oil trap and crankshaft lubrication 4-16
seal 9-81 Guide bearing bush 9-57
Dismantle compressor components 9-1 Guide bearing clearance check 8-42
Dismantle coupling 9-75 Guidelines for oxygen plant 8-3
Dismantle crankshaft sidewards 9-83 H
Dismantle cylinder 9-54
Hazard area 6-7
Dismantle electric motor 9-71 Hazard identification diamond 2-15
Dismantle gear oil pump 9-70 Hazard seriousness 1-8
Dismantle guide bearing 9-60
caution 3-4
Dismantle guide bearing bush 9-57 danger 1-8
Disposal 11-6 warning 1-8, 5-22
Dispose components 11-6
HD Laby® piston 4-19
Distance piece 4-18 HD Laby® pistons 4-23
Drain lubricating oil 9-27
Drive end 4-9 I
Drive system 3-3 Importance of cleanliness 5-3
Important notes 5-3
E
Inspect compressor plant 5-80
Electric motor 9-71, 9-71 Inspection with mirror and endoscope 10-13
Electric motor rating 6-3 Install compressor skid 5-22
Electrical hazard 2-6
Install pipe work 5-31
Electrical installation 5-66 Installation 5-1
Electrical motor and coupling 8-19 Instruction Manual
Emergency stop 3-11
applicability 1-4
External gas pipes 9-53 document structure 1-6
F revision sheets 1-3
Fabricate piping 5-32 symbols 1-8
Failed piston 8-49 target group 1-4
Fine-tuning adjustment 5-28 warnings 1-8
Fire protecting wall 3-13 Intended use 2-11
Flange connections 8-20 Intermediate ring 4-20
Flywheel 9-77 Internal leak gas pipes 9-49
Flywheel guard 3-13 dismantle and assemble 9-49
Foundation 5-18
J
Frame covers 9-26 Jackscrews 5-22
dismantle and assemble 9-26
L
G Labyrinth sealing system 4-3, 4-23
Gas Cooler 3-5 Lantern 4-25
Gas specification 2-15
Legal regulation 2-3
Gas system 3-4, 8-19 Level compressor skid 5-24

Index
Level indicator 3-13 Oil heater 4-11, 8-24, 9-29

LIB 3-10 Oil level switch 4-11
Lift compressor 5-13 Oil pressure 4-11
Lift compressor skid 5-15 Oil quality 8-34
Lift cylinder 5-14 Oil quantity 8-32
Lift plant components 5-16 Oil reservoir 4-5, 4-8
Lifting procedure 5-12 Oil return 4-17
Local instrument board LIB 3-10 Oil scraper 4-16, 4-17
LOCTITE® 8-30 Oil scrapers 9-56
Lubricant handling 2-7 dismantle and assemble 9-56
Lubricants 10-8 Oil shield 4-17, 4-18, 4-23
Lubricating oil Oil sight glass 4-8, 9-31
distribution 4-10, 4-13 Oil specifications 8-34
drain and refill 9-27 Oil strainer 4-11, 9-30
Lubricating system 3-8, 8-24 Oil syphon 4-8, 4-17
components 9-28 Oil trap 9-81
instrumentation 8-24 Operating elements 3-10
non-return valve 8-24 Operation 6-1
Lubrication clean piston rod 6-9
auxiliary lubrication pipe 4-17 prepare 6-4
crosshead 4-15 safety precaution 6-7, 8-3
gear oil pump 4-8, 4-10 Operation with process gas 6-7
guide bearing 4-16 Organic solvents 2-10
Lyes 2-9 Orifice plates 3-5
Oxygen 2-12, 2-19
M
commissioning 6-4
Main bearing 9-82
Oxygen plant
Maintain plant during decommissioning 5-82, 11-5
guidelines 8-3
Maintenance
compressor in general 8-27 P
plant 8-17 Passivate piping 5-37
prerequisites 8-3 Pickle piping 5-37
Maintenance practices 2-12 Pipe fastenings 8-20
Maintenance schedule 8-14 Pipe support 5-42
compressor 8-16 Pipe work
plant 8-15, 8-19 blowing out 5-71
Mandatory tightening torques 5-4 fabrication 5-31
Manley® valve 4-25, 4-28 sandblast 5-41
Marking of compressor components 8-27 Piping
Marking of packages 5-6 final assembly 5-62
Mass flow 6-3 Piston 4-22, 8-45, 9-32
Mechanical hazard 2-6 assemble and install 9-39
dismantle 9-36
N
Piston and piston rod
Name plate 1-5
assemble 9-39
NFPA-Rating 2-15
dismantle 9-33
Nitrogen 2-18
install 9-39
Non-drive end 4-10
Piston clearance 4-23
Non-return valve 3-12, 5-65, 9-7
measurement 8-51
NORD-LOCK® Securing System 8-30
Piston nut SUPERBOLT® 4-24
O Piston rod 4-22, 8-43, 9-32
Obligations 2-4 Piston rod gland 4-20, 8-44, 9-50
Oil change 8-32 assemble 9-51
Oil drain 9-28 dismantle 9-50

Index
Place compressor skid 5-24 Space requirement 5-10, 8-27

Plant Spacer ring 8-52
overview 4-3 Spare parts 12-1
Plant configuration and function 3-1 ordering 12-3
Pre-comissioning of compressor plant 5-68 original 12-4
Pre-commissioning 5-1 Spare parts drawings 12-15
cooling system 5-68 Spare parts list 12-8
prerequisite 5-68 Spare parts recommendation 12-6
Prelubrication pump 8-24 Spares inventory 12-5
Prepare installation 5-22 Standard volume 6-3
Preserve cleanliness 10-15 Standstill 5-80, 6-11, 11-3
Preserve compressor plant 11-3 Store components 5-8
Preserve compressor plant after installation 5-80 Suction pressure 6-3
Pressure monitoring 3-12 Suction strainer 8-21
Pressure ratio 4-19 Suction temperature 6-3
Pressure screw 4-25, 4-25 Suction valve 4-25
Pressure test Suction valves 8-61, 9-10
hydrostatic 5-64, 8-26 Suction volume 6-3
Preventive maintenance 8-1 SUPERBOLT® 4-24, 8-54
clean piston rod 8-43 preventive maintenance 8-55
Process gas 2-15 SWAGELOK® 5-58
Protection against loud noise 2-7 Switch off compressor 9-6, 9-83
Pulsation damper 3-5 Switch off cooling system 9-6
Purge gas 2-15 T
Purge plant 6-6, 8-7
Target groups 1-4
Purge system 3-5 Technical Documentation 1-4
Purging prior to maintenance 3-5 Technical support 5-3
Purging prior to normal operation 3-5
Temperature monitoring 3-11
R Term cross reference to API standard 1-6
Recommission plant 5-83, 11-5 Thermal hazard 2-6
Reference documents 1-4 Throttling points 4-20
Refill lubricating oil 9-27 Tighten foundation bolts of skid 5-30
Registered trademarks 1-10 Tightening methods 8-29
Relief valve 3-12, 4-11, 8-25, 9-31 Tightening torques
Revisions 1-3 method 8-17
Rotation speed 6-3 Tightening torques for attachment gear 5-12
Rotation speed control 4-30 Tools 8-8
Running in pistons 5-74 special 8-12
standard 8-8
S
Transport 5-1, 5-5
Safety
Trouble shooting 7-1
preventive measures 2-5
compressor noise 7-15
Safety advice 2-1
compressor shutdown 7-20
Safety devices 2-6, 3-10, 8-25
compressor start-up interlock 7-21
Safety measures 2-5
compressor vibrations 7-19
Safety of transport 5-5
cooling system 7-7
Safety valve 3-12, 8-25
lubricating system 7-9
Scope of supply 5-7
prerequisites 7-3
Serial number 1-5
process gas system 7-4
Shaft power (coupling) 6-3
Trouble shooting list 7-3
Shipping condition 5-7
Tube fittings 5-50
Shipping Package 5-5
Turn flywheel 5-70
Solid labyrinth pistons 4-23
Solvent discoloration test 10-14 U

Index
Ultraviolet light inspection 10-14

V
Valve 4-25
assembly 9-16
disassembly 9-13
disassembly and repair 9-13
dismantling 9-12
installation 9-21
Valve failures 8-62
Valve maintenance 8-61
Valve service 8-61
Valve types 4-25
Valves
diameter 4-26
fixation 4-25
location 4-25
VCI mat 5-82, 11-4
Vibration measurement 5-79
Vibration monitoring 3-12
W
Warning signs at compressor site 2-5
Warning symbols 1-8
Warranty 1-3
Wedge 4-15
Weights 5-10, 8-27
Wipe test 10-14
Y
Year of manufacture 6-3

Index

Index

Index

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Burckhardt Compression AG

Instruction Manual Compressor Type

Laby® Compressor Oxygen (O2+)

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 and Waste Disposal

17.01.2017 Rev. 001/vonstuerle_g 2D200B-1A_1 IM 102609en

IM 102609en 2D200B-1A_1 Rev. 001/vonstuerle_g 17.01.2017

1 Definitions for this Document

1.1 Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

17.01.2017 Rev. 001/vonstuerle_g 2D200B-1A_1 IM 102609en 1–1

1–2 IM 102609en 2D200B-1A_1 Rev. 001/vonstuerle_g 17.01.2017

Book Chapter Page Technical Date Description

Tab. 1-1 Revisions

If there have been necessary technical modifications, the present Instruc-

without Burckhardt Compression’s authorization.

1.3 Legal Disclaimer

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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

Tab. 1-2 Target groups

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1.5 Compressor Designation

The serial number is located on the name plate (1).

Fig. 1-2 Example for compressor designation

1 Number of cranks 3 Piston stroke

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1.6 Contact Address

Contact in Switzerland: Burckhardt Compression AG

1.7 Structure and Layout

1.7.1 Document Structure

1.7.2 Visual Elements

1.8 Term Cross Reference to API Standard

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Designation according to API Designation according to

Tab. 1-3 Term cross reference

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1.9 Warnings and Symbols

1.9.1 Level of Hazard Seriousness

1.9.2 Useful Information

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

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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!

Corrosion hazard, avoid contact with caustic substances!