START UP CHECK LIST -

RECIPROCATING COMPRESSORS

Compressor Model ___________________ Serial/No. F-_______________

Cylinder S/N C-______ C-______ C-______ C-______ C-______ C-______
Driver ___________________________________ Rated Speed_________________
Packager ________________________________ Packager Unit No.______________
Date Packager Shipped _____________________ Start Up Date _________________
Serviceman ______________________________ Customer ____________________
Location _________________________________ Field Contact _________________
Field Telephone No. ________________________ Unit Location __________________
Frame Oil - Make/Grade ____________________ _____________________________
_____________________________
Cylinder Oil - Make/Grade ___________________

Compressor Model ___________________ Serial/No. F-_______________

YES NO
Check List - Prior To Starting:
1. Are the correct Ariel parts book, technical manual, special tools,
and spares available? __________ __________

2. Have the design limitations for the compressor model such as

rod load, maximum and minimum speed, discharge temperature
__________ __________
been checked?
3. Have the design operating conditions been determined? __________ __________
Pressure, psig (barg): Suction ________ Discharge________
Temperature, °F (°C): Suction ________ Discharge________
Maximum RPM __________ Minimum RPM __________
4. Soft Foot Check & Frame Flatness: Have the compressor feet
and crosshead guide supports been shimmed so the machine is
not twisted or bent, and frame flatness for JGU:Z/4 & larger been
checked (Ref ER-82)? More than 0.002 inches (0.05 mm) soft foot
pull-down requires correction. Record compressor feet pull-down
readings: __________ __________
_______ _______ _______ _______
Drive-End
_______ _______ _______ _______

P1, at 4 added frame flatness requirements. P2 at 7 12515 11-22-04

7 & P6 at 16 rev’d to allow greater TIR for larger 6 011766 2-6-04

9 couplings. P5, at 7, clarified high discharge gas 5 8236 ---
temperature shutdown settings. 4 6887 --- 9 014565 11-19-07
3 6633 --- 8 012216 7-12-06
REV DESCRIPTION REV EC DATE REV EC DATE

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 START UP CHECK LIST -
RECIPROCATING COMPRESSORS

Compressor Model ___________________ Serial/No. F-_______________

YES NO
5. Have crosshead feeler gage clearances been checked with cyl-
inders mounted? Top is checked by inserting 0.5 inch (12.7 mm) __________ __________
wide feelers from one side edge across to the opposite side, at
both ends. See Technical Manual, Section 1, Clearances for limits.
Bottom is checked with a 0.0015 inches (0.038 mm) feeler at the
(4) corners. Feeler insertion is 0.50 inches (13 mm) maximum at
each corner. Record feeler values below:
Throw Record Crosshead to Guide Feeler Gage Clearances
Number Top minimum Top maximum Bottom max. Corner Insertion
1 ________ ________ ________
2 ________ ________ ________
3 ________ ________ ________
4 ________ ________ ________
5 ________ ________ ________
6 ________ ________ ________
6. Have the piping and supports been checked to be sure they do
not bend or stress compressor? __________ __________

7. Has the compressor to driver alignment been checked at site?

Maximum allowable 0.005 inches (0.13 mm) TIR on coupling hub
__________ __________
face and rim, except for hub O.D. >17 in. (.>43 cm) angular face
limit is 0° 1’ (0.0167°)1. Take thermal growth into account.
8. Have coupling face dial indicator readings been taken? Record __________ __________
in inches (mm) at the 3, 6, 9 and 12 o’clock positions on lines pro-
vided below:

Face Rim

9. Has the compressor crankshaft thrust clearance been checked?

See Technical Manual, Section 1, Clearances. __________ __________
Record compressor crankshaft thrust clearance here:
inches (mm)
10. Have piston end clearances been checked with feeler gages2?
__________ __________
See Technical Manual, Section 1, Clearances. Record below:
Throw No. 1 2 3 4 5 6

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START UP CHECK LIST -
RECIPROCATING COMPRESSORS

Compressor Model ___________________ Serial/No. F-_______________

YES NO
Head End _______ _______ _______ _______ _______ _______
Crank End _______ _______ _______ _______ _______ _______
11. Has piston rod runout been checked? See Technical Manual,
Section 5 for maximum acceptable readings. Record Below: __________ __________

Throw No. 1 2 3 4 5 6
Vertical:
Piston @ CE _______ _______ _______ _______ _______ _______
Mid-Stroke _______ _______ _______ _______ _______ _______
Piston @ HE _______ _______ _______ _______ _______ _______
Horizontal:
Piston @ CE _______ _______ _______ _______ _______ _______
Mid-Stroke _______ _______ _______ _______ _______ _______
Piston @ HE _______ _______ _______ _______ _______ _______
12. Has the compressor crankcase been filled with oil to the
proper level? Approximately 7/8 full in site glass, prior to starting. __________ __________

13. Has proper oil been installed if extreme ambient conditions

exist or special gases are compressed? __________ __________

14. Is the compressor crankcase oil level control working and set
at the proper level and properly vented? __________ __________

15. Is the crankcase oil supply isolation valve open? __________ __________
16. Does the crankcase low level shutdown work? __________ __________
17. Has the recommended oil filter element been installed? __________ __________
18. Are the oil filter element and all lube oil piping primed with oil? __________ __________
19. Is the low oil pressure shutdown installed and tubed correctly
to the downstream side of the oil filter? __________ __________

20. Does the low oil pressure shutdown work? __________ __________
21. Oil cooler? Compressor inlet oil temp. is 190°F (88°C) maxi- __________ __________
mum.
22. Is the crankcase oil temperature shutdown installed, set and
working? __________ __________

23. If oil is cooled, is there a temperature control valve? __________ __________

24. Is the crankcase breather element clean? __________ __________
25. Is the force feed lubricator box filled with oil? __________ __________
26. Is the force feed lubrication system primed? __________ __________

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Compressor Model ___________________ Serial/No. F-_______________

YES NO
27. Is the force feed lubrication system no flow shutdown installed
and working? __________ __________

28. Is the force feed blow out assembly installed? Check rupture
disc for color? See Lubrication section of the Technical Manual for
__________ __________
disc color vs. rating table.
29. Has the lubricator instruction plate or “Parts Book” Cylinder
Lubrication Sheet been checked for proper lube feed rate? __________ __________

30. Is there a working vibration shutdown mounted on the com-

pressor and adjusted properly? __________ __________

31. Are the primary and secondary packing-case, and the cross-
head-distance-piece vents and drains open, and when necessary,
__________ __________
tubed off of the skid or out of the building?
32. Is there some method of suction pressure control? __________ __________
33. Are the suction pressure, inter-stage pressure and discharge
pressure shutdowns set and working? __________ __________

34. Are the safety relief valves installed and working to protect cyl-
inders and piping for each stage of compression? __________ __________

35. Are the gas discharge temperature shutdowns installed, set

and working? __________ __________

36. Have the gas suction lines been blown out to remove water,
slag, dirt, etc.? __________ __________

37. Have temporary screens been installed at cylinder suction? __________ __________
38. Has compressor been prelubed prior to starting? If motor
driven, unattended or large frame models prelube at 10 psig (0.7
__________ __________
barg) & 30 seconds minimum?
39. For engine driven units, has the machine been rolled with the
starter to make sure it is free? The oil pressure should come up
__________ __________
noticeably while rolling on the starter.
40. For other drivers, has the machine been barred over by hand
to ensure it is rolling free? __________ __________

41.Does the driver rotation match the compressor rotation arrow? __________ __________
42.Have torque values been checked on all critical fasteners
where loosening could result in a safety hazard or equipment fail-
ure, and including: gas nozzle flange, valve cap, cylinder head,
compressor rod packing, hold down, crosshead guide support and __________ __________
coupling bolting?

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Compressor Model ___________________ Serial/No. F-_______________

YES NO
43. For machines compressing a combustible gas, have the piping
and compressor been purged to remove all air? __________ __________

44. Have start-up instructions for other package equipment been

followed? __________ __________

45. Is the compressor skid properly grounded to a suitable earth

ground? __________ __________

46.Has the Packager’s representative done the required review of

the Packager’s Start-Up and Operating Instructions for the unit
__________ __________
with the unit operator?

Check List - After Starting:

1. Did the oil pressure come up immediately? __________ __________
2. Are the oil filter pressure gauges working? __________ __________
3. Is oil filter differential pressure less than filter change value?
Reference value listed on filter information plate on compressor
top cover. __________ __________

4. Any strange noises or shaking in the compressor or piping? __________ __________

5. Is low oil pressure shutdown set at 35 psig (2.4 barg)? __________ __________

6. Is oil pressure set at 50 to 60 psig (3.5 to 4.2 bar) at operating

speed and temperature? Reference Technical Manual, Section 4. __________ __________

7. Are the high discharge gas temperature shutdowns set within

10% or as close as practical above normal discharge temperature
& not exceeding the maximum discharge temperature shutdown
__________ __________
setting for the service in which compressor is operating?
8. Is the distribution block indicator working and lubricator set for
proper break-in flow rate? __________ __________

9. Are there any oil leaks? If so, where? __________ __________

10. Are the scrubber dumps and high level shutdowns working? __________ __________
11. Are the scrubbers removing all liquids from the gas?
How often do they dump? (_____minutes) __________ __________

12. Are there sands or oxides in the gas? __________ __________

13. Is the overspeed shutdown set? __________ __________
14. Are rod packings sealing properly? __________ __________
15. Have all safety functions been tested to ensure shutdown of
unit upon malfunction? __________ __________

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Compressor Model ___________________ Serial/No. F-_______________

YES NO
16. Have coupling dial indicator readings1 been taken and within
allowable limits, after reaching normal operating temperatures and
components become heat soaked? Shutdown, vent gas system3
and record dial indicator readings, in the hot condition within 30
minutes, in inches (mm) at the 3, 6, 9 and 12 o’clock face positions __________ __________
on lines provided below:

Face Rim

17. If discharge bottle or head end cylinder supports are used,

have they been adjusted when components are heat soaked to
ensure there are no excessive forces that would cause detrimental
__________ __________
cylinder deflection?
18. Has fastener torque on gas nozzle flange, valve cap, cylinder __________ __________
head and compressor rod packing flange bolting been re-
checked2 when components are heat soaked?
19. Complete Ariel’s “Compressor Warranty Notification and Installation List Data”, copy this
completed “Start-up Checklist” and mail both to Ariel Corporation, 35 Blackjack Road, Mount
Vernon, OH 43050, USA, Attention: Administrative Assistant - Sales or fax to Ariel at 740-
397-3856, Attention: Administrative Assistant - Sales.

Footnotes

1. Maximum allowable 0.005 inches (0.13 mm) TIR on coupling hub face and rim, except
for larger hub O.D. angular face TIR limit:
>17 in. x 0.00029 = TIR max., in. (>43 cm x 0.0029 = TIR max., mm).
2. Piston end clearances need not be checked on cylinders where the compressor was
tested mechanically complete at the Ariel factory (compressor has an inspection tag)
and the crosshead-balance nuts have not been loosened since shipment from Ariel.
3. CAUTION!
BE SURE THAT THE COMPRESSOR IS COMPLETELY VENTED TO RELIEVE ALL
GAS PRESSURE, AND THE DRIVER WILL NOT EXERT TORQUE ON THE COMPRES-
SOR CRANKSHAFT THAT COULD RESULT IN INJURY, PRIOR TO TAKING COU-
PLING READINGS, RE-CHECKING BOLTING TORQUES ON PRESSURE
CONTAINING COMPONENTS OR REMOVING ACCESS COVERS FOR PERFORMING
INTERNAL INSPECTION OR MAINTENANCE ON THE COMPRESSOR. IN THE CASE
OF A DIRECT DRIVE MOTOR, THE BREAKER IS LOCKED OUT. FAILURE TO FOL-
LOW THESE STEPS CAN RESULT IN SERIOUS PERSONAL INJURY OR DEATH.

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