Section 6 - Engine-Compressor Start-Up

Overview

Section 6 - Engine-Compressor Start-Up

Overview 5. Fill cooling system with a solution of

water containing rust inhibitor or anti-
This chapter provides instructions on safely freeze which must be mixed before
starting an Ajax Compressor Unit. Topics in this pouring into the cooling system. Consult
chapter include: cooler manufacturer’s instruction sheets
for recommendations for rust inhibitors.
• Power Cylinder Pre Start-up Servicing
6. Tighten all cap screws and head stud nuts.
• Compressor Cylinder Pre Start-Up Gaskets shrink in time. After engine is up
Servicing to operating temperature, torque head
stud nuts again.
• Compressor Purging
7. Disconnect all lubrication lines at
• Start-Up Procedure (with bypass) cylinders and prime lubricator pumps by
hand until oil lines are completely full
• Start-Up Procedure (without bypass) and free of air.

8. Bleed fuel system at, or close to, the fuel

injection valve until fuel gas system is
Power Cylinder Pre Start-up free of air.
Servicing
Before starting the engine-compressor, the 9. Check fuel injection hydraulic system
following servicing steps must be performed. reservoir and hydraulic lines for dirt.
Refer to the General Data Section for capacities, Clean, if necessary, and fill with Ajax
sizes, etc. hydraulic fluid and bleed air from
hydraulic lines.
1. Fill crankcase to proper level with oil.
Proper method of determining oil level 10. Check control panel to insure that all
is explained in Section 1, which also safety devices are connected and that
contains specifications for suitable wiring or connections have not been
lubricants. loosened or damaged during shipment.

2. Remove side cover plates check cross-

head clearances.

3. Throw oil on all cross-head guide

surfaces and all piston rods until
reservoirs around cross-heads are full and
oil overflows into bottom of crankcase.

4. Pour oil in control box

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Section 6 - Engine-Compressor Start-Up
Compressor Cylinder Pre Start-up Servicing

Compressor Cylinder Pre 6. Loosen the lock nut and set screws on the
piston rod at the cross-head in the frame.
Start-up Servicing
!WARNING! 7. Turn the piston rod with a strap wrench to
obtain twice as much clearance on the
MAKE SURE ALL PRESSURE IS head-end (step 4) as on the crank end
RELIEVED FROM THE CYLINDER (step 5). The result will be that two thirds
BEFORE REMOVING ANY PART of the total end clearance is on the head
end and one-third is on the crank end.
Greater clearance on the head end
compensates for the thermal growth of
the piston rod and drive gear to give
!WARNING! approximately equal clearance at
operating temperature.
AJAX ENGINE-COMPRESSOR UNITS
CONTAIN NATURAL GAS THAT IS 8. Tighten the lock nut and set screws on the
FLAMMABLE AND EXPLOSIVE piston rod at the cross-head.
WHEN MIXED WITH AIR AND
EXPOSED TO AN IGNITION SOURCE. 9. By looking through suction port holes
ANYTIME THE COMPRESSOR HAS (valves were removed in step 4) sight
BEEN OPENED TO ATMOSPHERE across bore to insure that each discharge
FOR INSTALLATION OR MAINTE- valve is installed properly. Remember
NANCE IT MUST BE PURGED OF AIR that a valve opens in the same direction as
PRIOR TO STARTING THE UNIT the flow of the gas. A long dowel rod run
down throughout the suction port and
across the bore will move the discharge
1. Clean and remove any debris and dirt valve plate back and forth if the valve has
from incoming piping before connecting been installed properly. (If a dowel rod
to the unit. can open a valve, so can the gas).

2. Remove all suction valve covers and 10. Replace suction valves, cages, and
cages from the first stage cylinder. covers on the first stage cylinder. Just
before replacing the valve covers, insure
3. Remove suction valves and clean off any each valve is installed properly by
debris which may have collected. moving the suction valve plate back and
forth with a screwdriver.
4. Rotate the crankshaft until the first stage
compressor is at the outer end of the 11. Repeat steps 2 through 11 for the second
stroke. Using feelers, lead, or wax tapers stage cylinder and succeeding stages.
determine the clearance between the face
of the piston and the head end head. 12. By manually operating lubricator
pumps, remove all air from the
5. Rotate the crankshaft until step 4 can be lubrication tubing lines and prelube the
repeated on the crank end. piston rod packing and cylinder bore of
each cylinder.

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 Section 6 - Engine-Compressor Start-Up
Compressor Purging

13. Check cooler drive belts for tightness. • process piping removal

14. Adjust variable volume pocket to full • gasket replacement.

open (outward) position. Apply thread
lubricant to adjusting thread. Consult unit Purging Procedure
performance curve and make clearance 1. Close the bypass valve (if unit is so
adjustments to compressor cylinders equipped).
based on existing operating conditions.
2. Open the blowdown valve.
15. Pressurize compressor cylinders and
check for leaks. Replace or tighten as 3. Crack open the suction valve, allowing
required to stop leaks. gas to flow through the compressor.
cylinders, scrubbers, piping and cooler
16. Position line valves according to and out through the blowdown valve.
furnished start-up arrangement.
4. Allow gas to flow for approximately one
(1) minute.

5. Open the bypass valve to purge the

bypass line (if unit so equipped).
Compressor Purging
6. Close the blowdown valve.

7. Close the suction valve once a positive

!WARNING! pressure is reached - usually about 20-50
PSIG (1-3 Kg/cm2). If suction pressure is
AJAX ENGINE-COMPRESSOR UNITS
lower than this, then pressurize to
CONTAIN NATURAL GAS THAT IS
whatever the suction pressure is.
FLAMMABLE AND EXPLOSIVE
WHEN MIXED WITH AIR AND
8. Follow correct start-up procedures listed
EXPOSED TO AN IGNITION SOURCE.
below and include any additional items
ANYTIME THE COMPRESSOR HAS
specific to your compressor.
BEEN OPENED TO ATMOSPHERE
FOR INSTALLATION OR MAINTE-
NANCE IT MUST BE PURGED OF AIR
If no maintenance was performed and the unit
PRIOR TO STARTING THE UNIT
was running prior to a shutdown, purging may
not be required and the unit may be started using
the following procedure:
After any of the following events, the below
purging procedure must be used: Start-Up Procedure (with bypass)
1. Visually inspect the compressor and
• initial installation check the control panel to determine what
caused the unit to shut down. Record the
• valve cap removal cause of the shutdown in the log book. If
the visual inspection of the control panel
• scrubber maintenance indicates a mechnical problem with the

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Section 6 - Engine-Compressor Start-Up
Compressor Purging

unit, notify the responsible service 4. Walk around the unit and look for any
representative as soon as possible. Do not abnormal conditions (worn belts, oil
attempt to start the unit until after the leaks, etc.)
condition which caused the shutdown has
been corrected. If there are no mechanical 5. Correct any faults on the control panel. If
problems with the unit, continue with the the unit was shut down for vibration, then
startup procedure. pull the spark plug leads and leave the
existing shutdown showing on the panel.
Turn the unit over at least one full
: revolution by hand to listen for any
abnormal noises, resistance or other
Notice:In cold weather, follow the procedures related problems. Determine the cause of
described in ES-1006 in addition to the proce-
vibration and repair as necessary before
dures listed here
proceeding.
To insure against any hazardous malfunction
of this equipment, always use the specified 6. Make certain the bypass valve is open and
parts when making repairs that the suction gauge in the panel
indicates about 20-50 PSI (1-3 Kg/cm²)
in the cylinders. Close the suction block
2. Check to see that the fuel shutoff valve valve and blowdown valve to this level as
has closed and properly vented upon required.
shutdown.
7. Make certain the variable volume pocket
(VVP) is adjusted properly for the
loading of the unit.
!WARNING!
IF THE SHUTOFF VALVE DID NOT
CLOSE UPON SHUTDOWN, THEN THE
EXHAUST AND AIR SCAVENGING !WARNING!
SYSTEM COULD BE FILLED WITH
GAS, WHICH COULD IGNITE AND IF THE VVP IS SET TOO FAR IN OR
LEAD TO INJURY OR DEATH. TOO FAR OUT, MECHANICAL
DAMAGE CAN OCCUR DEPENDING
ON THE PRESSURE CONDITIONS. SEE
3. If the fuel shutoff valve did not close THE OPERATING CURVES OR GET
upon shutdown, then shut off the the THE OPERATING CONDITIONS FROM
main fuel gas supply, pull the spark plug YOUR DISTRIBUTOR OR THE
leads from the spark plugs, and push the FACTORY.
stop button on the annunciator panel to
disarm the ignition. The unit can now be 8. Make certain that the starting system has
manually barred over or cranked with the adequate pressure based on the starter’s
starter motor to purge the intake air and maximum rating (60, 90, or 150 PSIG
exhaust systems. starter).

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 Section 6 - Engine-Compressor Start-Up
Compressor Purging

9. Close manual fuel valve and reset the fuel

shutoff valve. Check pressure on locally
mounted or panel mounted gauge to !WARNING!
ensure the fuel system is pressurized.
IF THE UNIT FAILS TO START ON
THE FIRST ATTEMPT, WAIT TWO (2)
10. Close ignitor fuel ball valve (LE units
MINUTES BEFORE A RESTART
only).
ATTEMPT. UPON RESTART
ATTEMPT, ROLL THE UNIT OVER AT
11. For units with an annunciator panel -
LEAST FIVE SECONDS WITH THE
clear the panel by pushing the reset
STARTER BEFORE OPENING THE
button on the annunciator. The
MANUAL FUEL GAS VALVE. THIS
annunciator should read 00. If it does not,
WILL ALLOW ANY UNBURNED GAS
find and correct the fault, then activate
TO EXIT THE ENGINE PRIOR TO
the panel lock-out timer. For units with a
ADDING MORE FUEL
tattletale panel - reset any tripped
tattletale, then activate the startup timer.

12. Manually prelube the lubricator pump to 16. Open fuel to ignitors (LE units only).
clear the “no flow” function.

13. Open the manual block valve on the start 17. Maintain 300-360 RPM on the unit until
system. Pull the manual start lever or it is warm enough to accept the load
push the remote signal valve button to (check engine crosshead guide for
start cranking the unit. warmth). The manual fuel valve may be
opened fully. Adjust rpm with the
14. After 2-3 seconds, slowly open the governor to the desired speed.
manual fuel valve until you hear the
engine fire. 18. Turn the panel lock-out timer to zero and
arm all panel shutdowns.
15. Quickly release the start valve lever or
remote signal valve button once the
engine fires.
!WARNING!
NEVER LEAVE THE COMPRESSOR
SITE WITH THE LOCKOUT TIMER
RUNNING

19. Maintain a positive suction pressure

once the unit starts.

20. Once the unit has warmed up, open the

discharge block valve and then the
suction block valve.

21. Close the bypass valve to load the unit.

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Section 6 - Engine-Compressor Start-Up
Compressor Purging

22. Monitor all panel readings and set

shutdowns before leaving the site.
Confirm that all process valves are
positioned correctly once the unit is
running and that operating pressures are
as intended for the unit.

Start-Up Procedure (without bypass)

If the unit does not have a bypass valve, follow
the same procedures as above EXCEPT:

1. Close the discharge and suction block

valves.

2. Open the blowdown valve and bring the

unit down to zero pressure.

3. Start engine and warm up as in above

procedures.

4. Open the discharge block valve.

5. Open the suction block valve.

6. Close the blowdown valve to load the

unit.

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