CCi CC40 Operation And Maintenance Manual

Natural gas booster 40 hp @ 2200 rpm

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Operation and Maintenance

Manual

Natural Gas Booster

40 HP @ 2200 RPM

Table of Contents

Summary of Contents for CCi CC40

Page 1 Operation and Maintenance Manual Natural Gas Booster 40 HP @ 2200 RPM...
Page 2: Table Of Contents
Table of Contents INTRODUCTION………………….………………………………………….…………4 Contact Information ………………………………………………….………….4 How to Use This Manual ....……………………………….…………..4 Compressor Identification ………………………………………….…………...5 Parts and Service …………………………………………………….…………..5 SAFETY PROCEDURES …..…..………….……………………………………………6 STARTUP AND SHUTDOWN INSTRUCTIONS ……………………….……………7 Installation Instructions …………………………………………….…………...7 Purge and Leak Test Instructions ………………………………….…………...7 Starting The Compressor …………………………………………….………….8 Power Test …………………………………………………………….………….9 Setup Instructions …………………………………………………….………..10 ENGINE …………………………………………………………………………………10...
Page 3 APPENDIX ………………………………….………………………………………….26 Bolt Torques …………………………………………….……………………26 Recommended Spare Parts ……………………………………………………26 Shutdown and Alarm Setpoints………………………………………………..27 Compressor Compartment Panel Side …………………………………….…28 Compressor Compartment Compressor Side …………………………….…29 Engine Compartment Panel Side …………………….…………………….…30 Engine Compartment Compressor Side …………….……………………..…31 Warranty Information ……..…………………………………………………32 Inspection, Maintenance and Service Log……………………...…………….. 34 VI Planning Sheet……………………………………………………………….38 P&ID…………………………………………………………………………….
Page 4: Introduction
How to Use this Manual This manual contains instructions on the safe operation and preventative maintenance of your CCI natural gas booster. We urge you to read this manual prior to start-up or operation of the package. The Table of Contents permits you to quickly open the manual to any section.
Page 5: Compressor Identification
Compressor Identification An identification label is affixed to the left side of the trailer below the control panels. The label contains the date of manufacture, serial number, model, horsepower, and area classification. The model and serial number are required when seeking information concerning the operation and/or ordering replacement parts.
Page 6: Safety Procedures
Safety Procedures CAUTION: Read all instructions before operation A natural gas compressor has complex controls and operating procedures which are detailed in this manual and must be understood and followed for safe and effective operation. 1. Do not alter the plumbing or wiring in any way without authorization in writing by the manufacturer.
Page 7: Startup And Shutdown Instructions
Startup and Shutdown Instructions Installation Instructions 1. Jack and level compressor 2. Open front and rear louvers 3. Inlet ball valve closed 4. Inlet pressure reducing regulator to 0: All the way out 5. Attach Process Vent Pipe. Yellow pipe (loose in enclosure) screws into elbow at right rear and u-clamped to bracket on roof) 6.
Page 8: Starting The Compressor
(NOTE: START UP *Only required on initial startup on a location) 1. *When starting for the first time read all instructions for starting and adjusting unit. 2. *Set high suction pressure shutdown at 65 psi 3. *Set low suction pressure shutdown at 0 psi 4.
Page 9: Power Test
POWER TEST 1. Start with package running normal. 2. Raise suction pressure as high as possible,DO NOT EXCEED 70 psi. 3. Choke discharge to increase backpressure as high as possible,DO NOT EXCEED 250 psi. 4. When the engine RPM starts to drop, max HP has been reached. 5.
Page 10: Engine
Engine Safety Gauges The engine is equipped with instrument panels which contain shutdown gauges for High Engine Coolant Temperature and Low Engine Oil Pressure. The fault light for the Air Fuel Ratio controller indicates malfunction of the controller. Causes could be the O2 sensor needs replacement but commonly the unit just needs the power to be cycled.
Page 11: Stopping
Stopping Reduce the power requirements of the compressor compartment by reducing the suction pressure to 2-3 psi. Bring the engine to idle. Run the engine for a few minutes at idle to allow the coolant system to cool down before turning the Ignition switch to the OFF position.
Page 12: Spark Plugs
Spark Plugs Spark Plugs should always be replaced with the proper type and heat range. Stock plugs are AC DELCO R46 TS and the gap is 0.045 inches. Firing order is 1-3-4-2 The correct plug wiring is included for reference. Oil Filters The engine oil filter used is a PH11 or equivalent.
Page 13: Air Flow And Fan
Relieve all pressure from the compressor compartment Remove the 1” plug above the screw inlet Pour about 1 liter of suitable CCI screw compressor oil into the elbow and replace the plug. Follow the standard startup instructions when this is done.
Page 14: Oil And Filter
Oil and Filter Replace the oil at the recommended intervals with Compact Compression Inc. recommended Screw Oil. Fill it to the level shown below. When replacing the oil filter ALWAYS use an anti-seize product on the threads to prevent galling of the aluminum. Oil Fill Level Oil Filter...
Page 15: Coalescing Filter
Coalescing Filter The coalescing filter periodically needs to be replaced. It is housed in the upright vessel shown below. Replace it if the differential pressure reaches 8 psid.
Page 16: High Recycle Regulator
High Recycle Regulator Kimray 130 SGT-BP-D Pictured below is the 1” back pressure regulator. It controls the high recycle pressure. Turn the top adjuster inwards to increase the set pressure and outwards to decrease. If the pipeline gets backed up the discharge pressure will rise. To avoid having the compressor shut-down the high recycle allows gas back to the suction side and limits the screw discharge pressure to acceptable limits.
Page 17: Low Recycle Regulator
Low Pressure Recycle Fisher 627 The low pressure recycle is a pressure reducing regulator used to prevent the well pressure from becoming too low. To adjust, remove the top cap and turn the adjusting screw. In for increased setting and out to decrease. This regulator should be set above the low pressure shutdown switch and below the inlet regulator setting.
Page 18: Inlet Regulator
Inlet Regulator Kimray 230-SGT-PRB-D The inlet regulator pictured below is a balanced pressure reducing regulator. Its purpose is to limit the suction pressure to the screw when wellhead pressures are high. Turning the top adjuster inwards increases the set pressure and turning it outwards decreases the set pressure.
Page 19: Utility Regulator
Utility Gas Regulator Control Air 700-DF The regulator sets the pressure for the scrubber pneumatic dump and inlet pressure to the fuel gas regulator and clutch cylinder. Turn clockwise to increase and counter clockwise to decrease the setpoint. Recommended setting is 50 psig. If the pressure is set below 50 psi.
Page 20: Belts And Sheaves
When a ratio change is necessary the belts and driven sheave must be replaced. Due to the nature of the belt tensioner and belt alignment, only CCI sheave ratios are recommended. A table of available ratios can be found on the next page.
Page 21: Ratio Table
A table of suitable ratios is included. Contact CCI with new site conditions for selection of the proper ratio. RATIO BELT (Qty 3) SHEAVE BUSHING (3 Groove) 5VX750 5V1253 (12.5”) E35MM 5VX730 5V1093 (10.9”) SF35MM 5VX710 5V9253 (9.25”) SF35MM 5VX690 5V803 (8.0”)
Page 22: Engine Control Panel
Control Panel There are two control panels, the Compressor Compartment Panel is rated Class I, Division 2, and the Engine Compartment Panel is rated General Purpose. A full size wiring diagram is included in the Appendix. Circuit Breaker ratings are found on the wiring diagram.
Page 23: Compressor Control Panel
Compressor Control Panel and Components Inlet Pressure Gauge Discharge Line Wellhead Pressure Pressure Gauge Gauge Compressor Discharge Gauge Discharge Temperature Gauge (SD at 220F) Clutch Load/Unload Switch Start and Stop Procedures...
Page 24: Annunciator
• STOP – Shuts down unit on Code 52 and does not turn on the alarm output (Alarm output not used on CC40). • READ HOURS – Push anytime power is on to read current run time.
Page 25 -Check that engine has fuel gas. -Inlet regulator may be set too high and unit is running out of power. -Possible governor problem - Contact CCI if none of the above help. -Check that gauge is working properly -Check If fan Is turning/Check Belts -Check If louvers are open -Check wiring - should be NO circuit when temp <...
Page 26: Appendix
• Bolt Torques • Recommended Spare Parts Bolt Torques Bolts Torque (ft-lbs) 3/8” Flywheel Plate Drive Shaft Coupling Socket Head Capscrews Recommended Spare Parts CCI P/N Description 2107 Compressor Oil PGS 68 1825 Compressor Oil Filter Element 1031 Gas /Oil Seperator Filter Element...
Page 27: Shutdown And Alarm Setpoints
Shutdown and Alarm Standard Setpoints Code Set at Min 50 psi or 10 psi less than normal discharge pressure. Discharge Press Low SD 01 Whichever is higher. Coalesing Filter DP AL 02 8 psid Inlet Filter DP AL 03 8 psid Comp Oil Filter DP AL 04 20 psid Fire Loop SD 05...
Page 28: Compressor Compartment Panel Side
COMPRESSOR COMPARTMENT PANEL SIDE Recycle Block Valve Manual (Low & High) Recycle Valve High Utility Gas Pressure Regulator Recycle Valve Utility Gas pressure Knockout Recycle Filter Valve Fisher Fuel Regulator Suction Srubber Level Sight Glass Inlet Block Suction Manual Valve Control Blowdown Valve...
Page 29: Compressor Compartment Compressor Side
COMPRESSOR COMPARTMENT COMPRESSOR SIDE Compressor Scavenge Oil Bypass Line Valve Sight Glass Compressor Coalescor Oil Filter Filter Housing Oil Tank Temp. Compressor Oil Gauge Tank Level Gauge...
Page 30: Engine Compartment Panel Side
ENGINE COMPARTMENT PANEL SIDE...
Page 31: Engine Compartment Compressor Side
ENGINE COMPARTMENT COMPRESSOR SIDE...
Page 32: Warranty Information
It will reimburse or credit for necessary repairs or replacements of any defective or malfunctioning parts of said compressor with the exclusion of the major components which carry their own warranties. All replacements must be made with genuine or CCI approved parts.
Page 33 The requirements of the purchaser are: • shall notify CCI of any such defective part within 20 days from the time the purchaser obtains such knowledge • provide proof of purchase and in-service date to CCI when requesting warranty • shall properly operate and maintain the compressor in accordance with an authorized owner/operator manual •...
Page 34: Inspection, Maintenance And Service Log
CC40 Inspection and Service Report Date Hours Ratio (Initial Ratio = Suction Pressure (Initial SP = Discharge Pressure (Initial DP = Flow (Initial Flow = Outside Temperature Inspector Initials RUNNING CHECKS 1. RPM 2. Annunciator Warnings 3. Engine Oil P (30 — 50 psi) 4.
Page 35 STOPPED CHECKS Date 1. Engine Oil Change (700 hrs) 2. Engine CoolantChange (4,500 hr) (50/50) 3. Coolant added (Enter amount) 4. Engine Oil Filter Change 5. Engine Oil Lubrifiner Filter Check/Drain 6. Engine Crankcase Vent Can (Drain) 7. Engine Mounts 8.
Page 36 Date Comments...
Page 37 PSV Service Check Log Inlet Scrubber PSV Oil Separator PSV Coalescer PSV Date Signature S/N Date Signature S/N Date Signature Vessel Inspection Inlet Scrubber Oil Separator Date Signature Remarks Date Signature Remarks Component Serial Number Register Component Date Initial Date Initial Screw SN Scrubber SN...