Beruflich Dokumente
Kultur Dokumente
August 2007
COPYRIGHT
All rights reserved. No part of this publication may be reproduced, stored in a
retrieval system or transmitted in any form or by any means, electronic,
mechanical, photocopying, recording or otherwise without the prior permission
of Sundyne Corporation.
2007 Sundyne Corporation
WARRANTY
Sundyne Corporation warrants to Buyer for a period of twelve (12) months from the
date of being placed in service (but not to exceed eighteen (18) months after the
date of shipment) that the equipment at the time of shipment will be free from
defects of design, material and workmanship. If any defects or malperformance
occur during the warranty period, Sundynes sole obligation shall be limited to
alteration, repair or replacement at Sundynes expense, F.O.B. Factory, of parts or
equipment, which upon return to Sundyne and upon Sundynes examination prove to
be defective. Equipment and accessories not manufactured by Sundyne are
warranted only to the extent of and by the original manufacturers warranty. Sundyne
shall not be liable for damage or wear to equipment caused by abnormal conditions,
vibration, failure to properly prime or to operate equipment without flow or caused by
corrosives, abrasives or foreign objects. THE FOREGOING WARRANTY IS
EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER
EXPRESSED OR IMPLIED INCLUDING ANY WARRANTY OF
MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. In no
event shall Sundyne be liable for consequential or incidental damages.
4. SERVICING .............................................................................................................. 15
Regular Maintenance .............................................................................................................................................15
10. TROUBLESHOOTING............................................................................................ 54
11. OPERATION ........................................................................................................... 57
12. SPARE PARTS....................................................................................................... 58
13. SUNDYNE COMPRESSOR WARRANTY .............................................................. 62
Critical Start-up Checklist ....................................................................................................................................62
Lock-out/Tag-out Guidelines ...............................................................................................................................64
SINGLE SEAL ARRANGEMENT ..........................................................................................................................65
DOUBLE SEAL ARRANGEMENT ........................................................................................................................66
TANDEM SEAL ARRANGEMENT........................................................................................................................67
CAUTION
Sundyne compressors may handle hazardous,
flammable, and/or toxic fluids. Proper personal
protective equipment should be worn.
Precautions must be taken to prevent physical
injury. Residual fluids must be handled and
disposed of in accordance with applicable
environmental regulations.
Note: Safety procedures must be applied
prior to any installation, maintenance,
or repair of a Sundyne compressor.
Failure to follow safety precautions may
lead to injury!
Testing Equipment
Prior to performing a test on newly installed,
maintained, or repaired equipment; all personnel
in the immediate area must be warned.
Using Chemicals
Any chemicals to be used must be accompanied
by a relevant material safety data sheet (MSDS),
in accordance with government legislation. If
applicable, use chemical proof gloves.
Note: An eye wash station (or equivalent)
should be available in the event of
injury. If any hazardous or flammable
chemicals pass through the equipment,
a complete decontamination of the
equipment is required.
Using Forklifts
Any persons operating a forklift must have an
active recognized operator license.
EXPLOSION/FIRE HAZARD
Ensuring Electrical Safety
1.
Installation
Describes how to install the compressor and how to store it until you install it.
2.
3.
Start-up
Provides a procedure for starting and controlling the compressor. A critical start-up checklist is
included as Reference A.
4.
Servicing
Provides procedures for servicing the compressor.
5.
6.
Gearbox Disassembly
Provides procedures for disassembling & reassembling the gearbox of the compressor.
7.
8.
9.
10.
Troubleshooting
Provides tables for the following:
a) Looking up a problem.
b) Identifying the possible cause.
c) Selecting the corrective action.
11.
Operation
Provides general guidelines for controlling a compressor such as surge control, suction throttling,
discharge throttling, and speed control.
12.
Spare Parts
Contact and reference information.
13.
Reference A
Critical Start-up Checklist
Reference B
Lock-out/Tag-out Guidelines
Reference C
Seal Arrangement Drawings for single, double, and tandem configuration
Reference D
Phoenix Compressor/Gearbox Drawings
1. Installation
This section provides an introduction to the compressor, procedures for inspecting and installing it, and
procedures for storing it if you are not installing it immediately. It contains a subsection on each of the
following:
Introduction: This provides a brief description about the compressor and how it is used.
Inspection: As soon as you receive the compressor, inspect it thoroughly.
Short-term Storage: If the unit will be installed within 6 months follow these procedures.
Long-term Storage: If the unit will not be installed within 6 months follow these procedures.
Suction and Discharge Piping: Follow these procedures to set up the piping for suction and discharge.
Seal Environment Control System: Follow these procedures to set up the seal environment controls,
even if you use the standard system supplied by the factory.
Baseplate Grouting: Use this information for applying grouting to the baseplate.
Horizontal Unit Gearbox Support Bracket: Follow these procedures to drill and pin the gearbox
support bracket on a horizontal unit.
Driver and Coupling: Follow these procedures to align the driver and the compressor. Do this after
grouting, and before you connect the piping for suction and discharge.
Inspection
1. When you receive the Sundyne LMC/BMC compressor, check for any damage. If you find any, inform
the carrier and Sundyne promptly.
2. Use Outline drawings in the final data package to ensure that all auxiliary items are properly included.
3. Check the gearshaft carefully. Seal drag may cause it not to turn freely at first. This is normal. But if
the gearshaft binds, it may be damaged, or it may need adjusting.
Step 3: Make sure that the piping is aligned with the compressor flanges.
Step 4: Support all piping independently of the compressor.
Step 5: When you move the piping into place, never use excessive force at the flanged suction and
discharge connections. This could strain the unit.
Step 6: Use suction pipe that has a diameter at least as large as the diameter of the suction inlet of
the compressor.
Step 7: Make sure that the suction and discharge piping have no unnecessary elbows, bends, and
fittings. These increase the losses caused by friction. Also, be sure that all piping and fittings
are large enough to minimize losses caused by friction.
Step 8: Before you connect the piping to the compressor, tighten the hold down-bolts on the
compressor.
Step 9: Do not use elbow parts near the suction flange. A straight pipe run of at least 3 times the pipe
diameter is desirable between an elbow and the suction flange.
Step 10: Use block valves on both suction and discharge pipes to isolate the compressor during
shutdown, minimize process leakage, and reduce the likelihood of backflow through the
compressor, which can cause reverse rotation.
GAS BUFFER SYSTEM A gas buffer system must be used with double gas seals to prevent
process gas leakage out of the compressor. The buffer must be a cooled, dry, filtered gas, which
is compatible with the process gas and the compressor metallurgy. The buffer is introduced into
seal port 7 at a pressure range of 40 to 80 psi (2.8 to 5.6 kg/cm2) greater than compressor
suction pressure (max. of 160 psig 11.2 kg/cm2) and at an average temperature no higher than
250F (121C). Part of the buffer flows across the lower seal into the process gas and part flows
across the upper seal and is vented from port 1. A buffer flow of 1.0 to 2.0 scfm (0.028 to 0.056
Nm3/min) must be maintained through the seal cavity, and should be regulated by a valve or
orifice on port 2. It is also acceptable to provide a buffer into port 2 and regulate by a valve or
orifice out of port 7. The buffer system must be in operation prior to starting the compressor.
Refer to compressor specification sheet for specific buffer requirements.
A buffer gas may also be used between tandem seals to reduce process leakage when buffer
contamination of the process gas is not permissible. Contact the factory for buffer pressure and
flow requirements.
B.
LIQUID BUFFER SYSTEM A liquid buffer system is used with double liquid seals and is
functionally identical to a gas buffer. The buffer liquid is introduced into port 7 or 2, allowed to flow
through the seal cavity, and out the opposing port.
Buffer flow should be 0.5 to 3 gpm (2 to 12 liters/min) with an inlet temperature of 60 to 120F
(16 to 49C), and inlet pressure a minimum of 20 psi (1.4 kg/cm2) above process suction
pressure.
If a closed loop buffer system is used, the buffer must be cooled prior to returning to port 7.
Otherwise, heat generated by seal friction will build up in the buffer, resulting in shorter seal life. If
an open loop system is used, an orifice or valve on port 2 should be used to regulate flow to
proper value.
NOTE The compressor casing of units with double liquid seals must be drained prior to starting.
C.
SEAL FLUSH An optional seal flush system is available for use with single or tandem gas seal
arrangements when the process gas is contaminated with dust, dirt, or any other types of solid
particles. A clean, cool gas, either from external sources or cooled, filtered gas throttled from the
discharge is introduced into port 5 or 6 at a pressure slightly higher than suction pressure. Thus,
only clean gas will contact the seal face minimizing erosion and seal deterioration.
A flush is not required with a double gas seal due to the flushing action of the buffer leakage
across the lower seal.
D. PORT 1 PIPING Units equipped with gas seals must vent case drain port 1 to atmospheric
pressure and allow it to gravity drain properly. Otherwise oil could contaminate the outboard gas seal.
This port can be attached to a flare line, but should not have back-pressure in excess of 5 psi.
Baseplate Grouting
A rigid concrete mounting base is recommended for all installations. Use a non-shrink grouting to fill the
baseplate grout-fill holes. The concrete foundation should have minimum deflections and freedom from
resonant frequencies in the operating range of the equipment being supported. The stand shall be
secured in position by one inch diameter bolts. The bolts shall be installed in the foundation with sufficient
length to protrude one quarter inch above the nut. The customer shall provide a 4 x 4 x 1/4 steel plate
under each leveling screw.
BMC UNITS WITH HORIZONTAL STANDS: The base plate should be leveled prior to grouting. Grout
shall set for the time limit as determined by the grout manufacturer.
LMC UNITS WITH VERTICAL STANDS: The top of the stand (driver mounting surface) should be
leveled by shimming under the base prior to grouting. The channels are to be filled with grout through the
access holes. The nuts on the foundation bolts should not be tightened until the grout has set as
determined by the grout manufacturer.
Rev: E
For years the preferred gearbox lubricant for Sundyne pumps and compressors has been automotive
automatic transmission fluid (ATF). However, over time the additives in automatic transmission fluid have
changed to coincide with the technical improvements in automobile transmissions. The additives in the
new formulations of ATF, such as Dexron III, have been found to have negative effects on Sundyne
gearboxes and could compromise mechanical integrity and reliability of the equipment.
ISO Viscosity Grade 32 or 46 general purpose or synthetic oils are the recommended lubricants for
Sundyne gearboxes as shown in Table 1 below. ISO VG 46 lubricants are now recommended for high
horsepower gearbox models 33X and 34X with spherical roller bearings and high ambient temperature
installations. Gearbox lube oil should be changed twice yearly or more frequently in severe environments
which may be detrimental to the lubricant. Oxidized oil is frequently characterized by a darkening and/or
thickening of the oil. Operating of gearboxes with oxidized lubricant should be avoided.
Synthetic oils possess different characteristics than conventional mineral oils which make them desirable
for various extreme conditions such as high and low temperature operation. Synthetic oils offer very low
pour points, high temperature oxidation stability and a higher viscosity index.
The operation of Sundyne equipment in high or low ambient conditions may require special consideration
of gearbox lubricant and/or supplemental protective equipment such as heat exchangers or gearbox
heaters.
The lubricant chosen must be compatible with gearbox elastomers, Viton and Buna N. Any oil that
contains an inert additive such as PTFE, molybdenum disulfide or silicon should not be used in Sundyne
gearboxes. Use of lubricants containing inert additives will void the product warranty.
Table 1:
Use ISO Viscosity Grade 32 Lubricant **
Models: LMV/BMP-311
LMC/BMC-311F
LMC-BMC-311
LMV/BMP-313
LMC/BMC-313
LMV-322
All Sunflo Gearboxes
HMP-3000
HMP-5000
Models: LMV/BMP-331
LMC/BMC-331F
LMC/BMC-331P
LMV/BMP-333
LMC/BMC-333
LMC/BMC-337
BMP-338
BMP-348
** Use ISO VG 46 lubricant for high ambient temperatures above 40 C (100 F).
10
LMV/BMP-341
LMC/BMC-341F
LMC/BMC-341P
LMV/BMP-343
LMC/BMC-343
LMV-346
LMC/BMC-347
95 min.
32
1.5
0.20
Pass
Pass
Pass
25/0 max.
50/0 max.
25/0 max.
28 - 37
-7 (20) max.
204 (400) min.
41.4 to 50.6
6.5 min.
217 to 260
48.8 min.
95 min.
46
2.0
0.25
Pass
Pass
Pass
25/0 max.
50/0 max.
25/0 max.
11
LUBE OIL PRIMING KIT A pre-lube system is required on units operating at high speed,
high pressure, or high horsepower conditions. It is also mandatory with the use of certain
auxiliary equipment. The kit consists of a motor driven positive displacement pump, check
valve, gages, and necessary piping. To start compressor, operate the pre-lube pump at least
30 seconds with a minimum of 7 psig (0.492 kg/cm2) indication prior to starting the main
driver.
The pre-lube pump is to shut down only after main driver is at full operating speed.
B.
REMOTE HEAT EXCHANGER Some large water-cooled and all air-cooled heat
exchangers are mounted off the gearbox. Except for packaged units, the interconnecting
piping is the purchasers responsibility. The heat exchanger MUST be mounted lower than
the oil filter; otherwise, air pockets may be present in the lube oil lines at start-up, causing oil
starvation at the bearings. Equivalent length of piping and fitting must not exceed 20 feet
(6m), using minimum of 3/4 (19mm) I.D. tubing or pipe. If greater pipe lengths are required,
pipe diameter must be increased accordingly.
C.
GEARBOX SUMP HEATER A sump heater is required when ambient temperatures may
fall below the temperature at which the gearbox oil becomes too viscous for proper lube
pump operation. Both steam and electric sump heaters are available. The lube oil priming
pump must be operated anytime the sump heater is in operation.
12
3. Start-up
If a Sundyne supplied control panel is to be used with the Sundyne LMC/BMC compressor, use the
control panel recommended start-up procedure in addition to the steps below. Before starting the
LMC/BMC compressor, complete the following procedure in the order in which the steps are
provided:
Step 1:
Make sure that the driver has been serviced as per manufacturer recommendations.
Check motor rotation before installing coupling.
Step 2:
For the auxiliaries: Check the connections of the utilities; verify that the auxiliary piping
meets the requirements shown in the Outline Drawing.
Step 3:
Install flushing screens in all field-assembled piping connections. Clean these screens
prior to commissioning. Check frequently for cleanliness and clean as needed.
Step 4:
Drain any liquids (blow-down) from the compressor and inlet pipe.
Step 5:
Step 6:
Turn on the cooling water to lubrication systems heat exchanger (if applicable), or turn on
air cooled heat exchanger. Verify high points (e.g. heat exchanger and filters) have been
vented.
Step 7:
For double seal configurations, the buffer system must be pressurized to the pressure
specified on the spec sheet and on outline drawings prior to pressurizing the unit.
Step 8:
Step 9:
Step 10: Once the gearbox oil temperature has stabilized, adjust cooling water supply until the oil
temperature to the bearings is 120 - 160F on units equipped with water cooled heat
exchangers. Maximum recommended temperature is 180F.
13
Suction throttling (preferred method). Start compressor with the discharge valve open
while throttling the suction valve to bring the compressor to the design operating
point.
B.
Discharge throttling. Start the compressor with the suction valve completely open
while throttling the discharge valve to bring the compressor to the design operating
point.
C.
Other Methods Insure that the compressor does not go into surge (flow too low) or
that the design horsepower is not exceeded (flow too high) while starting or operating
the compressor. Check units specification sheet for flow limits
Series Operation:
In series operation, it is necessary to have a bypass from the discharge of the second stage
back to the suction of the first stage. A check valve should be placed in the discharge line
downstream of the bypass. Typical start-up procedure is as follows:
A.
B.
C.
D.
E.
Open the suction and discharge block valves and the bypass valve.
Start the second stage unit and maintain stable operation.
Start the first stage unit and maintain design flow to both units.
When sufficient pressure is being produced to overcome system back-pressure, the
check valve will open and the units will be on stream.
Close the bypass valve, being sure that the flow to the compressor is above the
surge point.
Parallel Operation:
Check valves must be placed in the discharge piping of each compressor to prevent backflow when one unit is started prior to the others. It is advantageous to install separate bypass
loops around each compressor for additional operational flexibility.
The first unit may be started as described above for single units. However, prior to starting
the second unit, it is preferable that the on-stream unit not be operating near its peak head
capability. This will lessen the chance of surging when the second unit is started.
14
4. Servicing
General Requirements
To increase the operating life of your compressor and keep it in good operating condition, you should
inspect and service it regularly. Measure all of the operating parameters documented in the specific
maintenance procedures and log your measurements. Make sure that all major equipment, such as
lubricating pumps, heat exchangers, and instrumentation, perform according to the manufacturers
recommendations. Whenever you find a deviation from specifications, identify its source immediately,
and take any corrective steps that are required to bring the unit into manufacturers specifications.
Regular Maintenance
Gearbox Oil
Check the level of the oil in the gearbox immediately before and after initial start-up, and regularly
while the compressor is running. Be sure to keep the level of the oil within the gearbox design limit.
The oil level must be maintained within the MIN/MAX range on the sight glass.
You can add oil to the wet sump gearbox while the compressor is running. See tagging information
on gearbox for where to add oil during operation. This location is different from the initial fill location.
Each must be used for its tagged purpose. Overfilling the gearbox will cause excess foaming and
overheating and should be avoided at all times.
Oil may be added to the external reservoir of the dry sump gearbox at the fill port.
Oil Pressure
The correct oil pressure from the main pump of the gearbox depends on the configuration of the
bearings and the characteristics of the lubricating oil used. In the normal operation, the oil pressure
supplied to the gearbox should be between 18-60 psig (1.2 - 4.2 Kg/cm2 ) (15 psi alarm, 10 psi
shutdown).
Seal Leakage
Seal leakage out of port 1 should be checked periodically. Seals should be replaced if leakage
increases to an unacceptable level. With double seals, buffer pressure and usage should be
monitored to insure that seals are functioning properly.
Driver
Inspect the driver to make sure that it performs according to the manufacturers specifications.
Coupling
Inspect the coupling according to the manufacturers specifications. Never operate the compressor
without first checking the coupling guard. A compressor with a missing or incorrectly installed guard
could cause serious or fatal injury.
15
QUANTITY
ITEM
NUMBER
936B
936C
936D
936E
936F
936G
936H
936J
60A
60A, 60B
60A, 60B
87A
1
1
1
1
1
1
2
3
1
2
2
1
NOTE:
An O-Ring repair kit is available. This kit contains the O-Rings required to replace the gearbox
and compressor mechanical seals.
16
Step 1
Remove the driver and gearbox from the compressor housing as follows:
BMC Units
Remove bolts (909D) securing the coupling guard. Remove the coupling guard. Disengage both ends
of the spacer coupling and remove the floating shaft. Attach a hoist to the gearbox using eyebolts in
the tapped holes on the bearing plate. Eyebolts can also be placed in the gearbox input housing as in
above photo. Remove nuts (914A) from the compressor casing studs and disconnect gearbox
bracket (BK01AW04) from the main base. Store any shims between the bracket foot and the main
base. Remove the gearbox and seal housing from the compressor casing by moving them toward the
driver until the impeller clears the compressor casing. Place gearbox on a suitable support with the
impeller facing upward.
17
NOTE:
Step 2
Step 3
Step 4
18
Step 2
19
Step 3
Step 4
Step 5
20
Step 6
Step 7
21
Step 8
Step 9
22
23
QUANTITY
AR
1
1
1
1
1
Step 1
Remove impeller bolt (3), and impeller (2).
Step 2
Inspect impeller and procure a new one if required.
Step 3
Inspect diffuser for signs of damage (i.e. gouging in the bowl areas due to erosion or mechanical
damage)
Step 4
The impeller spacer (158C) is required to align the blade side of the impeller shroud flush with the
diffuser cover (15). The impeller spacer (158C) thickness (D dimension of Figure 5.1) must be
determined and the correct spacer installed during the replacement of any one of the following
components: gearbox assembly, gearbox high speed shaft (A130), or high speed shaft bearings
(151A or B), impeller (2), seal housing (30), diffuser cover (15).
NOTE:
The original clearances for your compressor as shipped from the factory for the impeller and
diffuser are recorded and supplied as part of the final data package.
Step 5
The Impeller to Diffuser Cover Alignment Procedure
Align the impeller (2) with the diffuser cover (15) as follows:
The Impeller to Diffuser Cover Alignment Procedure requires multiple assemblies of the stacked
rotating elements mounted on the end of the high speed shaft assembly. The procedure is attempted
after the gearbox is completely assembled with the shaft end play checked and within its specification
of 0.015 +/- 0.002. This procedure also assumes that all components have been checked and are in
good order. If not, then new parts must be procured.
The 1st assembly includes only the mating rings, shaft sleeves, impeller spacer (158C), and impeller
(2) and is done without any o-rings, mechanical seal, seal housing (30) or diffuser cover (15). The
purpose of the 1st assembly is to ensure that all stacked components are compressed and fit tight
when the impeller is torqued to specification. A visual and physical check of these stacked
components is required to ensure that they cannot be spun in relation to the shaft.
The 2nd assembly requires that all components be installed, except the Item #936G O-Ring between
the impeller spacer (158C) and impeller (2). The purpose of this assembly is to check the impeller (2)
24
shroud height in relation to the diffuser cover (15) and to determine the correct thickness of the
impeller spacer (158C).
In the 3rd assembly, once the correct impeller spacer (158C) is determined, the impeller spacer
(158C), the o-ring (936G) between the impeller spacer (158C) and the impeller (2), and the impeller
(2) are assembled for the final time to complete the assembly.
5a. Assemble the gearbox, less the gearbox mechanical seal and mating ring, the process
mechanical seal(s) and mating ring(s), the seal housing (30), the diffuser cover (15), and impeller
(2). Ensure end float is within recommended limits; i.e., 0.015 +/- 0.002.
5b. With the diffuser cover (15) removed from the seal housing (30), set the diffuser cover bottom
side up on a work bench. Set the impeller (2) in the recessed portion of the diffuser cover and
measure the distance from the outside flat surface of the diffuser cover to the front or blade side
of the impeller shroud as close to the outside edge of the shroud, as possible. The impeller
should be recessed into the diffuser cover a minimum of 0.025. If the dimension is less than
0.025, contact Sundyne Compressors in Arvada, Colorado.
5c. Place the gearbox upside down on a workbench or gearbox stand so the end of the high speed
shaft (A130) protrudes upward. All checks from this step on, should take place with the high
speed shaft resting down on its upper thrust washer or upper thrust tilt pad bearings.
5d. Assemble the seal component stack-up onto the high speed shaft (A130) without using the
mechanical seals, O-Rings, seal housing (30), or diffuser cover (15). With the high speed shaft
(A130) extending upward, slide on the gearbox mating ring (51D), and then the following parts:
For double seals, assemble the upper shaft sleeve (50B), the process mating ring (51C), the
lower shaft sleeve (50A), the impeller spacer (15C) and the impeller (2).
For single seals, assemble the shaft sleeve (50), the process mating ring (51A), the impeller
spacer (158C), and the impeller (2).
For tandem seals, assemble the upper shaft sleeve (50B), the upper process mating ring (51C),
the lower shaft sleeve (50A), the lower process mating ring (51A), the impeller spacer (158C), and
the impeller (2).
5e. To install the impeller (2):
-Check the shaft OD pilot fits and the impeller bore pilot fits and ensure that they are clean and free of
burrs. Clean up, deburr and polish, as needed, to prevent damage to each during assembly.
-Heat the impeller in an oven heated to 350F for 30-60 minutes.
-Apply a very small amount of anti-seize compound onto the shaft pilot fits to ease the installation and
removal of the impeller and to prevent galling.
-Lower the heated impeller onto the shaft on top of the stacked up parts, place a soft metal washer
over the impeller, install the impeller bolt (Item #3), and torque per Table 8.1. A soft metal washer is
placed between the impeller and the impeller bolt to prevent damage to the end surfaces of each
part.
-Allow the impeller to cool. This process can be accelerated by blowing shop air past the heated
wheel.
5f. During the cooling process, retorque the impeller bolt (3) 3-4 separate times to 50 ft. Ibs. When
the impeller is cool, retorque one final time per Table 8.1.
5g. Once the impeller is installed and cool, recheck the stacked components to ensure that they are
all tight and cannot rotate in relation to one another.
25
NOTE:
Steps 5d-5g serve to check that all stacked components are tight and not loose during
assembly. There is no way to check these stacked components with the seal housing
installed. Since the impeller to shaft fit is not a loose or slip fit, it is possible to assemble the
stacked components and achieve the required torque, even though the stacked components
could remain loose and free to turn in relation to the shaft. This could lead to component
damage if allowed to operate in this condition.
5k. Before installing the diffuser cover (15), remove the o-ring (936E) from behind the diffuser cover,
then install the diffuser cover, without the o-ring, on to the seal housing (30).
5L. Reinstall the impeller using the same procedure described in step 5e above.
5m. Measure the distance between the top of the impeller shroud and the diffuser cover (15) per
(Figure 5.1). The impeller shroud should extend .000-.030 beyond or above the diffuser cover
(with the gearbox upside down). This is the E dimension in (Figure 5.1). If the shroud height is
measured out of tolerance, determine the correct impeller spacer thickness and replace it with
one of the correct size to ensure the proper shroud height (E dimension).
Table 5.3
Part Number
SP01AD02XXF
SP01AD02XXA
SP01AD02XXG
SP01AD01XXB
SP01AD01XXH
SP01AD01XXC
SP01AD01XXD
SP01AD01XXE
SP01AD01XXJ
Thickness
0.018
0.030
0.040
0.050
0.060
0.070
0.090
0.110
0.020
5p. Install the impeller spacer (158C) with the correct thickness and the o-ring (936G) between the
impeller spacer and the impeller.
26
5s. When the impeller is completely cooled, remove the impeller bolt (3) and the soft metal washer
and then reinstall the impeller bolt, without the soft metal washer and torque per Table 8.1.
5t. Record the thickness of the impeller spacer (158C) and the impeller shroud to diffuser cover
alignment (Dimension E in Figure 5.1) for future reference.
Step 1
The required impeller to diffuser clearance is 0.035 - 0.055 inches, see (A) dimension in
(Figure 5.1). This clearance is obtained by installing shim spacers (158A) between the diffuser and
compressor casing, see (B) dimension in the (Figure 5.1). The recommended procedure for
determining shim spacer requirements is as follows:
Step 2
Refer to (Figure 5.1). The seals, seal housing, diffuser cover, and impeller must be installed on the
gearbox. The diffuser must be bolted into the compressor case (1).
Step 3
Using electrical solder, make a ring that is slightly smaller in diameter than the impeller blade
diameter. Place the solder ring on the diffuser and center it around the inlet eye. Use tape to hold the
solder in place.
Step 4
Install the complete compressor assembly and gearbox in to the compressor case and tighten four
equally spaced seal housing nuts (914A) onto the case studs. Use the proper torque given in Table
8.1. Then remove the seal housing nuts and carefully lift out the compressor assembly from the
compressor case.
Step 5
Measure the thickness of the solder ring at points where it contacted the impeller blades and record
the average thickness. This is the A dimension in (Figure 5.1). This impeller to diffuser clearance
must be between 0.035 and 0.055 inch (0.089 and 0.140 mm).
Step 6
If the impeller clearance is not within the proper range, calculate the required change in shims. Add
or remove diffuser spacers (158A) to adjust the clearance to the correct range.
27
28
NOTE:
The shim spacers are available in sets of five, including one each of:
Table 5.4
0.005 inch (0.13 mm)
0.010 inch (0.25 mm)
0.015 inch (0.38 mm)
0.020 inch (0.51 mm)
0.030 inch (0.76 mm)
Step 7
Install the spacers (158A) in compressor case (1).
Step 8
Install O-Ring (936C) on the diffuser (13).
Step 9
Install diffuser in compressor case and tighten the three screws (906D) per torque Table 8.1.
NOTE:
If a PTFE O-Ring (936C) was installed, perform the following steps, (10) through (14) prior to
final assembly of the compressor casing to the seal housing (30). If an elastomer O-Ring was
used, proceed to Step 15.
Step 10
Place casing (1), with diffuser (13) installed, on solid work surface.
Step 11
Place three of the compressor casing attaching hex nuts (914A) or other suitable spacers on upper
surface of diffuser.
Step 12
Lower the gearbox assembly onto the hex nuts. Install four of the compressor casing nuts (914A) and
tighten. This step is necessary to compress the PTFE O-Ring (935C) and maintain the proper final
impeller-to diffuser clearance.
Step 13
Remove the gearbox assembly from the case and remove the hex nuts that were used as spacers.
Retorque three screws (906D) to proper torque values.
Step 14
Reassemble the compressor with another solder ring and recheck the impeller clearance.
Step 15
Record the new diffuser spacers (158A) thickness (B dimension) and the impeller to diffuser
clearance (A) dimension in (Figure 5.1). Remove the compressor assembly from the compressor
case and place short strips or coils of electrical solder taped out on the flat portion of the diffuser.
Step 16
Reinstall the compressor assembly and retighten the case nuts. Loosen the nuts and remove the
assembly. Measure the solder at the flattened portion and record the diffuser to cover clearance
(C dimension) in (Figure 5.1). This dimension must be within 10% of the as shipped C dimension
as shown in the final data package.
29
Step 17
Reassemble the compressor installing all the O-Rings into the proper positions. Tighten the
compressor case nuts to the proper torque listed in Table 8.1.
CAUTION: When PTFE O-Rings are being used, special consideration must be taken to
allow for cold flow. Retorquing may be required to obtain proper torque value.
6. Gearbox Disassembly
Note:
Disassembly.
Step 1
Step 2
30
Step 3
Step 4
Step 5
31
Step 7
32
Step 8
Step 9
33
34
35
O-ring
36
37
38
39
40
41
Step 23 (continued)
42
43
Remove lube jets, then clean and wash all gearbox housings (101B), (102), and (101A)
with solvent and blow dry with clean high pressure air.
Step 2
Make certain to flush out all lube passages and blow dry with clean high pressure air.
Reinstall lube jets into housings immediately.
Step 3
Inspect all bearing locations for critical size requirements (see Table 7.1). If any
dimensions are found to be out of tolerance replace that housing or bearing.
Step 4
Inspect all bearings for damage, if any damage is found replace the bearings with new
items.
Step 5
Inspect all shaft bearing surfaces for scratches, burns, dents, or dings. If bearing
surfaces on shafts are burned and/or scared the shaft should be replaced. Scratches
nicks or dings on shafting should be lightly stoned and polished to remove high spots.
Step 6
Step 7
Inspect all shafts with gears. If gears are missing teeth, or are burned, replace gear or
integral gear shaft as required. If gears show abnormal wear patterns, or have nicks and
dings on the gear teeth, lightly stone or hone and polish nicks and dings from gear teeth.
If abnormal wear pattern is evident this could indicate a bent shaft.
Step 8
Inspect the bearing thrust faces on the idler shaft (A140). If thrust faces are burned or
scored, replace the shaft. Check the thrust surface on the lower spur gear for
abnormalities or replace the shaft assembly.
Step 9
Inspect the thrust face on the lower idler spur gear that is pressed onto the idler shaft
(A140). If the thrust face on this gear is burned or scored replace this gear. If there are
nicks or dings in the thrust face lightly stone or hone and polish these areas back to the
original surface.
Step 10 Inspect the internal lube pump (A160) o-ring seal groove. If there are any nicks or dings
in this area, polish or hone them back to the original surface. If this cannot be
accomplished replace the lube pump (A160). If your gearbox had a catastrophic lube
failure due to the lube pump (A160) you should replace the lube pump as a complete
assembly.
Step 11 Inspect the gearbox seal. If the carbon seal nose is nicked, scratched, or dinged,
disassemble the seal and try to lap the seal nose back into tolerance. The flatness
specification is two light bands or .00002 flatness minimum. If this cannot be achieved
replace the carbon seal nose. Check the constant force spring inside the seal retainer. If
it is cracked, bent or deformed other than the cone shape, it should be replaced. Contact
your customer service representative for part numbers on this seal.
Step 12 Inspect all the sleeves and spacers that were disassembled from the high speed shaft,
Process End. If there are any nicks or dings in the sleeves or spacers lap the locating
surfaces back into tolerance. The specification for these sleeves and spacers is two light
bands flatness or .00002 flatness and parallel conditions between the faces of the
sleeves or spacers of .0003 maximum. If these specifications cannot be maintained then
replace the sleeves or spacers with new hardware.
Step 13 Inspect the process seals. If the carbon seal nose is nicked, scratched or dinged,
disassemble the seals and lap the seal nose back into tolerance. Specification for
44
flatness on these seal noses are two light bands or .00002 flatness. Install a seal repair
kit for the specified seals in your unit. See your Sundyne Compressor Specification Sheet
or Recommended Spare Parts List Bill of Materials for the part numbers.
Step 14 Inspect all rotating faces in your unit (process and gearbox). If rotating faces are nicked,
cracked, or have wear rings from seal contact replace them with new hardware. Check
the flatness of the rotating faces to factory specifications. Flatness is specified at two light
bands or .00002 flatness. The rotating face for the gearbox seal (51D) is to have a matte
finish applied. The matte finish is specified as 10-15 Ra micro finish, and still maintaining
the flatness of .00002 or two light bands.
Step 15 Inspect the high speed shaft shoulder where the gearbox rotating face locates. Check for
nicks or dings, and raised surfaces on this shoulder. If any abnormalities are found, the
shoulder will need to be relapped to factory specification of two light bands flatness or
.00002. If this specification cannot be met replace the high speed shaft (A130).
Step 16 Inspect the high speed shaft (A130) thrust surfaces. If these show abnormal wear, burns,
gouges, deep circular scratches or wear patterns, replace the high speed shaft (A130)
with a new assembly.
Step 17 Lubricate all other parts thoroughly with light turbine oil.
Description
101B
HO06AY01/HO06AY02
Upper, Gearbox Housing
102
101A
HO05AY01/HO05AY02/HO05AY03
Lower, Gearbox Housing
151D
151C
151B
151A
Characteristics
45
Critical Size
4.3311.0005
3.6255.0005
4.3311.0005
3.1880.0005
3.1880.0005
3.6255.0005
2.5065.0005
1.7545.0005
1.5015
1.5015
Idler Shaft
Upper Bearing
(400 HP Gearbox Only)
Lower Idler
Bearing & Shaft
Clearances
Maximum clearance
for replacement:
0.0063 inches
(.16 mm)
Input Shaft
Upper Bearing
Input Shaft
Lower Bearing
46
47
NOTE:
For accurate checking of shaft end play, all parts must be dry and free of oil.
Step 1
Install the lower journal bearing (151A) in to the lower gearbox housing (101A). Install the
hex head cap screws (905M) and the lock washers (154D). Tighten screws (905M) to
correct torque specification.
Step 2
Install the upper high speed shaft journal bearing (151B) into the bearing plate (102).
Install the hex head cap screws (905N) and tighten to the specified torque.
Step 3
Place both thrust washers (155A) and (155B) (if required) into lower high speed journal
bearing. Place the high speed shaft assembly (A130) into the lower gearbox housing
installing it through the lower high speed shaft journal bearing (151A).
Step 4
With the aid of two large diameter alignment bolts (909C), install the bearing plate (102)
without the o-rings (936T), (936TT) and (936YA). Clamp the bearing plate (102) and the
lower gearbox housing (101A) together with two C clamps or bolts.
Step 5
With the shaft in a vertical position, move the shaft up and down while measuring the
total end play with a dial indicator or depth micrometer. Shaft end play must be .015 +/.002 inch. If end play is not within this limit, calculate the shim thickness required to place
the shaft within the proper end play. Select the required thickness shim using (158)
series shim spacer sizes. Do not install shims below the lower bearing.
Step 6
Remove the alignment bolts (909C) and the C clamps from the bearing plate (102) and
lower gearbox housing (101A). Now remove the bearing plate (102).
Step 7
Remove the upper high speed journal bearing (151B) from the bearing plate (102).
Step 8
Place the required shim thickness over the upper high speed journal bearing (151B) and
reinstall the upper high speed journal bearing (151B) into the bearing plate (102). Tighten
hex head cap screws. Refer to table 8.1.
Step 9
Repeat steps 3 through 5, and verify high speed shaft (A130) end play. When end play is
within factory specification, repeat step 6.
Step 10 Remove the high speed shaft (A130) and the thrust washers (155A).
Step 11 Install thrust washer (155A) into lower high speed shaft journal bearing (151A) and install
a thrust washer (155B) into the upper high speed journal bearing (151B) with the flat side
(NO GROOVES) towards the high speed journal bearing (151A).
Step 12 Lubricate the upper and lower thrust washer (155A) with light turbine oil and install the
high speed shaft (A130) into and through the lower high speed journal bearing.
48
Location
Oil Filter Manifold
Gearbox Seal
Journal Bearings
Chemical Barrier Gasket
Gearbox Halves
Gearbox Halves, Alignment
Sight Glass
Size
3/8 - 16 x 1/2
1/4 - 20 x 1/2
#10 - 24 x 1
1/4 - 20 x 5/8
1/2 - 13 x4
5/8 - 18 x 4 17/64
#8 - 32 x 1/2
English
22 - 25 ft-lbs
75 - 80 in-lbs
35 - 40 in-lbs
75 - 80 in-lbs
60 - 65 ft-lbs
60 - 65 ft lbs
10 - 12 in-lbs
Metric
30 - 34 N-m
8.5 - 9.0 N-m
4.0 - 4.5 N-m
8.5 - 9.0 N-m
81 - 88 N-m
81 - 88 N-m
1.0 - 1.4 N-m
906D
905E
905F
905G
914A
914A
905A
905P
Location
Impeller Bolt/Inducer:
LMV/BMP-801, 802, 806, 322, 311, 331
LMV/BMP-341, 346
LMV-313, 343, BMP-338, 348 (High
Flow)
LMC/BMC 3X1P, 3X1F, 3X3, 3X6P, 3X7
Diffuser Attaching Screws
Mechanical Seal No. Spacer
Throttle Bushing/Mechanical Seal
Double Seal with Spacer
Case Nuts
Case Nuts
Seal Housing to Gearbox
Separator
Size
English
Metric
1/2 - 20
1/2 - 20
3/4 - 10
36 - 40 ft-lbs
65 - 70 ft-lbs
85 - 90 ft-lbs
49 - 54 N-m
88 - 95 N-m
115-122 N-m
1/2 - 20
1/4 - 20
1/4 - 20 x 12
1/4 - 20 x 12
1/4 - 20 x 3/4
3/4 - 10
7/8 - 9
3/8 - 16 x 1 3/4
1/4 - 20 x 5/8
36 - 40 ft-lbs
95 - 102 in-lbs
95 - 102 in-lbs
9 5- 102 in-lbs
95 - 102 in-lbs
250 - 275 ft-lbs
300 - 330 ft-lbs
35 - 40 ft-lbs
95 - 102 in-lbs
49 - 54 N-m
11 - 11.5 N-m
11 - 11.5 N-m
11 - 11.5 N-m
11 - 11.5 N-m
340 - 375 N-m
405 - 445 N-m
47 - 54 N-m
11 - 11.5 N-m
Location
Size
English
Metric
Impeller Bolt/Inducer:
LMV/BMP-801, 802, 806, 322, 311, 331
1/2 - 20
36 - 40 ft-lbs
49 - 54 N-m
LMV/BMP-341, 346
1/2 - 20
65 - 70 ft-lbs
88 - 95 N-m
LMV-313, 343, BMP-338, 348 (High
3/4 - 10
85- 90 ft-lbs
115 - 122 N-m
Flow)
LMC/BMC 3X1P, 3X1F, 3X3, 3X6P, 3X7 1/2 - 20
36 - 40 ft-lbs
49 - 54 N-m
906D
Diffuser Attaching Screws
1/4 - 20
70 - 75 in-lbs
8.0 - 8.5 N-m
905E
Mechanical Seal No. Spacer
1/4 - 20
70 - 75 in-lbs
8.0 - 8.5 N-m
905F
Throttle Bushing/Mechanical Seal
1/4 - 20
70 - 75 in-lbs
8.0 - 8.5 N-m
905G
Double Seal with Spacer
1/4 - 20
70 - 75 in-lbs
8.0 - 8.5 N-m
914A
Case Nuts
3/4 - 10
160 - 200 ft-lbs
217 - 270 N-m
914A
Case Nuts
7/8 - 9
225 - 245 ft-lbs
305 - 332 N-m
905A
Seal Housing to Gearbox
3/8 - 16 x 1 3/4
27 - 30 ft-lbs
47 - 54 N-m
905P
Separator
1/4 - 20 x 5/8
70 - 75 in-lbs
8.0 - 8.5 N-m
* When using Teflon o-rings, allow 15 minutes between torquing for the Teflon to cold flow. Repeat torquing
until there is no change in torque.
49
9.
Step 1
Wash all gearbox housings and be certain the lubrication galleys are open.
Step 2
Step 3
Step 4
Freeze lower idler journal bearing (151C) in dry ice for 1/2 hour and install into lower
gearbox housing (101A) with socket head cap screws (905AA).
Step 5
Install lower high speed journal bearing (151A) and lower thrust washer (155A), no shims
will be used.
NOTE:
If the unit includes thermocouples and probes refer to the section of this manual for GearboxAuxiliary Hardware Installation for additional instructions.
Step 6
Step 7
Install lube oil pump (A160) with o-ring (936Z) into bearing plate (102). Lubricate o-ring
(936Z) with Vaseline before installing lube pump.
Step 8
Install sump tube fitting (944B) and (944C) into the bearing plate (102).
Step 9
Install pipe plugs as required and relief valve (175) into bearing plate (102).
Step 10 Install upper high speed journal bearing (151B) into bearing plate (102) and upper thrust
washer (155B). Use Vaseline to hold upper thrust washer in place.
NOTE: SHIM BEHIND THE UPPER HIGH SPEED JOURNAL BEARING ONLY TO
ACHIEVE [.015 +/-.002], see Section 8.
Step 12 Install idler shaft (A140). Pull high speed shaft (A130) up approximately 1.0 to 1.5 and
slide idler shaft (A140) into the lower idler journal bearing (151C) meshing the gear teeth
on the lower idler shaft spur gear and the high speed shaft gear.
Step 13 Install o-rings (936YA) and (936T) and (936TT) into the lower gearbox housing (101A).
Step 14
Install the bearing plate (102) onto the lower gearbox housing (101A). Be careful
not to knock the upper thrust washer (155B) out of its location. Be careful not to scratch,
ding, or dent the upper high speed journal bearing (151B).
Step 15 Install o-rings (936Y) and (936TQ) into the bearing plate (102).
50
Step 16 Install lower input shaft roller bearing race into the top of the bearing plate (102) so it
locates against the lube pump (A160).
Step 17 Install the sump tube (173) into the sump tube fitting (944C).
Step 18 Install input shaft assembly (A120) into lower input shaft roller bearing. Pull up on the
idler shaft (A140) approximately 1.0 to 1.5 and mesh the input shaft assembly (A120)
gear with the idler shaft (A140) gear. Make certain that the input shaft assembly (A120)
slot fits over the lube pump (A160) drive pin.
Step 19 Freeze upper idler journal bearing (151D) in dry ice for 1/2 hour. Install the upper idler
journal bearing (151D) into the upper gearbox housing (101B). Use socket head cap
screws (905AB) to secure the upper idler journal bearing (151D) to the upper gearbox
housing (101B).
Step 20 Install the lube jet (174D) into the upper gearbox housing (101B).
Step 21 Install the upper gearbox housing (101B) onto the bearing plate (102).
Step 22 Install alignment bolts (909C) and fasten gearbox housings together. Use specified
torque value from chart, see Table 8.1.
Step 23 Install fasteners (909B) into gearbox housing and tighten. Use specified torque value
from chart, see Table 8.1.
Step 24 Install input seal (115) over input shaft assembly (A120) and press into upper gearbox
housing (101B), seating the input seal (115) firmly against the locating shoulder in the
upper gearbox housing (101B).
Step 25 Turn the complete gearbox assembly over so the high speed shaft (A130) is pointing
vertically toward the ceiling.
Step 26 Install the rotating face (51D) over the high speed shaft (A130) with the chamfer in the
rotating face (51D) toward the high speed shaft shoulder (A130).
Step 27 Install the roll pin (918D) into the lower gearbox housing (101A). Use a soft mallet to seat
the roll pin (918D) into place.
Step 28 Install the gearbox seal (60C) and the o-ring (936P) onto the lower gearbox housing
(101A). Use socket head cap screws (905E) and lock washer (916A).
Step 29 Install o-ring (936H), upper process seal (60B), into seal housing (30).
Step 30 Install rotating face (51D) onto high speed shaft (A130).
Step 31 Install o-ring (936K), sleeve (50B), onto high speed shaft (A130).
Step 32 Install o-ring (936J).
Step 33 Install thermal barrier gasket (87A) onto seal housing (30).
Step 34 Install seal housing (30) onto lower gearbox housing (101A).
Step 35 Install hex head cap screws (905A), lock washers (154AT), flat washers, (916AG), seal
washers (916S), through seal housing (30) and tighten screws to specified torque value.
51
Step 36 Install rotating face (51C) over high speed shaft (A130).
Step 37 Install o-ring (936J) over high speed shaft (A130).
Step 38 Install sleeve (50A) over high speed shaft (A130).
Step 39 Install o-ring (936J) over high speed shaft (A130 ASSY).
Step 40 Install o-ring (936H), lower process seal (60A) into seal housing (30).
Step 41 Install o-rings (936D), (936E), onto cover (15).
Step 42 Install cover (15) onto seal housing (30).
Step 43 Install rotating face (51A) over high speed shaft (A130).
Step 44 Install impeller bolt (3) into high speed shaft (A130).
Step 45 Install impeller (2) over impeller bolt (3).
Step 46 Install impeller bolt (3).
Step 47 Tighten impeller bolt (3) to correct torque specification, see Table 8.1.
Step 48 Install initial fill pipe (951D), (947L), (924RF), into upper gearbox housing (101B).
Step 49 Install vent pipe (951C), (947D), (186) into upper gearbox housing (101B).
Step 50 Install pressure gauge (942F), (177), (193C), into upper gearbox housing (101B).
Step 51 Reinstall the assembly of the gearbox/process end into the compressor housing (1).
Step 52 Reconnect all lubrication line and electrical connections.
52
53
10. Troubleshooting
Gearbox and Compressor
Many factors affect the performance of your compressor. Among them are suction pressure,
temperature, molecular weight, driver speed, flow rate, and discharge control. You need to check all
of these when there is a problem with the compressor and when you are analyzing the performance
of the system. For details on the performance of the compressor including the performance curve,
final data package sections 1 and 2 and specification sheets.
Table 10.1 provides information for analyzing gearbox and compressor problems.
Table 10.1 Troubleshooting for Gearbox and Compressor
Trouble
Possible Cause
Driver overloaded.
Check voltage.
54
Trouble
Possible Cause
55
Possible Cause
Investigative/Corrective Action
56
11. Operation
Some form of control is required for the majority of SUNDYNE compressor applications. The purpose
of control is twofold: 1) to achieve the desired performance as required by process conditions and 2)
to protect the compressor from mechanical damage due to surge or overload conditions.
This section is a general guideline on controls. A control system should be selected only after
completion of a detailed analysis of the specific installation.
Surge Control
It is recommended that a surge control system be installed whenever there is any chance
that the process flow could decrease appreciably from design flow. In most surge control
systems, a flow sensor is placed in the suction line to the compressor. The signal from this
sensor is input to a controller which controls a valve in the bypass loop. When the minimum
safe flow is reached, this valve opens and the flow through the compressor is kept above the
surge point. Again, the recycled gas must be cooled to prevent heat build-up. Both pneumatic
and electrical surge control systems are available.
Suction Throttling
Suction throttling is generally the most economical control method with a constant speed
drive. Throttling the control valve on the suction side causes a reduction of inlet pressure to
the compressor. Although the compressor creates the same compression ratio as if it were
unthrottled, the discharge pressure is reduced. The net result is to lower the total head output
to the system. The reduction of inlet pressure correspondingly decreases inlet gas density,
and thus, power consumption. Suction throttling also has the advantage of slightly lowering
the compressor surge point.
Discharge Throttling
Discharge throttling is control by means of a valve placed at the compressor discharge. A
constant speed compressor will always operate on its design head-flow curve. For a given
system operating point, the compressor will operate at the system flow rate, thus producing
more head than the system requires. This excess head is throttled by the discharge valve.
Since the throttling occurs downstream of the compressor, there are no power savings by this
method. Discharge throttling offers no real advantages over suction throttling, but is
nonetheless an acceptable control method.
Speed Control
Speed control is the most efficient means of compressor control. To operate at points below
the design head-flow curve, the driver speed may be reduced accordingly. This creates an
infinite family of head-flow curves on which the compressor may operate. Since consumed
horsepower, assuming constant inlet conditions, varies as the cube of the speed, substantial
power savings can be realized. Also, the compressor surge point is lowered proportional to
the speed decrease. This method is used mainly on turbine driven units although variable
speed motors or mechanical drives are available. Since the main lube oil pump in the
SUNDYNE compressor is driven by the gearbox input shaft, provision must be made so the
speed is not reduced to a point where adequate lube oil pressure is no longer present.
57
Flow Bypass
Flow bypass requires a recycle line from the compressor discharge to suction. The
compressor is operated at the desired flow or discharge pressure and the excess flow not
required by the process is recycled through the bypass. A cooler is required in the loop to
cool the recycled gas to normal suction temperature. This method is generally less efficient
than other methods discussed, but may be warranted in some special situations.
General
Assemblies, subassemblies and components of the Sundyne compressor are illustrated on
the exploded and cross sectional views in Reference D. Refer to your Sundyne Compressor
Specification Sheet for those options applicable to your compressor. The corresponding parts
lists, keyed to each part by item number, identify detail parts by part name, quantity and
location. A complete bill of materials list for the compressor and gearbox end is included in
the final data package. Refer to the unit outline drawing for a list of the major kit bills of
material.
2.
58
3.
Repair Kits
Seal and O-ring repair kits are not illustrated herein, but may be purchased directly from
Sundyne Corporation. Seal repair kits contain all normal wearing parts (springs, washers, orings, carbon faces, etc.) of the compressor or gearbox mechanical seals.
O-ring repair kits contain all o-rings necessary for maintenance or overhaul of the
compressor. The use of these kits reduces maintenance time, prevents assembly mistakes,
simplifies stocking and inventory, and reduces delivery time.
4.
Phone Number:
Fax Number:
+1-303-940-2989
+1-303-940-2826
Phone Number:
Fax Number:
+011-333-80-38-3300
+011-333-80-38-3366
Sundyne Nikkiso
27-10, Ebisu 2-Chome, Shibuya-Ku
Tokyo 150-0013, Japan
PHONE:
FAX:
+81-3-3444-6475
+81-3-3444-6806
59
LMC-341F
TYPICAL RECOMMENDED SPARES LIST
FLUID END ITEMS
LOC NO.
3
87A
2
50A
50B,50
51C
60A
60B
--
(1)
OPTION
ALL
ALL
ALL
DS,TS
DS,TS,SS
DS,TS
SS,TS
DS,TS
ALL
TYPICAL
PART NUMBER
BO03AD07DB3
GK01AW01
JM01AD87DD6800
SL01AD16DD
SL01AD02DD
RJ09AD20RE
SE04AD21F
SE04AD21F
RKORC311FUC
DESCRIPTION
BOLT, IMPELLER
GASKET, THERMAL
IMPELLER,COMPRESSOR
SLEEVE, LOWER
SLEEVE, UPPER
RING, MATING, UPPER
SEAL, LOWER
SEAL, UPPER
O-RING
1
0
1
0
0
0
1
1
1
1
CLASS (2)
3
2
1
1
2
1
1
0
1
1
1
1
2
1
2
1
2
1
2
2
NOTES:
(1) Options: SS = Single Seal, DS = Double Seal, TS = Tandem Seal,
(2) Class 1 = Minimum recommended spare parts necessary to perform a startup and inspection
of a new unit.
Class 2 = Minimum recommended spare parts necessary to cover 1-2 years of normal service
Class 3 = Minimum recommended spare parts necessary for critical service, or units that will be
installed in remote locations.
(3) * Items are alternate items, and should be purchased according to user's preference
(seal kits are available for mechanical seals only).
Revised 10/3/00
60
LMC-341F
TYPICAL RECOMMENDED SPARES LIST
GEARBOX ITEMS
TYPICAL
LOC NO.
A160
115
-125C
125D
151A
151B
151C
151D
155A
155B
51D
60C
936ZG
936P
936T
936TQ
936TT
936Y
936YA
936ZF
A130
OPTION
WS
ALL
AA
ALL
ALL
ALL
ALL
ALL
ALL
AA
AA
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
(1)
PART NUMBER
PU04AW02
20-314
22-141
21-108
21-108
BT20AD0860B
BT20AD0860B
BE09AY02A
BE09AY01A
WA05AA01320
WA05AA01320
RJ09AA21SD
SE04AA53A
14-057UC
14-055UC
14-324UC
14-324UC
14-324UC
14-322UC
14-322UC
14-323UC
SH01AY05E1L0
CLASS
DESCRIPTION
PUMP, LUBE, REVERSIBLE
SEAL, ASSY, INPUT
FILTER, OIL, HILCO
BEARING, INPUT, UPPER
BEARING, INPUT, LOWER
BEARING, HIGH SPEED, LOWER
BEARING, HIGH SPEED, UPPER
BRG, JOURNAL, LOWER IDLER
BRG, JOURNAL, UPPER IDLER
WASHER, THRUST, LOWER
WASHER, THRUST, UPPER
RING, MATING
SEAL, ASSY, GEARBOX
O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
SHAFT, ASSY, HIGH SPEED
1
0
1
2
0
0
0
0
0
0
0
0
1
1
2
2
2
2
2
2
2
2
0
2
1
1
6
1
1
0
0
0
0
0
0
1
1
4
4
4
4
4
4
4
4
1
(2)
3
1
1
6
1
1
1
1
1
1
1
1
1
1
4
4
4
4
4
4
4
4
1
NOTES:
(1) Options: WS = Wet Sump , AS = As Applicable
(2) Class 1 = Minimum recommended spare parts necessary to perform a startup and inspection
of a new unit.
Class 2 = Minimum recommended spare parts necessary to cover 1-2 years of normal service
Class 3 = Minimum recommended spare parts necessary for critical service, or units that will be
Installed in remote locations.
Revised 10/3/00
61
COPYRIGHT
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or
transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise
without the prior permission of Sundyne Compressors.
SAFETY WARNING
Sundyne Compressors manufactures centrifugal process gas compressors to exacting International Quality
Management System Standards (ISO 9001 - 1987) as certified and audited by Lloyd's Register Quality
Assurance Limited. Genuine parts and accessories have been specifically designed and tested for use with these
products to ensure continued product quality and performance. As Sundyne Compressors cannot test all parts
and accessories sourced from other vendors, incorrect design and/or fabrication of such parts and accessories
may adversely affect the performance and safety features of these products. Failure to properly select, install or
use authorized Sundyne Compressor parts and accessories is considered misuse and damage or failure caused
by misuse is not covered by Sundynes warranty. Additionally, modification of Sundyne Compressor products
or removal of original components may impair the safety of these products and their effective operation.
Reference A
Critical Start-up Checklist
Know Your Machine
Before servicing and starting up the Sundyne line mounted compressor (LMC), carefully review the
specification sheet, the outline drawings, the performance curves, and this instruction manual. You
should be familiar with the configuration of the compressor before you start and operate it.
62
Driver Instructions
Carefully follow the installation and starting instructions provided by the manufacturer of the driver.
This is included in the final data package.
Auxiliaries
1. Check the utility connections.
2. Verify that the auxiliary piping conforms to Sundynes drawings.
3. Verify the connections of the switches, the instruments, and the set points.
4. Calibrate the flow instruments and the other transmitters.
Start Compressor
1. Suction throttling (preferred method): Start the compressor with the discharge valve open while
throttling the suction valve, to bring the compressor to the design operating point. See
specification sheets for the inlet conditions and flow rate.
2. Discharge throttling: Start the compressor with the suction valve completely open while throttling
the discharge valve, to bring the compressor to the design operating point.
3. Variable speed (as applicable): Start the compressor with the suction valve and the discharge
valve open. Check the pressure in the system. If it exceeds the surge point of the compressor (see
the specification sheet and the performance curve), you will need a bypass to protect the
compressor from surging during ramp-up to speed. Never operate the compressor above the
maximum design speed.
Heat Exchanger
If a heat exchanger for the gearbox is installed, adjust the cooling flow to keep the temperature of the
gearbox sump at 120-180F (49-82C).
Check
Check the following items. Each of these parameters significantly affects the performance of the
system. Head rise, Flow rate, Power consumption, Inlet pressure, Temperature; and Molecular
weight.
Coupling
There are two types of connections between the motor and gearbox; a splined shaft or a coupling.
For splined connections, the splined shaft must be lubricated with the supplied spline grease and the
two
o-rings installed prior to the mounting the motor. It is recommended that the input shaft be rotated by
hand prior to mounting the motor. If the unit has a coupling, be sure coupling gap is correct and
bolting between coupling halves is tight. The instruction manual contains coupling set-up information.
63
Process Conditions
Do process conditions; suction pressure, suction temperature, discharge header pressure, and mole
weight agree with specification sheet information? Check with your Sundyne Corporation
representative if you must test a different gas than shown on the specification sheet.
Piping Connections
Are the following bolted/threaded connections tight:
a. Compressor flange bolts?
b. Seal environment piping and port connections?
c. Cooling water connections to heat exchanger? (if applicable)
d. Gearbox oil drain plug?
e. Compressor case drain plug?
Reference B
Lock-out/Tag-out Guidelines
Follow Your Companies Lock-Out / Tag-Out Procedure When Servicing Sundyne
Compressors.
Never remove a lock or tag applied by someone else. Additional locks or tags should be applied if
multiple groups are working on the equipment. Each responsible work group leader should apply a
lock or tag. Always treat conductors and equipment as if they are energized.
Reference C
Seal Arrangement Drawings for Single, Double and Tandem Configurations
64
65
66
67
Reference D
Phoenix Compressor/Gearbox Cross-section Drawing
Phoenix Gearbox Module Drawing GB01AY01
68
69
70
72
73
74
75
76
77
14845 W. 64th Avenue Arvada, Colorado 80007 USA +1-303-425-0800 FAX: +1-303-425-0896 www.sundyne.com
Sundyne Europe Dijon (Longvic) France +33 (0) 3.80.38.33.00 FAX: +33 (0) 3.80.38.33.66
Sundyne Nikkiso 27-10, Ebisu 2-Chome, Shibuya-Ku Tokyo 150-0013, Japan +81-3-3444-6475 FAX: +81-3-3444-6806