Syndyne Blower

OVERHAULING REPORT OF 1C0610B DEHAYDRATION
GAS BLOWER
(LMC- 311 F)
21 – 25 January, 2015
OVERHAULING REPORT OF DEHYDRATION BLOWER
1C0610B
Page 2 of 37
Activity Name Designation Date Signature
Prepared By Feb 01, 2015

M.ASHRAF KHAN SR.MECHANICAL TECH.
Reviewed By AHMED MASOOD SR.MECHANICAL ENGINEER Feb 01, 2015
Approved By SAJID BASHIR MAINTENANCE SUPREDETANT Feb 01, 2015
CONTENTS
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1.0 BACKGROUND
2.0 HISTORY
3.0 DISMANTLING
4.0 FINDINGS AND OBSERVATIONS
5.0 RE-ASSEMBLY
6.0 SPARES USED
7.0 SEAL LEAK TEST
8.0 INSTALLATION ON LOCATION
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BACKGROUND
The Regeneration Gas Blower function is used in the dehydration regeneration system
to blow the hot gas across the regenerating dehydration bed.
At Bhit Gas Field there are two blowers installed in parallel (one running, one standby)
on each train. Each is a single stage high speed centrifugal compressor connected to
the motor through a gearbox. A small stream of gas from the process gas exiting the
dust filter is used for the dehydration bed regeneration duty. This stream enters the
blower at 600Psig and is discharged at approximately 650 Psig. The gas exits the
blower discharge and is routed to the Regeneration Gas Heater E-0620. The discharge
of the blower also has a non return valve to prevent back flow into the compressor.
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Lube Oil System
The integral Sundyne lube oil system consists of the following major parts
• Gear Box Oil Sump
• Main Lube Oil Pump
• Oil Heat exchanger
• Oil Filter
Oil is taken from the sump by the lube oil pump which is pumped through internal
passages to an externally mounted manifold, then through the heat exchanger and the
filter and back into the gearbox to the various lube oil jets. After passing through the
bearings the oil drains back into the sump. The gearbox sump holds approximately 7.4
liters of oil (not including auxiliary piping and heat exchanger). The main lube oil pump
is a constant displacement gear type directly driven by the input shaft. The oil filter is a
disposable pleated paper element type.
HISTORY
The blower was taken in for major overhauling based on the completion of the running
hours recommended by the Original Equipment Manufacturer (Sundyne). The running
hours completed by the blower were 40182 hrs.
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DISMANTLING
1. Compressor
1. Remove bolts securing the coupling guard and then remove the coupling guard.
2. Disengage both ends of the spacer coupling and remove the coupling spacer.
3. Remove the coupling hub by using a plate puller and inner pack jack. The depth
of the coupling hub and the input shaft was found to be 0.80 mm.
4. Remove nuts from the compressor casing studs and release the stiffening
brackets. Attach the special turnbuckles to the gearbox. Using the turnbuckles,
lift the gearbox and seal housing from the compressor casing. Care needs to be
taken to prevent damage to the impeller. The assembly is rotated for working
on the compressor impeller.
5. Prevent impeller from rotating by using the special locking tool and remove
impeller but and then the impeller. Note that the impeller nut has left-hand
threads.
6. Remove the spacer washer and diffuser cover from the seal housing.
7. Remove the seal rotating face of the lower seal of the tandem seal arrangement
and the lower shaft sleeve.
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8. Detach seal housing from the gearbox by removing the cap screws. Dismantle
the seal assembly for inspecting and cleaning.
9. Remove gearbox mechanical seal along with the rotating face.
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10. Gearbox
1. Remove the fill vent piping by unscrewing the ¾-inch pipe elbow.
2. Remove bolts and remove the gearbox input housing by lifting the tapping on
the underside of the input housing with a soft hammer.
3. Using a hammer and punch, remove input shaft lip seal. Exercise care to avoid
damaging the gearbox housing.
4. By slightly Lifting the idler shaft out of the lower bearing liner disengage the
upper idler and input shaft gears, then remove the low speed shaft from the
gearbox bearing plate.
5. Remove the gearbox bearing plate, idler shaft and the output shaft.
6. Dismantle the gear pump from the gearbox bearing plate
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7. Remove the upper journal bearing.
8. Remove the lower journal bearing and thrust washer.
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FINDINGS AND OBSERVATIONS
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Compressor Gas side
Part description Remarks
Compressor Casing In good condition
Diffuser In good condition
Cover diffuser In good condition
Good condition –
Seal housing
Alignment pins properly installed & in good state
Impeller Good condition – can be reused
Sealing
In good condition
Shaft sleeve lower
– can be reused
In good condition
Shaft sleeve upper
– can be reuse
Mating ring lower Dirty – little circular grooves
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-normal wear -
Little circular grooves -

Mating ring upper
Normal wear
Gearbox mating ring One Little circular deep groove
Retainer was full of dust (Process

Mechanical seal lower
depot) – No failure
Retainer in good condition

Mechanical seal upper
No dust foreseen
Primary seal failure – Two tips

Gearbox mechanical seal
(material removal on the primary seal edge)
Every O-ring, lip seal & gaskets
were in place & in normal condition

O-ring, lip seal, gaskets
of operation.
No failure to report
Gearbox
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In good condition
Input shaft
Both ball bearings have been changed.
In good condition
Idler shaft
Both ball bearings have been changed.
¤ Superficial scratches on the thrust runner face
¤ Run out in tolerance ( 0.015mm)
¤ Both cylindrical surfaces in contact with journal bearing
were in tolerance (upper diameter 38.02mm & lower

High speed shaft
diameter 38.01mm) Can be reused
Lower journal bearing Normal wear - Can be reused
Grooves on the pads
Upper journal bearing >>> Pads must be changed – the cartridge can be
considered as a emergency spare part
In good condition
Upper housing
¤ Both ball bearing liners have been controlled and in
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tolerance (90.00 mm each)
¤ Lube jets have been tested
>>> Can be reused
In good condition
¤ Ball bearing liner has been controlled and was in
Bearing plate tolerance (90.00mm)
¤ Lube jet tested
>>> Can be reused
In good condition
Lower housing ¤ Lube jets tested
>>> Can be reused
Normal wear
Lub oil pump >>> Changed by security
>>> Now considered as a emergency spare part
RE-ASSEMBLY
a) Gearbox
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1. Install the lower journal bearing into the gearbox output housing. With no shim
spacers installed, tighten the screws.
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2. Install the upper journal bearing or bearing assembly into the bearing plate.
With no shim spacers installed, tighten the screws.
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3. Place the lower thrust washer into lower journal bearing. Place the high-speed
shaft assembly into the gearbox output housing.
4. With the aid of dowel bolts, install bearing plate without o-rings.
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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 (0.38 + 0.05mm). End play was found to be 0.79 mm
6. Remove the alignment bolts and bearing plate with upper journal bearing.
Remove high speed shaft, thrust washer and the lower journal bearing. Then
install the required shim spacers (0.41 mm) in place on the gearbox output
housing, fix the lower journal bearing and install the high speed shaft. Final float
was found to be 0.38 mm.
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7. Install new upper and lower ball bearings on the idler shaft by heating bearings
to 90 C.
8. Continue re-assembly of the gearbox by placing idler shaft in the lower half of
the gearbox.
9. Install the lube oil pump in the bearing plate. Position bearing plate on the
lower half of the gearbox.
Lub oil pump (New configuration)
Lub oil pump
(Old
configuration)
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10. Install the low speed shaft assembly into the bearing plate with the shaft aligned
so that the lube oil pump pin slips into the slot in the low speed shaft.
11. Install the sump tube and pipe connectors into the bearing plate.
12. Lower the upper gearbox casing on the bearing plate by using guide pins and
slightly hammer to assemble. Tighten the bolts to finish assembly
13. Install the input shaft double lip seal by using the special tool.
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14. Install dust cover.
15. Rotate the gearbox and install the gearbox seal rotating face and stationary
face. Tighten to proper torque values.
16. Compressor
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1. Install the dry gas seal mating face in the seal housing.
1. Assemble seal housing with the gearbox casing.
2. Install rotating face and the process dry gas seal assembly.
3. Install the diffuser cover plate without o ring, place the spacer washer and then
install the impeller on the output shaft. The clearance between the impeller and
the cover was found to be 0.25 mm from all around the impeller. The original
spacer of height 1.90 mm was used.
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4. Place lead wires on the impeller vanes at four different locations to check the
diffuser impeller gap.
5. Rotate and guide the assembly into the diffuser casing and tighten bolts to get a
firm fit. Loosen bolts and check the crushed thickness of the lead wires with a
vernier caliper to ensure the diffuser impeller gap found 1.9mm.
6. Assemble gearbox assembly and diffuser casing and check the clearance again.
The final clearance was found to be 1.9mm.
7. Install O rings and box up the compressor.
8. Install the coupling hub by heating it to 150 C. Then fix the coupling spacer.
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SPARES CONSUMED
Sno Part Description Quantity
1 Ball bearing (Input shaft upper ) 1
2 Ball bearing (Input shaft lower ) 1
3 Ball bearing (Idler shaft lower) 1
4 Ball bearing (Idler shaft upper) 1
5 Lower journal bearing 1
6 Upper journal bearing with tilting pad 1
7 Lube oil pump (New configuration) 1
8 Lip seal (New configuration Mech seal ) 1
9 O-ring 4
10 Gasket housing 2
11 Thermal barrier gasket 1
12 Mechanical seal (oil) 1
13 Mechanical seal process lower 1
14 Mechanical seal process upper 1
15 Mating ring (oil seal) 1
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16 Mating ring process lower 1
17 Mating ring process upper 1
18 O-ring kit 1
19 Thrust washer lower journal bearing 1
20 Lock washer 6
21 Oil filter 1
SEAL LEAK TEST
To check the proper functioning of the Mechanical seal a test was performed inside
the workshop by pressurizing the casing with nitrogen at 50 psig. The casing discharge
was blinded to maintain the pressure inside the casing and a pressure indicator was
installed at the suction. After 25 mins the pressure inside the casing was found to be
near 47 psig. The recommended drop in pressure is 4.41 Psig every 15 mins. This test
showed that the mechanical seals were properly installed and are fit for running.
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INSTALLATION ON LOCATION
The compressor was installed on site and the motor was mounted. The necessary
connections were made and Sundyne recommended lube oil was poured into the
gearbox and the auxiliary circuit.
No leakage of the mechanical seal or any kind of abnormal noise was reported. The
following parameters were noted after the compressor was started.
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Units Start-Up After 2 hrs
Suction Pressure Psi 600 600
Discharge Pressure Psi 640 640
Oil Temperature °F 85 133
Oil Pressure Psi 33 33
Filter Differential Pressure Psi 5 5
Overall Vibrations mm.s-1 1.9 1.9
DIS-ASSEMBLY TEAM MEMBERS
ASHRAF KHAN, RASHID, NAWAZ , AQEEL, USAMA
RE-ASSEMBLY TEAM MEMBERS
ASHRAF KHAN, JAMIL, NAWAZ, AQEEL, USAMA
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SEAL OVERHAULING REPORT OF 1C0610B DEHAYDRATION

GAS BLOWER
(LMC- 311 F)
04 – 06 February, 2015
Activity Name Designation Date Signature
Prepared By Feb 08, 2015

Rashid Iqbal/Waqas SR.MECHANICAL TECH.
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1C0610B
Page 32 of 37
Reviewed By AHMED MASOOD SR.MECHANICAL ENGINEER Feb 08, 2015
Approved By SAJID BASHIR MAINTENANCE SUPREDETANT Feb 08, 2015
HISTORY
The blower was overhauled on 25 January 2015 and due to excessive seal leakage it is
decided to overhaul the blower seals. So on 04 February 2015 we get permit from
production team and shifted the blower to mechanical work shop for seals
overhauling.
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DISMANTLING:-
9. Remove bolts securing the coupling guard and then remove the coupling guard.
10. Disengage both ends of the spacer coupling and remove the coupling spacer.
11. Remove nuts from the compressor casing studs and release the stiffening
brackets. Attach the special turn buckles to the gearbox. Using the turnbuckles,
lift the gearbox and seal housing from the compressor casing. Care needs to be
taken to prevent damage to the impeller. The assembly is rotated for working
on the compressor impeller.
12. Prevent impeller from rotating by using the special locking tool and remove
impeller but and then the impeller. Note that the impeller nut has left-hand
threads.
13. Check the high speed shaft float found 0.40mm.
14. Remove the spacer washer and diffuser cover from the seal housing.
15. Remove the seal rotating face of the lower seal of the tandem seal arrangement
and the lower shaft sleeve.
16. Dismantle the seal assembly for inspecting and cleaning.
17. Remove gearbox mechanical seal along with the rotating face.
FINDINGS AND OBSERVATIONS:-

1. Oil found in process gas faces.
2. Carbon/dust soaked with oil found between processes, buffer seals.
3. Diffuser cover bolts washer damaged.
4. Seal vent pipe orifice found blocked.
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Assembly work:-
5. Install the new gear box oil seal assembly in the seal housing.
6. Diffuser cover bolts washer made from machine shop with o-ring slot.
7. Install the new buffer gas seal assembly in the seal housing.
8. Install the new process gas seal assembly in the seal housing.
9. Install all O rings new and box up the compressor.
10. Check the high speed shaft float found 0.40mm.
11. All bolts tighten according to the recommended torque values.

Note: old Seal retainers used in buffer gas and process gas seals.
SEAL LEAK TEST

To check the proper functioning of the Mechanical seal a test was performed inside
the workshop by pressurizing the casing with nitrogen at 60 psig. The casing discharge
was blinded to maintain the pressure inside the casing and a pressure indicator was
installed at the suction. After 20 mins the pressure inside the casing was found to be
near 56 psig. The recommended drop in pressure is 4.41 Psig every 15 mins. This test
showed that the mechanical seals were properly installed and are fit for running.
INSTALLATION ON LOCATION
The compressor was installed on site and the motor was mounted. The necessary
connections were made and Sundyne recommended lube oil was poured into the
gearbox and the auxiliary circuit.
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No leakage of the mechanical seal or any kind of abnormal noise was reported. The
following parameters were noted after the compressor was started.
Units Start-Up After 3 hrs
Suction Pressure Psi 600 600
Discharge Pressure Psi 640 640
Oil Temperature °F 80 140
Vibration report:-
Last Measurement Deviation Report
*********************************
Database: Train-1.rbm
Area: DEHYDRATION UNIT-1
Report Date: 07-Feb-15 16:19
Reference Value is the PREVIOUS DATA
POINT POINT CURRENT REF ABS. % ALR
ID DESCRIPTION VALUE VALUE UNITS DELTA DEV. SYM
----- -------------------------------------------------------------------
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1- C-610 B - REGEN GAS BLOWER (07-Feb-15) PARM = OVERALL
M1H=Motor Outboard Horizontal .950 .557 mm/Sec .393 70
M1P=Motor Outboard Horz Peakvue .240 .248 G-s -.0078 -3
M1V=Motor Outboard Vertical 1.064 .769 mm/Sec .295 38
M1A=Motor Outboard Axial .702 .466 mm/Sec .236 51
M2H=Motor Inboard Horizontal 1.118 1.352 mm/Sec -.234 -17
M2P=Motor Inboard Horz Peakvue .420 .344 G-s .076 22
M2V=Motor Inboard Vertical .868 1.138 mm/Sec -.269 -24
M2A=Motor Inboard Axial 1.846 1.864 mm/Sec -.018 -1
G1H=Gearbox Inboard Horizontal 1.818 2.392 mm/Sec -.575 -24
G1P=Gearbox Inboard Horz Peakvue .431 .522 G-s -.091 -17
G1V=Gearbox Inboard Vertical 1.678 1.956 mm/Sec -.278 -14
G1A=Gearbox Inboard Axial 1.251 1.244 mm/Sec .0073 1
G2H=Gearbox Outboard Horizontal 1.096 1.794 mm/Sec -.698 -39
G2P=Gearbox Outboard Horz Peakvue .435 .560 G-s -.125 -22
G2V=Gearbox Outboard Vertical 1.259 1.381 mm/Sec -.122 -9
G2A=Gearbox Outboard Axial 1.014 .933 mm/Sec .080 9
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----------------------------------------------------------------------------
% - Maximum Percentage Alarm
+ - Maximum Delta Alarm
# - Maximum Value Alarm
TEAM MEMBERS
Rashid iqbal
Waqas Ali
Abdul moqeet
Aqeel Ahmed
37

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OVERHAULING REPORT OF 1C0610B DEHAYDRATION

Activity Name Designation Date Signature

Prepared By Feb 01, 2015

Reviewed By AHMED MASOOD SR.MECHANICAL ENGINEER Feb 01, 2015

Approved By SAJID BASHIR MAINTENANCE SUPREDETANT Feb 01, 2015

4.0 FINDINGS AND OBSERVATIONS

6.0 SPARES USED

7.0 SEAL LEAK TEST

8.0 INSTALLATION ON LOCATION

Lube Oil System

• Gear Box Oil Sump

• Main Lube Oil Pump

• Oil Heat exchanger

9. Remove gearbox mechanical seal along with the rotating face.

6. Dismantle the gear pump from the gearbox bearing plate

7. Remove the upper journal bearing.

8. Remove the lower journal bearing and thrust washer.

FINDINGS AND OBSERVATIONS

Compressor Gas side

Part description Remarks

Compressor Casing In good condition

Diffuser In good condition

Cover diffuser In good condition

Impeller Good condition – can be reused

Part description Remarks

Mating ring lower Dirty – little circular grooves

Little circular grooves -

Gearbox mating ring One Little circular deep groove

Retainer was full of dust (Process

Retainer in good condition

Primary seal failure – Two tips

Every O-ring, lip seal & gaskets

were in place & in normal condition

Part description Remarks

¤ Superficial scratches on the thrust runner face

¤ Run out in tolerance ( 0.015mm)

¤ Both cylindrical surfaces in contact with journal bearing

were in tolerance (upper diameter 38.02mm & lower

Lower journal bearing Normal wear - Can be reused

Grooves on the pads

considered as a emergency spare part

tolerance (90.00 mm each)

¤ Lube jets have been tested

>>> Can be reused

¤ Ball bearing liner has been controlled and was in

Bearing plate tolerance (90.00mm)

¤ Lube jet tested

>>> Can be reused

Lower housing ¤ Lube jets tested

>>> Can be reused

Lub oil pump >>> Changed by security

>>> Now considered as a emergency spare part

Lub oil pump

14. Install dust cover.

1. Assemble seal housing with the gearbox casing.

7. Install O rings and box up the compressor.

1 Ball bearing (Input shaft upper ) 1

2 Ball bearing (Input shaft lower ) 1

3 Ball bearing (Idler shaft lower) 1

4 Ball bearing (Idler shaft upper) 1

5 Lower journal bearing 1

6 Upper journal bearing with tilting pad 1

7 Lube oil pump (New configuration) 1