Sttlas Copco INSTRUCTION MANUAL for ATOMIZING AIR COMPRESSOR MODEL #SC-6 Manufactured for: European Gas Turbines S.A. Sales Order # SC-72073 thru SC-72076 ATLAS COPCO COMPTEC INC. Parts and Service Centre 20 School Road Voorheesville, NY 12186 USACONTENTS Description Page PREFACE i Safety Precautions ..... son preface-3 ii Warranty ... von preface-4 iii “Limit of Liability ....... .n preface-5 iv. Receiving and Storage son prefce-6 1,0 GENERAL DESCRIPTION .. 1.1 General Information and Data 1.2. Compressor Description ... 2.0 INSTALLATION ... Ded 2.1 Installation Summary ou Del 2.2 Shipping and Packing .. 2-1 2.3. Setting and Leveling 2d 2.4 Piping Connection: 2-2 2.5. Blectrical Connections/Conttol System 22 2.6 Lube System Preparations 2.7. Coupling Alignment...... 2.8. Installation Pre-Start Check. 2.9 Compressor Start-up 3.0 Operation Record. 3.0 LUBRICATION SYSTEM. 3.1. Lube Data and Requirements... 3.2. Description 33 Oil Filter Cartridge Replacement». 3.4 Oil Changing Procedure .... 4.0 SEAL SYSTEM ...... 5.0 MAINTENANCE... 5.1, Vibration & Rotor Position Monitoring 5.2. Major Maintenance... 5.3. Inspection. 5.4 Reassembly 6.0 SPARE PARTS .. 7.0 BILLS OF MATERIAL... 8.0 DRAWINGS European Gas Turbines SA . preface 2 ‘Atlas Copco Sales Order #SC-72073 thru SC-72076SAFETY PRECAUTIONS WARNING: Centrifugal compressors have high speed rotating components and can cause fatal injury, Only qualified personnel should be allowed to install, operate, and maintain this com- pressor and the associated equipment. To protect personnel from injury, the proper safety pre- cautions contained in this manual must be followed, + Use proper care and procedures in handling, lifting, installing, operating, and maintaining the equipment. + Do not touch energized circuits or rotating parts + Wear proper hearing protection when in close proximity to machinery with high noise levels. + Do not by-pass or render inoperative any safeguards or protective devices. * Periodically check safety devices. + If gas piping downstream of the compressor must remain pressurized while maintenance is being performed on the compressor, be sure that a blind flange has been installed to prevent inadvertent back-flow of air through the machine, Do not rely on a check valve. + Do not remove any compressor parts, including guards, shields, screens, caps, or plugs before relieving pressure from the system. Oil or air under pressure can cause severe injury, or death, + Do not operate the compr tion and Data) sor at pressures and speeds above its rating (re: "General Informa- + To avoid electrical shock, disconnect all power sources from the machine and accessories before maintenance. Safe maintenance practices with qualified personnel are imperative. + Ground electrical components and the machine in accordance with the national electrical code and consistant with sound local practice. + Do not leave loose items (for example, tools, rags, or machine parts) on the compressor or ‘gear assembly prior to start-up. + Do not use flammable solvents for cleaning parts + Keep dirt out of exposed openings by covering them with clean cloth or kraft paper. + Do not use parts of the compressor or its piping as a ladder; use temporary scaffolding. + Do not touch hot portions of the equipment; for example, the intercoolers or compressor housing. ‘The owner, lessor, or operator of the compressor unit is hereby notified and forewarned that failure to observe common safety precautions, whether specifically stated herein or not, may result in injury to personnel or damage to equipment. CS EEE! European Gas Turbines SA preface 3 Atlas Copeo Sales Order #SC-72073 thru SC-72076WARRANTY The following product warranty is quoted from Atlas Copco’s General Terms and Conditions of Sale: Atlas Copco warrants to the purchaser that the products manufactured by Atlas Copco and affiliates shall be free of defects in design, material and workmanship for 18 months from date of shipment to purchaser, or 12 months from date of initial start up, whichever occurs first. Normal wear parts are sold AS IS and are not covered by warranty, Should any failure to conform with warranty appear prior to or after shipment of the product to the purchaser during the specified periods under normal and proper use and provided the product has been properly sorted, installed, handled, and maintained by the purchaser, Atlas Copco shall, if given prompt notice by purchaser, repair or replace the non-conforming product or authorize repair or replacement by the purchaser and reimburse the purchaser for reasonable expenses incurred, ‘When the nature of the defect is such that itis appropriate in the judgement of Atlas Copco to do 80, repairs will be made at the site of the product. Repair or replacement under the applicable ‘warranty shall be made at no charge for replacement parts, warranty labor, and servicemen transportation and living costs when work is performed during normal working hours (8am to 4:30 pm). Labor performed at other times will be billed at the overtime rate then prevailing for services of Atlas Copco personnel. Atlas Copco’s warranty does not extend to products not manufactured by Atlas Copco or affili- ates, As to such produets, the purchaser shall be entitled to proceed only upon the terms of the particular manufacturer's warranty. Warranty does not apply to defects in material provided by purchaser or design stipulated by purchaser. ‘THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OF QUALITY, WRITTEN, ORAL OR IMPLIED, AND ALL OTHER WARRANTIES, INCLUDING WITHOUT LIMITATION ANY WARRANTY OF MER- CHANTABILITY OR FITNESS ARE HEREBY DISCLAIMED. Correction of nonconformities as provided above shall be purchaser’s exclusive remedy and shall constitute fulfillment of all liabilities of Atlas Copco (including any liability for direct, indirect, special, incidental or consequential damage) whether in warranty, strict liablility, contract, tort, negligence, or otherwise with respect to the quality of or any defect in products delivered hereun- der. net European Gas Turbines SA prefecet Ailas Copco Sales Order #SC-72073 thru SC-72076LIMIT OF LIABILITY ‘The following statement of liability is quoted from Atlas Copco’s General Terms and Conditions of Sale: IN NO EVENT SHALL ATLAS COPCO BE MADE LIABLE FOR SPECIAL INDI- RECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES, however arising, whether in warranty, strict liability, contract, tort, negligence or otherwise, including but not limited to loss of profits or revenue, loss of total or partial use of the products or facilities or services, downtime cost, or claims of purchaser for such or other damages whether on account of products furnished hereunder or delays in delivery thereof or services performed upon of with respect to such prod- ucts. iii Atlas Copco’ liability on any claim whether in warranty, strict liability, contract, tort, negligence or otherwise for any loss or damage arising out of, connected with, or resulting from this contract or the performance or breach thereof, or from design, manufacture, sale, delivery, resale, rep: replacement, installation, technical direction of installation, inspection, servicing, operation or use of any product covered by or furnished under this contract shall in no case (except as pro- vided in the section entitled “Patent Indemnity” (contained in General Terms and Conditions of Sale) exceed the purchase price allocable to the product or part thereof which gives rise to the claim, All causes of action against Atlas Copco arising out of or relating to this contract ot the perform- ance hereof shall expire unless brought within one year of time of occurrence thereof. European Gas Turbines SA, Atlas Copco Sales Order #SC-72073 tha SC-72076 oeGENERAL DESCRIPTION GENERAL INFORMATION AND DATA Customer Name: European Gas Turbines $.A. Customer Address: Belfort, France User: European Gas Turbines S.A Job Site Location: Customer P.O, No.: 53732157PT1 ATLAS COPCO COMPTEC Sales Order No.: SC-72073 thru SC-72076 Serial Number: _ACC9672073/74/75/16 _ Model No.: SC-6 Type: ‘Atomizing air compressor No. of Stages: 1 DESIGN CONDITIONS Type of Gas Air Flow (Ib/sec) 10.58 Relative Humidity(%) 0 Mole Wt. 28.96 Specific Heat Ratio(K) 1.39. Comp. Factor (Z) 999 Inlet Press. (psia) 192 Inlet Temp. (°F) 239 Disch. Press. (psia) 283 Disch Temp. (°F) 348 Coolant n/a Coolant Flow (GPM) n/a Max. Cool. Press. (psig) __n/a Coolant Temp (°F) nla Required Horsepower 460 Comp Speed (RPM) 34526 Driver Horsepower 500, Driver Speed (RPM) 2980 Driver Voltage Service Factor na Driver Hertz 50 Physical Conditions, Outline Drawing # 9455350057 Length 24.5" Width 35.9" Height _ 50.3" Weight __2,100# Connections: Inlet Flange 6 In,_300_ Lbs. RF. Discharge Flange 4 In,_300_ Lbs. RF. Oil Supply 12 In,_=__ Lbs, NPT Oil Drain 4 In. 150. Lbs. RE. European Gas Turbines SA, Ld Atlas Copco Sales Order #SC-72073 thru SC-72076COMPRESSOR DESCRIPTION ww 12 The compressor consists of an overhung, open-type impeller and inlet shroud installed in a nodular cast iron housing. The impeller is mounted directly on the high speed pinion shaft which is supported by two tilting pad bearings ‘The main motor drives the pinion through a flexible disc coupling and single-step speed increaser gear supported in two sleeve bearings. The gears are of hardened steel and ground to AGMA Q- 13 standards. The gearbox is horizontally split in the pinion plane permitting easy inspection of the high speed bearings and removal or installation of the complete rotor assembly. A unitized fabricated steel base supports the gear casing and compressor housing. ‘The lube oil system is supplied by the customer. Oil supply and return connections are provided. European Gas Turbines SA, a Ailas Copco Sales Order #SC-72073 thru SC-72076INSTALLATION .. 2.0 INSTALLATION SUMMARY The compressor has been fully shop tested and shipped directly to the job site, Therefore, instal- lation requirements are reduced to a minimum to put the compressor into service. The following is a list of operations to be performed to install the compressor. Set and level the compressor on its base; bolt down. Connect piping. Connect the lube system. Align the coupling/motor. Connect electric power. Check the control system. Perform a pre-start check. Perform initial start-up. Sx aways tis recommended that the compressor be installed as soon as possible upon receipt. If the compressor is not to be installed immediately, refer to the receiving and storage procedure in the front of this book. SHIPPING AND PACKING .. 22 Unless otherwise specified by the Customer, the compressor package has been given no special shipping preparation. Basic procedures were followed at the factory to protect against rust and corrosion in general and all machines are run at the factory. Although they are shipped without oil, a film of rust inhibiting oil remains on the parts during shipment. Upon receipt of the compressor it is recommended that all bearing and oil reservoirs be filled to the proper level with the recommended oil. Connection openings have been properly covered to protect against dirt entry and damage. These covers should not be removed until just before connections are to be made. Itis recommended that an “installation log” be established to record dates, time and data such as oil reservoirs changing data, quantity of oil, type and make; base level setting; coupling align- ment (see Alignment Sheet); machine and control checks and inspections. SETTING AND LEVELING. sone 23 ‘The compressor has been designed and constructed such that there are no unbalanced forces or couples at operating conditions, The foundation should be of adequate size and rigidity to support the compressor. The compressor should be bolted to the base to resist piping forces. Shims should be used to insure a solid contact between the compressor and the base. Caution should be exercised when shimming and bolting not to distort the base. Grouting is not permis- sible since it is important to allow the base to expand freely. The recommended bolting arrange- ‘ment is shown on the Foundation Drawing, European Gas Turbines SA 2 ‘Atlas Copco Sales Order #SC:72073 thru SC-72076PIPING CONNECTIONS ALL PIPING MUST BE SUPPORTED SO THAT MINIMUM WEIGHTS AND STRAINS ARE IMPOSED ON ALL PIPE CONNECTIONS. THE OUTLINE DRAWING INDI- CATES THE MAXIMUM ALLOWABLE FLANGE LOADINGS. Piping should be installed such that when a connection flange is broken after the machine has been run and is still warm, no misalignment of the flanges can be seen. It is required that the customer install drain valves in all low points of his piping system. Low point drains must have constant bleed orifices or automatic drains to ensure that no liquids will collect on the inlet piping of the compressor, Provisions (such as expansion joints, pipe hangers and supports) should be installed to compensate for thermal expansion of the piping and the compressor. It is suggested that in-line screens or strainers be installed in inlet lines. ELECTRICAL CONNECTIONS/CONTROL SYSTEM. FAILURE TO PROPERLY GROUND THIS MACHINE MAY CAUSE SERIOUS INJURY TO PERSONNEL. The following list contains the required alarm and shutdown set points which must be incorpo- rated into the customer’s control system. Required Alarm and Shutdown Set Points Discharge temperature (high) Alarm... 375°F Shutdown... 400°F Oil pressure (low) Ala soecsnes 15 PSI Shutdown... 12 psig Oil temperature (high) Alarm... 135°F Shutdown 145°F Inlet temperature (high) Shutdown... 275°F Inlet Temperature (low) Alarm .. .« 200°F Vibration (high) Alar .essessene 0.9 mils Shutdown... 1.0 mils LUBE SYSTEM PREPARATION THIS COMPRESSOR HAS BEEN SHIPPED WITHOUT OIL. Oil supply to the compressor is required at 15-25 psig and 120°R. Refer to the section above for recommended alarm and shutdown set points. Neen ee EEUU EES Buropean Gas Turbines S.A, 22 ‘Atlas Copeo Sales Order #SC-72073 thru SC-72076COUPLING ALIGNMENT... 27 ‘The main drive coupling should be checked at installation and at maintenance turnaround periods. ‘The initial alignment should be done with both motor and compressor gearbox at equal temperature. At such time the following are the desired settings for angular and parallel alignment: 1. Angular face reading vertical and horizontal should be set zero-zero +.002 T.LR. at the indicator stem. 2. Vertical parallel offset should be such that the drive motor is .003 inch higher than the low speed compressor shaft (,006 inch T.LR.) 3. Horizontal parallel offset should be set zero-zero #.002 TLR The above tolerances are to be considered the maximum allowable for continuous safe operation between tumaround periods ALL MATCH MARKS AND PARTS LOCATIONS MUST BE CAREFULLY NOTED AS THEY MUST BE REASSEMBLED IN THE SAME MANNER AS THEY WERE DISAS- SEMBLED IN ORDER TO MAINTAIN BALANCE. 1, Remove center member assembly. 2. Check Angular Alignment. Mount a dial indicator securely to the driver coupling hub with the extension arm toward the driven hub, Place the indicator stem to indicate the face of the driven hub near the outside diameter as shown by indicator “A” on the Alignment Chart. Set the indicator on “0” and rotate the drive hub 360° recording indicator readings on the Alignment Chart at each 90°. If unable to rotate 360° due to the coupling guard, then three readings may be taken every 90° and the fourth reading calculated by adding both horizontal readings and subtracting the single vertical reading. An example is shown below: 10) +(-4)- The horizontal and vertical variation should not exceed .001" total indicating reading per inch of hub diameter at the indicator stem. 3. Check Parallel Alignment Place the indicator stem to indicate the outside diameter of the driven hub as shown by Indicator “B” on the Alignment Chart. Rotate the driver hub 360° recording the indicator readings on the Alignment Chart at each 90°. A three reading alignment may be used as described above if indicating is restricted. The horizontal and vertical variation should not exceed .001" total indicator reading per inch of distance between shaft ends of the desired settings. ES European Gas Turbines SA 23 Alas Copco Sales Order #SC-72073 thru SC-720764, Alignment Adjustment Should either angular or parallel misalignment be greater than that allowed, an adjustment should be made to the location of the driver either by shims or relocation, as the case may be, INSTALLATION PRE-START CHECK . 28 The compressor package has been given a full mechanical shop test and unless otherwise specified by the customer has not been given any special packaging or shipping treatment. After following the above installation procedures, the compressor is ready for a pre-start check and initial start-up. ‘The following is a list of items to be checked in preparation for start-up: 1, Remove all loose material from the compressor, such as tools, rags, loose parts, ete. 2, Verify that the gearbox oil supply pressure is between 15 and 25 psig and that the oil supply temperature is a minimum 90°F, but no greater than 135°F, The oil supply design pressure is 20 psig and oil supply design temperature is 120°F. 3, Rotate the compressor shaft by hand at the main drive coupling to ensure ease of rotation and that there is no rubbing. Make main power available for the driver. Bump the driver to check for proper rotation. See driver instructions in the manufacturer's instruction manual for further checks. COMPRESSOR START-UP .. 2.9 Prior to starting the turbine, the following check list must be verified for atomizing air compres- sor start-up. 1. The minimum allowable compressor inlet temperature is 200°F (93°C). Atlas Copco recommends an inlet temperature 15 to 20°F (8-11°C) greater than the dew point. Note: The dew point at 155 psia (11 bara) is 195-200°F (90-93°C). At maximum inlet pressure of 155 psia (11 bara) and an inlet temperature of 215°F (102°C), adequate superheat will be available. we 2 2, Failure to maintain the specified compressor inlet conditions will result in the following problems: a. A temperature too low will cause excess water to be blown across the high pressure buffer seal and will cause rapid erosion of the seal, followed by excessive leakage. b. Small droplets of water at high inlet velocity will cause impeller erosion. c. Slugs of water from low points in the air supply system can cause abrupt failure of the compressor. 4. Inlet temperatures in excess of 250°F (121°C) may cause the impeller to become separated from the compressor shaft. 3, To prevent accumulation of condensate verify that the precooler low point drain is not plugged and that there are no low points downstream of the precooler where condensate could collect. Any Iow points must be drained before start-up to prevent damage to the compressor, European Gas Turbines SA. 2d Ailas Copco Sales Order #SC-72073 thru SC-720764, To prevent impeller and housing erosion by solid particles, the blowdown line from the cyclone separator should remain open, 5. Adequate oil supply pressure and temperature must be provided to the compressor before starting the turbine: 25 - 30 psig (1.7 - 2.1 barg) 100°F min. (38°C) 145°F max. (63°C) OPERATION RECORD...... It is recommended that an operation log be established and operating conditions are recorded periodically. It is suggested that the readings include inlet and discharge pressure and tempera- ture, oil pressure and temperature, oil filter pressure, vibration level, etc. 3.0 European Gas Turbines SA 25 Atlas Copeo Sales Order #SC-72073 thru SC-72076ALIGNMENT DATA SHEET INSPECTOR _ DATE. DRIVER COMPRESSOR “yp | T [NZ PARALLEL MISALIGNMENT INDICATOR "8" RUNOUT B | t | ver] HOR ANGULAR MISALIGNMENT RUNOUT. INDICATO! VER | HOR R B Buropean Gas Turbines SA, ae ‘Atlas Copeo Sales Order #SC-72073 thru SC-72076LUBRICATION SYSTEM LUBRICATION DATA AND REQUIREMENTS.. System Data Reservoir Capacity (gallons) System Flow (gpm) Bearing Supply Pressure (psig) Bearing Supply Temperature (°F) 120 Bearing Drain Temperature (°F) 150 Reservoir Temperature (°F) N/A Normal Filter Diff. Pressure (psi) N/A Filter Change Diff. Pressure (psi) N/A Filtration (microns) 10 Coolant Flow (gpm) N/A Coolant Supply Pressure (psig) N/A. Coolant Supply Temperature (°F) N/A Recommended Oil TBC Hours 8000 Periodic oil sample analysis is recommended. Compressor Lubrication Requirements Recommended Oil or Equal ISO VG 32 (refer to data on following pages) European Gas Turbines SA BL Atlas Copco Sales Order #SC-72073 thru SC-72076Lubricants for Expansion Turbines and Turbocompressors 1. Application Lubricating cls for turbomachinery manufactured by Atlas Copco “Appliad Compressor Technique" (ACT) must be sulted for the following applications. — Lubricating/cooling of * bearings. * tooth systems + seals In turbocompressors and turbines — Lubrication of driving/output machines * electric motor generator + steam turbine including regulating oil * gas turbines — Lubrication of directly lubricated tooth couplings For these applications, highly-refined paratfin-base mineral cils with a good viscosity and temperature behavior and addlives designed to increase aging stability and resistance to corrosion are employed, ‘This specification does not permit the use of oils with additives aimed at reducing wear which contain high pressure admixtures with E.P. properties to improve the bearing capacity of the lubricating film, 2. Requirements ‘The employed lubricating oil must correspond to DIN 51816, part 1 (latest edition). To assist the user, the associated requirements and tests aro laid down In the enclosure. In a lot of cases, testing to — DIN —'so — ASTM Js possible, For two very important requirements, ie — water separation property — air separation property testing is only possible to DIN. Ifthe user's oll supplier cannot give information about these properties, ACT is willing to — have an oil sample examined — make the associated DIN odltion available. Mixed additives must not have negative impacts on metallic and non-metallic materials in the oll system, Adgl- tives must not have metallo-organic, phosphorourisuphurour and zincous compounds, as even in the presence of slightest traces of theso materials doposits are likely to form in temperature-strained areas (bearings/seals), hich lead to interferences in operation, Additives must remain homogenously dissolved in the base oil at all temperatures between pour point and 175°C, even if the oll is mixed with other approved alls. In counteright, the ‘ll must nat be cloudy or have any solid foreign impurities. The quality of the oil must not alter by mechanical fitction or centrifuging, 3, Supervision of oll quality during operation ‘The standard oll of renowned oll suppliers is substantially better than the requirements laid down in the enclo- sure. Differences in requirements aro an important information on the quality ofthe individual olls for the user as itis always likely that an oll which is alot better of worse than required can be employed for the longest time in the turbomachine, For correct ol viscosity class please refer to the instruction manual. Ifthe examination ofthe oil in operation results in the finding that the oil no longer fulfils the requirements, we recommend changing the oil. Should this oil change become necessary in intervals of less than two years, the oll ‘supplier must be contacted to make proposals for remedy. ACT is of course also wiling to give the user advice in such a case, Ol samples must be taken alter thorough mixing ofthe cil with running oil system (minimum operating time 1 hour). The oil sample should be taken from continous flow. ‘The amount of oil to be taken from the flow should be at least 1 lire. It should be filed into a cleaned receptacle to bo closed immediately. Buropean Gas Turbines S.A. 32 Aalas Copco Sales Order #SC-72073 thru SC-72076Enclosure For turbomachinery, lubricating oils of viscosity class ISO VG 32 and ISO VG 46 nach DIN 61519 are employed, Subee- quent data are minimum requirements for operation. Turbine Oi! Requirements | Testing to Turbine Oi Requirements | Testing to lcissite.toonsiso2 1)| 032 | To4s iessic.tooinsisce | tose | Toa {'SOssoosiyeless 1) | 180VG92| 1sove4s | OISI512 | consivettecton 52-1003, oinsi759 | 1803843 __Joopper, depres of 1802160 | Per, deg t eanesion ASTD 120 | kinematical viscosty DIN S185 Jtmmas)at40°0- min, | 20.8 414 | pivsise2 | nteorestonpropontios Is03i04—_iorstet marie bins1686 max} 352 soe | asmapacs — |soa water ona DP 7120 a ASTM D865 lVscostyindex Vt 290 OwNsisea | Cotteslone-emperaion I 's0 2000, : astiozz7o [Aging propery: increase DIN s1887 ctnoutalzaton ater 520 DP 4263 | 000 hours. ASTMDB4S Denaty 15 (gm 08 owNs1767 jaterc isoa5s —|na KOH) ASTMOG41 — Bosringcapecty:; 6) in st3s4 nt ro) 2 > nomal FZ test Fasnpomcoc rc) | 2475 ws | omsrare (roma - |e cr} ser | 965 | asta ne |Poupsim 2) (0) 8 DIN preNs ts0g016 7 e212 ASTMDO7 41) In special turbine applications, it also might become necessary to use oils of viscosity classes 10, 22 and 68 Neutatzation number No s02 IN 51889, 79 (oils of viscosity classes 10 and 22 are Ce-type oils acc. mg Koni) 3) IsODP 6st DIN 81517 part 2), which are described in the instruction asmuog74 imcoraall Onde ashes (/s005) 001 DIN-EN7 | 2) Having extreme site concitions (low temperatures) you = have to use an oil with a lower pourpoint [content of sot orlgn underthetimtet | oIsiss2 | ator (g/1009) ‘quantativeraceabily | 9) Used olf may have an increase of NZ for +0.2. Water content (/100 9) Under the imitot_ | iN ss82 4) For water-steam compressors, values might be somewhat | quaitabvetraceabiny | 180.9738 higher. Should an increased water content be detected 4) Lenliniimed also in other turbomachinery, the water must withdrawn ~ {rom the oil system by appropriate action, Water separation property | 300 binsises, yes BY SPP eter epoca | al 5) FZG = research institute for the manufacture of toothed wheels and gears, Munich FRG, <6 DINSi261 at50° (minutes) Foaming property DiNs1566 Foam quanty $8283 easosoasa | De 62e7 Foam sablity $1/82153 10.0 ASTMDaG2 European Gas Turbines SA. Ailas Copco Sales Oriler #SC-72073 thru SC-72076 33SEAL SYSTEM... SEAL SYSTEM OVERVIEW ‘The compressors ate provided with a labyrinth-type gas seal to reduce the leakage of air. Porting is provided to keep the gearbox from becoming pressurized. In addition, a labyrinth-type oil seal is also provided to keep gearbox oil from migrating along the shaft. The gearbox breather contains a replaceable/cleanable element and has a drain connection to the gearbox sump. European Gas Turbines SA. a Allas Copco Sales Order #SC-72073 thru SC-72076This compressor has been supplied with one radial displacement probe on the high speed shaft. These detect excessive vibration and shutdown at prescribed levels to prevent extensive damage to the bearings and, more importantly, the gears, The system consists of a proximity probe, cable and proximeter (with 200 mV/mil output). PROBE, CABLE AND PROXIMETER CALIBRATION CHECK ... S11 1. Using the micrometer fixture on the Bently Nevada TK3 wobulator, set the probe with zero gap. 2, Measure the proximeter output voltage (D.C.). 3. Starting at zero gap, record the gap and voltage at .010-inch increments until no increase in voltage occurs. 4. Plot the voltage (y-axis) vs probe gap (x-axis) and measure the slope (change in Y / change in X). This gives the correct probe/proximeter gain (should be 200 mV/mil pk-pk for Bently ‘Nevada proximeter systems and 100 mV/mil for Metrix-based systems). | tot eal Lt a || | 4 7 TTT rrr rl 18 i—t T “6 a Prox. output zg -« { ‘ Gap (in) voltage 5 | Th | 008 Bows tT Change + 003 -78 a. i 0305.0 ‘J 1 J oo 87.0 4 | ‘change 048 ine 070 19.0 ~ ; 084154 | 104-495 “4 120 222.1 198-224 T on G6 eS Tod 0 i281 Tao one 0 ae ae Typical transducer curve Enropean Gar Turbines SA 5 Atlas Copco Sales Order #SC-72073 thru SC-72076MAJOR MAINTENANCE Prior to attempting to perform any major maintenance on your Atlas Copco compressor, strongly recommended that the people who are going to perform this work are familiar with equipment of this type and have read these instructions and reviewed the related drawings. The following operations will be explained: + Shroud Removal + Gear Cap Removal * High Speed Bearing, Seal & Rotor Removal + Low Speed Bearing & Drive Gear Removal + Inspection + Reassembly SHROUD REMOVAL . 1, Remove inlet piping to the compressor. we 5.201, 2, Remove all but two bolts and lock washers holding the shroud to the compressor housing. Leave the top and bottom bolts in place. Install sling, lifting eye or fixture to shroud and take up slack with a crane or hoist. 3. Place two (2) guide pins, a minimum of 12” long, 180° apart on the horizontal in two of the bolt holes from which the bolts were removed in step 2. 4, Remove the two remaining bolts holding the shroud to the compressor housing, 5. Use the three (3) jacking bolt holes in the shroud to separate the shroud from the compressor housing. Tighten the jacking bolts evenly to prevent the shroud from cocking in the com- pressor housing. Should a fixture not be available, install another sling behind the flange to balance the assembly. The shroud can now be removed the rest of the way from the compres- sor housing. Care must be used as the shroud will tip when it is removed from the com- pressor housing. Make sure the shroud does not hit and damage the compressor impeller. 6. Once the shroud has been removed from the compressor, place it on a wooden pallet or some blocks of wood. It is recommended the shroud not be placed directly on a concrete floor as damage can occur. 7. Do not attempt to remove the impeller from the shaft. This is an assembly and cannot be disassembled while in the compressor. Removal of the rotor assembly will be covered later in s procedure. GEAR CAP REMOVAL 25.2.2 1. Remove the vibration probe(s). The radial probe(s) is removed by unscrewing the top of the serew-cover head, disconnecting the probe cable from the extension cable, loosening the lock nut, and unscrewing the vibration probe assembly from the compressor. Once the probe has been removed, the tip of the probe should be protected (it chips easily) and stored in a safe place. Wrap the probe tip in a soft material (clean rags, soft rubber, etc). 2. If supplied, remove the end cap from the gear box, This is done by removing the bolts and lock washers from the gear box. ————————————_ ________ European Gas Turbines SA. 52 Atlas Copco Sales Order #SC-72073 thru SC-720763. Remove any seal piping from the compressor housing that might interfere with the gear cap removal. Mark these lines so they are reinstalled in the proper location during re-assembly. 4. Remove the bolts and two dowel pins holding the gear cap to the gear box. Place two guide pins at least 12" long in two comer bolt holes opposite each other to prevent the gear cap from swinging until it is clear of the drive gear. 5. Rig the holes supplied in the top of the gear cap to an overhead hoist to allow a straight vertical pull. Carefully remove the gear cap. Make sure the gear cap is lifted straight up so it doesn’t swing and damage the drive gear. 6. Place the gear cap on a wooden pallet or some blocks of wood. Do not place it directly on the ground or floor as the split-line may become damaged and cause future oil leaks. HIGH SPEED BEARING, SEAL AND ROTOR REMOVAL, 5.2.3 NOTE: The high speed bearings are tilting pad-type beatings. Caution must be used during removal and replacement as it is possible for pads to fall out of the bearing shell either damaging the pads or falling into the oil sump. 1, Remove the upper half of the high speed journal bearing. This is the high speed bearing nearest the compressor inlet. The two halves of the bearing are held together with two small screws, Once the two screws have been removed, rotate the bearing until the split line of the bearing matches the split line of the gearbox. Carefully remove the upper half of the bearing, If the upper half of the bearing will not come off by hand, it may be pryed off using small allen wrenches placed in the oil feed holes on the outer diameter of the bearing. Do not attempt to split the bearing by using a screwdriver or a chisel as a wedge. Store in a safe place. Leave bottom half of the bearing in place. 2. ‘Remove the high speed oil seal. The top half lifts off and the bottom half is removed by rolling it out around the shaft. If it is necessary to tap the lower half of the oil seal to remove it, use a soft material such as wood or plastic, Using a hard material will damage the split line of the oil seal. 3, Buffer Seal Removal. Using the four tapped holes provided, pull the top half of the buffer seal towards the motor. This will probably be a very tight fit and may require making a special puller. For the seal to come out, the split line on the seal must match the split line on the gearbox. Once the top half of the buffer seal has been removed, the bottom half must be rolled around the rotor. It will probably be necessary to tap the bottom half of the seal in order to rotate it around the shaft. Use a soft material such as plastic or wood to do this to prevent damage to the split line of the buffer seal. Repeat this procedure to remove the second section of the buffer seal. 4, Remove the high speed journal/thrust bearing and positioning shim. Remove the two small allen head screws holding the two halves of the bearing together. Remove the top half of the bearing. The positioning shim will remain attached to the bearing. The rotor assembly should now be resting on just the lower portions of the high speed journal bearings, Care should be used as the rotor will tip toward the inlet due to the weight of the impeller. European Gas Turbines SA Atlas Copco Sales Order #5C-72073 thru SC-720765. Remove the rotor assembly. On large machines, this is at least a two-person operation. One person should support the compressor impeller from the inlet. ‘The other should lift the pinion from the opposite end and roll the lower half of the high speed journal bearing out from under the shaft. The rotor assembly is then removed from the inlet of the compressor. Extreme care should be used so that seal teeth, bearing and probe areas or gears are not damaged. Scratches in these areas, especially the probe surfaces, could result in expensive repairs. 6. Once the rotor assembly has been removed, all parts should be stored in a safe, dry area to prevent damage from moisture, mishandling or process gas. LOW SPEED BEARING AND GEAR REMOVAL... oes 5.24 1. If just the low speed bearings are going to be inspected or changed, it is not necessary to remove the drive gear. Remove the two small allen screws holding the two halves of the low speed bearings together, Rotate the bearing so that the split line of the bearings matches the split line of the gearbox. Remove the top half of each bearing. Make sure each half of the bearing is marked for location as the halves are not interchangeable. To remove the lower halves of the low speed bearings, it is necessary to lift the drive gear slightly. This is done by putting a steel rod through one of the holes drilled through the drive geat (approximately 3/ 4" in diameter) and rigging to an overhead lift. It is not necessary to lift the gear far, just enough to take the weight off the low speed bearings. The bottom half of the low speed bearings can now be rolled out. 2. To remove the drive gear, remove the upper halves of the low speed bearings as described above, Remove the center section of the main drive coupling. Rig the gear for lifting out of the gearbox by placing a steel rod in one of the holes drilled through the gear and attaching it to an overhead lift. Carefully remove the gear from the gear box. Do not set the gear directly on the floor. It is recommended that it be placed on a stand so that it is supported on the bearing journals. 3. If the compressor is not going to be re-assembled immediately, it should be covered to protect it from dirt and moisture and appropriate measures should be taken to protect it from damage. INSPECTION After or during disassembly, the following parts should be looked at carefully to determine whether they can be reused or replaced. 5.3 1. The wheel should be examined for rubs, corrosion, erosion, water damage, or cracks. If there is a build-up on the impeller, it should be cleaned prior to inspecting. A solvent and a wire brush are a suitable way to clean the impeller. If any metal has been removed from the impeller, it will affect the balance of the rotor and can lead to vibration problems, The shafts should be inspected for wear and scratches in the bearing areas. Any build up or discoloration in the bearing areas should be inspected carefully. Never use an abrasive on the bearing areas to clean off build-ups. Also inspect the probe areas of the high speed shaft for scratches or dents. Any marks in these portions of the shaft will show up as vibration on the vibration monitor giving a false vibration reading. European Gas Turbines SA, 54 Alas Copco Sales Order #SC-72073 thru SC-720763. The gears should be examined for unusual wear, chips, cracks or broken teeth. 4. The bearings should be checked for wear, cracks, scratches, discoloration and build-up due to overheating Special attention should be paid to the high speed bearings, as a high speed bearing failure can cause severe damage to the rotating elements in the compressor. 5. The seals should be inspected for rubs, split line damage and bent labyrinth teeth. The tecth on the buffer seal (high speed gas seal) are on the shaft, not the seal itself. Minor rubbing on these seals is common. If the labyrinth teeth on the shaft are not damaged, the seal can probably be reused if it has rubbed slightly. 6. A general inspection of all stationary parts, gear box, compressor housing, shroud and dif- fuser should be made prior to reassembly, Check for cracks or unusual wear. REASSEMBLY... All clearances and other assembly specifics are shown on the gearbox/compressor housing assembly drawing. Prior to reassembly, all parts should be cleaned thoroughly. All old Permatex should be removed from the gear box split line. This can be done by using a solvent, rags and a scraper, Acetone works well to clean off Permatex. Low Speed Bearing and Gear Installation 1. Place the lower half of the low speed bearings in the bearing bores. Place oil on both the journals and thrust faces. 2. Carefully place the low speed gear in the bearings 3. After oiling the top halves of the bearings, install them and connect the top and bottom halves with two small screws. (Note: Not all of the low speed bearings are equipped with these two sotews.) Bearing halves are not interchangeable, 4, The anti-rotation pins in the bearings must be placed in the grooves machined for them in the lower portion of the gearbox. 5. Make sure the bearings are pushed tight against the gearbox by pushing the gear against one bearing, holding that bearing in place and pushing the gear against the other bearing. 6. Check the thrust clearance of the low speed bearings by inserting feeler gauges between the thrust face of the bearing and the thrust face of the gear. 7. Install the low speed oil seal using silicone grease on the inner and outer diameter. High Speed Rotor Assembly and Bearings 1. Place the lower halves of the high speed bearings in their bores in the compressor housing. Oil the bearings. 2. Before the rotor is put into the compressor, place the o-ring that goes around the high speed oil seal over the shaft, Once the shaft has been installed, it is difficult to get this o-ring past the drive gear. 3. Place the rotor into the compressor through the inlet. Sr European Gas Turbines SA, Ee ‘Atlas Copco Sales Order #SC-72073 thru SC-720764. Place the rotor into the lower halves of the high speed journal bearings. 5. Do not install the top half of the high speed journal bearing at this time, as the space is needed to install the high speed seals, High Speed Seal Assembly 1. Push the lower half of the high speed buffer seal into the upper half of the seal area. It may be necessary to tap the seal to getit into place. Once itis in place, rotate it so itis in the lower portion of the seal area, Once again, it may be necessary to tap it in order to get it into position. Do not use ahard material to tap the seal; plastic or wood is recommended. If you have difficulty rotating the seal into place, lifting the compressor end of the rotor up and down helps. 2. Once the bottom half of the buffer seal has been installed, install the top half and bolt the two halves together. To install the high speed oil seal, place the o-ring which was previously installed, around the lower portion of the oil seal and roll into place. Apply a very light coating of silicon sealant to the split line of the lower oil seal. 3. Install the upper portion of the oil seal. It will be necessary to stretch the o-ring slightly to install the upper portion of the oil seal. Make sure the anti-rotation pin of the seal is installed in the groove machined for it in the gearbox. Carefully wipe off any excess silicon sealant. 4, Install the upper half of the high speed journal bearing after oiling it. Make sure the anti- rotation pin is installed in its groove. 5. Do not install the gear cap at this point, The high speed rotor has to be positioned before the gear cap is installed, Shroud Assembly 1. Make sure the shroud and diffuser have been cleaned and assembled. 2. Place the o-ring around the shroud and coat it with silicone grease. 3. Using the same rigging and guide pins used earlier in this procedure, install the shroud, It may be necessary to pull the shroud in with four bolts for the last inch. Tighten these bolts evenly to avoid binding. 4. Once the shroud is in place, finish installing the shroud to the compressor using the housing bolts. It is recommended that these bolts be coated with an anti-seize compound when they stalled to prevent future difficulties when the shroud is removed. 5. Set the wheel-to-shroud clearances. If the rotor, thrust bearing, or shroud has been changed, or the compressor housing has been removed, it will be necessary to adjust the wheel-to-shroud clearance, ‘A. With the shroud installed tightly and the high speed positioning shim packs not installed, place a dial indicator on the end of the high speed pinion nearest the motor. B. Push the rotor assembly towards the shroud until the compressor wheel contacts the shroud. AC this point, zero the indicator, Qa Pull the rotor assembly back towards the motor. D. Install shims from the high speed positioning shim pack between the bearing flange and the gearbox as shown, ree European Gas Turbines SA 5.6 Ailas Copco Sales Order #SC-72073 thru SC-72076E, Push the rotor towards the inlet as far as it will go. The bearing should hit the shim before the wheel hits the shroud. The reading on the indicator will be the wheel- to-shroud clearance. Record this reading. Once the proper clearance has been obtained, install shims on the opposite side of the bearing flange to hold the bearing in place. F, Remove the shim and push the rotor forward towards the shroud to make sure the indica- tor returns to zero. If not, repeat steps A thru E until it does. G, Rotate the rotor 90° and repeat steps A thru E until you have taken four readings 90° apart. These readings should not vary more than .005", If they do, contact the Atla Copco Service Department. Use the smallest reading for the wheel-to-shroud clearance, H. Check high speed thrust clearance with shims installed. 6. After both the pinion and drive gear have been installed, visually check to make sure that the two gears are lined up properly. There should be a minimum of 90% contact between the teeth of the two gears. For example, if the gears are 3” wide, at least 2.7" of the gears must be in contact. Incorrect contact is usually caused by foreign matter being trapped between the bearings and bearing bores. If one or both of the gears have been changed, the backlash of the gears should be checked in four places. The backlash will normally be .010" to 025", If it is not, contact the Atlas Copco Service Department for advice. Replace any other piping that was removed (ex: inlet pipe). 8, After making sure that all bearings and seals are properly positioned so that their anti-rotation pins are in the slots machined for them in the lower half of the gearbox and that both surfaces of the split line of the gearbox have been properly cleaned, apply a thin coat of Permatex #3 (aviation grade) to the split line of the gearbox and the area where the geat cap and compres- sor housing join. Do not put Permatex on the bearings, To prevent leakage at the comer where the gearcap and compressor housing intersect with the gearbox, a thin bead of silicone sealant may be applied. CAUTION; Do not apply any silicone sealant in the vicinity of the bearings (at least 1 -2 inches away). 9. With the same rigging that was used to remiove the gear cap, carefully lower the cap so that it remains level and does not swing and damage the drive gear. 10, Replace the two dowel pins and the bolts holding the gear cap to the compressor housing. Tighten the bolts. Start from the center of the gear cap and work toward the outside, 11, Replace the end cap after sealing it with Permatex #3 (aviation grade). 12, Replace any seal piping that was removed earlier, 13, Replace the vibration probes that were removed earlier. When replacing these probes, be careful not to damage the probe tips. Set the gap to the specified voltage. LE European Gas Turbines SA. 57 Ailas Copeo Sates Order #SC-72073 thru SC-72076RECOMMENDED SPARE PARTS... Drawing # Item Qty Description Part # 9455100065 4 1 Rotor assembly 9455120020 1 1 Seal, oil o 0808149002 8 1 Seal, shaft input, split. . 0235038G01 111 Seal, buffer... . 0808008G19 12 1 Shim, thrust bearing. 0402023001 13° 2 Bearing, journal/thrust.. 0801218461 141 Bearing, TPI.... 0805835200 15 1 Bearing, TPY/thrust 1420010088 18 1 Probe, vibration 1420110227 20 4 O-ring. 0800004172 ea! 0801046001 2 1 0800004458 ‘93 1 .. 0801124000 242 O-tINg ern 0801125000 36 -1__‘*Filter, exhaust, 1-1/2" 1420090254 49 1 Shim, laminated 0420211001 9455215037 5 1 Proximitor..... 1320708082 6 1 Cable, extension .. 1320708081 * Usage key: E=Emergency, M=Maintenance, S To order spare parts, send purchase order to: Atlas Copco Comptec, Ine. 20 School Road Voorheesville, NY 12186 (518)765-3344 Usage* E E EM bo on on od ot EM BM\/ EM EM V EM E/M EM EM Include the following information: unit, model, serial number, item, quantity, part number and description: LS European Gas Turbines SA, Allas Copeo Sales Order #SC-72073 thru SC-72076 61Be BILLS OF MATERIAL LISTING BM# Description ACC9672073 Top Level Bill of Material ACC9672074 ‘Top Level Bill of Material ACC9672075 Top Level Bill of Material ACC9672076 Top Level Bill of Material 9455000097 Main Assembly (dwg #9455000064) 9455100065 Core Unit Assembly 9455120020 Rotor Assembly (dwg #9455120011) 9455215037 Enclosure Assembly, Proximitor 9455300078 Ship Loose Bill of Material SL European Gas Turbines SA, rd ‘Atlas Copco Sales Order #SC-72073 thru SC-72076wa faznn sen nsnn nn mnm mene n mene nan R RRR GaxzxzoouznvunzoeHosnonoonannononnHononnannonn ezotzooe axa BSGRARHRR GRAS RM RAGA RSH RHA RRR xuTusTend ‘NOTsATEOSaG ana u1as 3901 was osrsraon onraeae OxEE SONWERTON want ow GHNTHOW BHSINTS XORNEED scaze-os 9-08 xiNn muo> NoTATIDSEG Siva “mig Cte “NOE Mwy “AMM Ms 4 onrieeae sarwas BING “WOs 8052 “KON “MOG F “ARY “WOES 6 = IaKOaKOD ‘WeRGWH 40 TIE ‘TEas1 sToNrs pazaweo coaeo swine arsooFuunuannannnane BaSSSSSadaGE GSR gesenaaeneeeens = gous 6zoreo0z sua cereanie go "Ize Teast sTORIS ‘exanoo coos semeNe oot XW 00 No @ woot nS ‘Hoo no @ WE 0 NX 4 We oo x S$ ‘eo NK a oot # wamo sens 995 1/5 Ka x ok ME oot TaHUSSY YOSETUAOD WO NIM ray sawn aLumend ‘noTzaTeDsaq ANTGWNE S¥o Nvadowna 9-05 1/4 wa NoTsaTeDsaa you twig vagy cae + # oxmeeaa sanus ADE “HOE “AR “HOE CLOeL96IO" - INENOUHOD T gowe —szotzo0r suv pera a0 DaLanoD oDa09 SwILY erso¥nog ww sontmia sounename Noa xs @ Roa x oa x oR wrsr sz no sanz aNTEWIL S¥O NVEEouna 9-95 T/z HE ROTLaTNOSEE : Nog “Ma CARE “ana + 4 oxnexa i NOE “HOE = “ARY “WOE PLOZLSEIOW - INENOANOD sh Tepe storzooz amv ‘eran 40 TITG TaAgT aTONTS ‘DaUANCD oDaeD SHIN issoova fussmanaes seorzooe aia Baaaadaaads sams TereeDe 40 Tare TanRT aTOKIs crow “waa “ase “maa = oxmeraa HOE “HOU = “ARL “WOG SLOZLS6DOW - IATENOEHOD ‘oazanoo cogoa swIEY arso0%aoa Bzzonanaze eee ecaecslal szotzooe sia BGESSSaRaS sonra sonuTas ‘8LanOD oDa09 STIX ‘ADL “WOE 9L0ZL9699¥ - INENOANOD arso0% ie1 ova Eannausvunwnnannonen Qannnasnannaannnnnn scotzooz aiva BagGSGRRASASA Raed EEAova fozoza Bannan scotzoor azva Badsaa stoteest ava “waa sais 00000000 Siva “KOR ‘perwane 0 TIE ‘Teast dtomrs seeur para goswertos GSHSINIA USTIGIKE NOINTa sontermsea Suete-o8 9-05 ASS¥ woLoU NoTLATIOSSC Nog “mua T “AME “Mua Trooetssts - # oxrana NOS "WOa “ASW “HOE OzOOTTSSFE - LNENOGHOD pavawoo ooa0 sway arso01ova Boon Baan scotzooe aia Bags sows ‘erwanen go T1T@ ‘Tana atonrs c9/essez-08 1/S we NOTUaTEOSSC SsSut “NOs “maz “ARE “MWe ~ # ommewa SPSLT “ND “WOE T “AEX “MOG @LoooESSrE - ENHNOGHOD DauawoD oDa0> svn arsoo¥DRAWINGS . Drawing # Description 9455000064 ‘Main Assembly (B/M #9455000097) 9455001562 Coupling (Modification) 9455100065 Core Unit Assembly 9455120011 Rotor Assembly (B/M #9455120020) 9455215037 Enclosure Assembly, Proximitor 9455350057 Outline Drawing 9455360057 Foundation Bolting Diagram European Gas Turbines S. — ah 81 Atlas Copco Sales Order #SC-72073 thru SC-72076