Professional Documents
Culture Documents
LMC/BMC-311F Compressors
December 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.
TABLE OF CONTENTS
Text Symbols..................................................................................................................1
Equipment and Safety Precautions..............................................................................1
Explosion / Fire Hazard .................................................................................................2
Using this Manual ..........................................................................................................3
1. Installation..................................................................................................................5
Introduction to the Sundyne Compressor.........................................................................5
Inspection ........................................................................................................................5
Short Term and Long Term Storage ................................................................................6
Installing the Suction and Discharge Piping - Guidelines .................................................7
Seal Environment Control System ...................................................................................7
Baseplate Grouting ..........................................................................................................8
Horizontal Unit Gearbox Support Bracket ........................................................................9
Driver and Coupling .........................................................................................................9
2. Lubricating Oil System..............................................................................................9
3. Start-up .....................................................................................................................13
Compressor Control During Start-Up .............................................................................14
Run-In of the Compressor..............................................................................................14
4. Servicing...................................................................................................................15
Regular Maintenance.....................................................................................................15
5. Maintenance .............................................................................................................16
Gearbox Disassembly................................................................................................16
Diffuser Gap Set-up Impeller/Diffuser Cover Alignment.............................................21
Impeller/Diffuser Clearance Calculation.....................................................................24
6. Gearbox Disassembly .............................................................................................26
7. Gearbox Reassembly ..............................................................................................34
8. Troubleshooting ......................................................................................................47
9. Operation .................................................................................................................50
10. Spare Parts .............................................................................................................51
11. Sundyne Compressor Warranty ...........................................................................53
Reference A
Critical Start-up Checklist ...........................................................................................49
Reference B
Lock-out/Tag-out Guidelines ......................................................................................54
Reference C
Seal Arrangement Drawings for Single, Double, and Tandem Configuraiton ........55
Reference D
Compressor Drawings.................................................................................................59
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 fluid 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.
Note:
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:
Note:
Note:
Using Forklifts
Note:
EXPLOSION/FIRE HAZARD
Note:
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.
Maintenance
Provides procedures for disassembling the LMC/BMC compressor and its seal housings.
6.
Gearbox Disassembly
Provides procedures for disassembling & reassembling the gearbox of the compressor.
7.
Reassembly
Procedure for Checking High-Speed Shaft End Play
8.
Troubleshooting
Provides tables for the following:
a) Looking up a problem.
b) Identifying the possible cause.
c) Selecting the corrective action.
9.
Operation
Provides general guidelines for controlling a compressor such as surge control, suction throttling,
discharge throttling, and speed control.
10.
Spare Parts
Contact and reference information.
11.
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
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.
Be sure the storage area has: Humidity below 65%; and temperature range from 45 to 85F
(7C to 29C).
2.
Do not allow contact of airborne chemicals with the internal components of the unit.
3.
If the unit is being stored near strong chemicals or salt water, protect it immediately.
4.
5.
Make sure that the factorys shipping covers for housing flanges and seal ports are securely in
place.
6.
7.
8.
9.
Because storage location and unknown factors at the site of storage are beyond our control,
Sundyne does not accept any liability for damage to the equipment during storage, nor do we
guarantee the quality of the equipment during and after the storage period. An Extended Warranty
will be null and void if the proper equipment preparation is not maintained.
Step 2:
Install a strainer to protect the impeller from damage by mill scale, welding slag, or other
foreign particles.
Step 3:
Make sure that the piping is aligned with the compressor flanges.
Step 4:
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.
A. 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.
Lock out starting switch on driver prior to working on coupling, following lockout/tag-out procedure.
UNITS WITH VERTICAL OR HORIZONTAL STANDS - ALIGNMENT-If other than Sundyne supplied couplings are used, they must be flexible disc or gear type couplings
capable of tolerating parallel and angular misalignment of .005 inch maximum as well axial end play of
.060 inch maximum. Always refer to the coupling manufacturers recommendations for installation and
maintenance.
The motor and compressor coupling hubs are normally installed at the factory. For alignment
specifications, see Coupling Manufacturers Bulletin in the Final Data Package. Align the driver and
compressor after grouting and before you connect the suction and discharge piping. After you install the
piping, inspect the alignment again.
The oil used in Sundyne gearboxes must meet the specifications presented in Field Engineering
Bulletin 40.2.04. In general, an ISO viscosity grade 32 oil will meet these specifications. Before using any
oil, you should verify its properties by consulting its manufacturer. Failure to use the proper gearbox
lubricant will void the warranty.
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.
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
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
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
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
5. Maintenance
The following procedures apply to all configurations of
the Sundyne LMC/BMC-311F centrifugal
compressors. Refer to the specification sheet to
determine the specific configuration and optional
Item
Qty.
87A
O-Ring Seal
936B
O-Ring Seal
936C
O-Ring Seal
936D
O-Ring Seal
936E
O-Ring Seal
936F
O-Ring Seal
936G
O-Ring Seal
936J
O-Ring Seal
936K
O-Ring Seal
936P
Single Seal
Double Seal
Tandem Seal
O-Ring Seal
16
936H
NOTE
An o-ring Repair Kit is available. This kit contains
the o-rings required to replace the gearbox and
compressor mechanical seals.
STEP 1
Step 2
If diffuser removal is required, insert three eyebolts
(customer furnished 1/2-13 UNC) into tapped holes in
the surface of diffuser (13). Loosely thread a length of
rope through these bolts and tie ends together. Grasp
the rope between bolts and lift the diffuser. This step will
require that o-rings 936B and 936C be replaced.
17
NOTE
The gearbox can be worked on while in a horizontal
position. However, the diffuser cover must be
supported to prevent it from falling off when the
impeller is removed.
STEP 3
Prevent impeller from rotating and remove impeller (2).
Note that the impeller has a left-hand thread. Antirotation tools for both the input shaft and output shaft are
available through Sundyne.
CAUTION
The impeller is dynamically balanced and should be
replaced or rebalanced if it shows any sign of
damage.
Step 4
Lift diffuser cover (15) from seal housing.
18
Step 5
Remove shim spacer (936G).
Step 6
Remove the seal rotating face (51A) of single or tandem
seal arrangement or the lower shaft sleeve (50A) on
units equipped with double seals.
Step 7
Remove the single seal (60A) of the single seal
arrangement or the lower mechanical seal (60A) and
seal spacer (52) of the double seal arrangement or the
lower mechanical seal of the tandem seal arrangement.
If the compressor has a single seal arrangement,
remove seal housing (30) and gasket (87A). Remove
hex head cap screws (905F) and washers (916B).
Remove throttle bushing (21B).
19
Step 7 (continued)
If upper seal of double or tandem seal arrangement
requires removal, detach seal housing (30) and gasket
(87A) from the gearbox by removing hex head cap
screws (905A).
Double Seal Remove hex head cap screws (905F),
washers (916B), upper mechanical seal (60B), and seal
rotating face (51C).
Tandem Seal Remove hex head cap screws (905F),
washers (916B), upper mechanical seal (60B) and seal
rotating face (51C).
Step 8
Carefully inspect the seals for abrasive particles,
excessive seal face wear and any binding of the seal
face washer.
Replace or rebuild a faulty mechanical seal. Seals may
be rebuilt by replacing the seal face washer, wedge
rings, o-ring, and springs. A seal repair kit is available.
Replace or lap the seal rotating face if the wear track is
rough or worn to a depth greater than 0.0002 inch
(0.005mm).
A combined total of 0.010 inch (0.25mm) maximum may
be removed from the surfaces of the compressor and
gearbox seal rotating faces. Excess material removal
will result in incorrect seal face loading causing
increased seal leakage.
Remove any high spots on the end surfaces of the lower
shaft sleeve and impeller hub to insure that the seal
rotating face will not be distorted by clamping force of
the impeller bolt.
Reassemble the seals, throttle bushing, if used, seal
housing, and impeller using an O-ring Repair Kit. All
o-rings that were disturbed by disassembly should be
replaced. During re-assembly, carefully check the
torque values listed in Table 1.
The impeller may rub on the diffuser cover plate (15)
until o-rings (936D and 936E) are compressed by
tightening hex nuts (914A). Check the gearbox input
shaft for freedom of rotation after the compressor is
assembled and all bolts are tightened per Table 1.
20
Item No.
Impeller Spacer
158C Series
O-ring Packing
936C
O-ring Packing
936E
O-ring Packing
936F
O-ring Packing
936G
*Required only if diffuser is removed.
Qty.
As Required
1*
1
1
2
NOTE
Unless the diffuser (13) or cover (15) have
been changed, the diffuser gap should not
require adjustment.
(5) Turn gearbox bottom side up so that the seal
housing is on top.
(6) Be sure that the high-speed shaft (130) is
pushed in the X direction (see Figure 2) as
far as possible, (i.e. the shaft is pushed
against the upper thrust washer) (155B or tilt
pad thrust bearing 151B). Measure the
distance from the outside flat surface of
diffuser cover to the front or blade side of the
impeller shroud as before. Record this
dimension and not its direction. This is the
E dimension in Figure 2. Record on
Figure 3.
Gearbox Assembly
Gearbox High-Speed Shaft (130)
High-Speed Shaft Bearings (151A or B)
Impeller (2)
Seal Housing (30)
Diffuser Cover (15)
NOTE
The original clearances for your compressors as
shipped from the factory for the impeller and diffuser
are recorded and supplied as part of the final data
package. Figure 3 can be used to record values.
21
22
23
Part No.
Thickness
Impeller/Diffuser Clearance
Calculation
SP01AD02XXF
0.018 (0.046mm)
SP01AD02XXA
0.030 (0.075mm)
SP01AD02XXG
SP01AD02XXB
0.050 (0.127mm)
SP01AS02XXH
Gearbox Assembly
SP01AD02XXC
SP01AD02XXD
SP01AD02XXE
(8)
(9)
Impeller (2)
24
Customer
S/N
Model
Date
Shift
Assembled By:
Name (Not Clock #)
A. Impeller Clearance
B. Shim Thickness
C. Diffuser Gap
D. Spacer Thickness
E. Shroud Ht.
F. Impeller Blade Ht.
Impeller Diameter
NOTE
The purpose of this step is to set the
clearances between the impeller and
the diffuser such that it will not rub,
but is close enough that the
machine will run efficiently. When
the compressor is not running and
no suction pressure is supplied, the
high-speed shaft will be sitting
against the lower thrust bearing.
The gap must be sufficient to insure
that the impeller will not touch the
diffuser. If the compressor is set up
with too large a clearance, the
efficiency will be low.
When all gaps and clearances, A, E
and C are within specifications, check
Figure 3 to be sure all values are
recorded. Disassemble compressor
and reinstall all o-rings, mechanical
seals, etc. Reassemble and install
compressor into case.
25
Item No.
Qty.
185
115
936AG
O-ring Seal
936M
O-ring Seal
936N
O-ring Seal
936P
O-ring Seal
936T
158 Series
As Required
Housing O-Ring
* Shim Spacers
* Available in sets of five 0.005 inch (0.13mm), 0.010 inch (0.25mm), .05 inch
(0.38mm), 0.020 inch (0.51mm), 0.030 inch (0.76mm)
NOTE:
In order to disassemble the gearbox, it is
necessary to complete steps one through seven
under Procedure for Disassembling
Compressor.
Step 1
Drain oil from the gearbox.
Step 2
Remove upper shaft sleeve (50B) on double or
tandem seal arrangements or sleeve (50) on single
seal equipped units.
26
STEP 3
Remove gearbox seal screws and gearbox
seal.
Removing three hex head screws.
STEP 4
Remove gearbox seal O-ring.
Use extraction tool to remove O-ring.
STEP 5
Remove gearbox seal mating ring.
Remove mating ring with extraction tools.
STEP 6
Invert the gearbox and remove fill and vent
fitting.
Use a pipe wrench to remove the inch
pipe elbow first. Next, use the pipe wrench
to loosen the pipe and remove from the
gearbox.
27
STEP 7
Loosen and remove gearbox bolts, (7 total).
STEP 8
Loosen close tolerance alignment pin.
STEP 9
Drive close tolerance alignment pins out, (2
pins).
Use hammer to tap pin out.
28
STEP 10
Remove upper gearbox housing.
A mallet can be used to tap around the
edges of the housing to loosen the idler
shaft and assist the housing in lifting off.
Note: Use hooks or eyebolts and a hoist
when possible to avoid personal
injury.
STEP 11
Remove idler shaft assembly.
Removing the idler shaft assembly
disengages the upper idler and input shaft
gears.
Technician is pointing to idler shaft.
STEP 12
Remove input shaft assembly.
STEP 13
Remove the lube pump spring and the lube
pump.
29
STEP 14
Inspect the condition of the lube pump antirotation pin.
Extraction tool is touching anti-rotation pin.
STEP 15
Remove bearing plate.
STEP 16
Remove and inspect upper thrust washer.
Washer will slide off of the shaft.
STEP 17
Remove idler shaft assembly.
30
STEP 18
Remove high-speed shaft assembly.
STEP 19
Remove and inspect lower thrust washer.
STEP 20
Remove and inspect upper journal bearing
after removing from bearing plate.
Unscrew three hex head screws.
31
STEP 21
Remove input shaft lip seal.
STEP 22
Remove the sump tube.
STEP 23
Remove lower bearing shims.
STEP 24
Remove lower bearing shims.
Use hex key to remove the lube jets.
32
STEP 25
Blow out lube passage.
Using air tool to blow out lube passages.
33
7. Gearbox Reassembly
The following replacement items will be required as a result of the gearbox disassembly:
Part
Item No.
Qty.
185
115
936AG
O-ring Seal
936M
O-ring Seal
936N
O-ring Seal
936P
O-ring Seal
936T
158 Series
As Required
Housing O-Ring
* Shim Spacers
* Available in sets of five 0.005 inch (0.13mm), 0.010 inch (0.25mm), .05 inch
(0.38mm), 0.020 inch (0.51mm), 0.030 inch (0.76mm)
STEP 1
Insert shim under lower journal bearing.
STEP 2
Install lower journal bearing.
Insert 3 hex head screws.
Note: Torque to 40 in-lbs
Note: Above picture has thrust washer
already installed over journal bearing.
34
STEP 3
Install lower thrust washer if not already in
place.
STEP 4
Install high-speed shaft assembly.
STEP 5
Re-install the sump tube into the bearing
plate.
STEP 6
Re-install the upper journal bearing into the
bearing plate.
Note: Tighten hex head screws to 40 in-lbs.
35
STEP 7
Install new thrust washer.
Thrust washer is silver disc in center.
STEP 8
Install bearing plate without gasket using
alignment pins.
STEP 9
Clamp bearing plate to the lower gearbox
housing.
Clamping the bearing plate to housing.
Note: C clamps can be utilized to perform
this task.
36
STEP 10
Inspect endplay of the high-speed shaft.
Note: Endplay must fall within these
tolerances, 0.015 +/- 0.002
Measuring endplay of High Speed Shaft.
Note: For complete instructions for checking
endplay refer to the Procedure for Checking
High Speed Shaft Endplay later in this manual
STEP 11
Remove bearing plate and install lower housing
gasket and o-ring at oil passage
STEP 12
Lubricate the journal bearings, high-speed
shaft, journal/thrust face with standard
gearbox lubricant.
Lubricating the high-speed shaft.
37
STEP 13
Lubricate the lower idler bearing.
STEP 14
Install idler shaft assembly.
Note: The idler shaft assembly sits at a
slight tilt to allow installation of the
bearing plate.
STEP 15
Install the bearing plate.
38
STEP 16
Install lube pump.
STEP 17
Install lube pump spring.
The lube spring sits inside the lube pump.
STEP 18
Lubricate the lube pump.
STEP 19
Install input shaft assembly.
Note: Notice the input slots for the oil pump
drive pins.
39
STEP 20
Push on input shaft to verify engagement of
drive pins.
STEP 21
Set idler shaft assembly in place and
engage input gears.
STEP 22
Lube input shaft bearings and upper idler
bearings.
STEP 23
Install upper housing gasket and o-ring.
40
STEP 24
Install upper gearbox housing.
Note:
STEP 25
Install close tolerance alignment pins.
Note: Install first pin as noted on the bearing
plate.
STEP 26
Install new lip seal.
Note: Use lip seal installation tool #TH006AA-47 to install lip seal.
Putting lip seal onto lip seal installation
tool.
41
STEP 27
Install remainder of gearbox hex head bolts.
Installing washers and nuts onto gearbox
bolts.
Note: Torque to 65 ft-lbs.
STEP 28
Install fill and vent fitting.
Note: Use pipe dope on all pipe threads.
Use pipe wrench to tighten fitting after
sliding into place.
STEP 29
Install shaft anti-rotation device to prevent
the impeller from spinning.
42
STEP 30
Turn gearbox over.
STEP 31
Install gearbox-mating ring.
STEP 32
Install gearbox-mating ring o-ring
43
STEP 33
Install gearbox seal o-ring onto gearbox
seal.
STEP 34
Install gearbox seal.
STEP 35
Install three gearbox seal hex head screws.
Note: Torque screws to 75-80 in-lbs.
44
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.
45
Parts List
1. General
4. Repair Kits
3. Gearbox Exchanger
A gearbox exchange can be arranged for a
fixed price. A replacement gearbox,
completely tested and with a full one year
warranty can be shipped to anywhere in
the continental United States within 48
hours after receipt of the expedited order in
Arvada.
46
8. 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.
See final data package.
Table 2 provides information for analyzing gearbox and compressor problems.
Table 2 Troubleshooting for Gearbox and Compressor
Trouble
Possible Cause
Driver overloaded.
Check voltage.
47
Trouble
Possible Cause
Driver overloaded.
(continued)
48
Possible Cause
Investigative/Corrective Action
49
9. 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 controlled 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.
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
50
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.
51
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,
o-rings, 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
52
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.
53
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.
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).
54
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 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.
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 Companys 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
55
Item
No.
21B
50
51A
51D
60A
61A
62A
65A
68A
69A
60C
61C
62C
64C
65C
69C
Part Name
Throttle Bushing
Slinger Sleeve Assembly
Sal Rotating Face
Seal Rotating Face (Gearbox)
Mechanical Seal (Lower)
Retainer & Drive Sleeve Assembly
Seal Face Washer
Coil Spring Set
Backing Ring
O-ring Packing
Mechanical Seal (Gearbox)
Retainer & Drive Sleeve Assembly
Seal Face Washer
Seal Retaining Ring
Coil Spring Set
O ring Packing
Qty.
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
Item
No.
158C
905E
905F
905L
916A
916B
916K
936G
936H
936J
936K
936P
Part Name
Shim Spacer
Hex Head Cap Screw
Hex Head Cap Screw
Hex Head Cap Screw
Washer
Washer
Washer
O-Ring Packing
O-Ring Packing
O-Ring Packing
O-Ring Packing
O-ring Packing
56
Qty.
1
3
3
3
3
3
3
2
2
1
1
1
Item
No.
50A
50B
51C
51D
52
Part Name
Shaft Sleeve (Lower)
Shaft Sleeve (Upper)
Seal Rotating Face
Seal Rotating Face (Gearbox)
Seal Spacer
60A
61A
62A
65A
63A
68A
69A
1
1
1
1
2
1
1
60A
61A
62A
63A
64A
65A
68A
1
1
1
1
1
1
1
60B
61B
62B
65B
63B
68B
69B
1
1
1
1
2
1
1
Qty.
1
1
1
1
1
Item
No.
60B
61B
62B
63B
64B
65B
68B
Part Name
Mechanical Seal (Liquid Seal)
Retainer & Drive Sleeve Assembly
Seal Face Washer
Seal Spring Backup Disc
Seal Retaining Ring
Coil Spring Set
Seal Wedge Ring
Qty.
1
1
1
1
1
1
1
60C
61C
62C
64C
65C
69C
1
1
1
1
1
1
Shim Spacer
Hex Head Cap Screw
Hex Head Cap Screw
Hex Head Cap Screw
Washer
Washer
Washer
O-Ring Packing
O-Ring Packing
O-Ring Packing
O-Ring Packing
O-Ring Packing
1
3
3
3
3
3
3
2
2
1
1
1
158C
905F
905G
905L
916A
916B
916K
936G
936H
936J
936K
936P
Item
No.
50A
50B
51A
51C
51D
Part Name
Qty.
1
1
1
1
1
60A
61A
62A
64A
65A
68A
69A
1
1
1
1
1
2
1
60B
61B
62B
64B
65B
68B
69B
1
1
1
1
1
2
1
Item
No.
60C
61C
62C
64 C
65C
69C
Part Name
Qty.
1
1
1
1
1
1
158C
905E
905F
905L
916A
916B
916K
936G
936H
936J
936K
936P
Shim spacer
Hex Head Cap Screw
Hex Head Cap Screw
Hex Head Cap Screw
Washer
Washer
Washer
O-Ring Packing
O-Ring Packing
O-Ring Packing
O-Ring Packing
O-Ring Packing
1
3
3
3
3
3
3
2
2
3
1
1
58
Reference D
Compressor/Gearbox
Figure 7
59
61
Item
No.
116
117
118
119
904A
905J
905R
909D
914D
Part Name
Coupling
Input Coupling
Coupling Housing
Hub
Screw
Hex Head Cap Screw
Hex Head Cap Screw
Hex Head Bolt
Hex Nut
Qty.
1
1
1
1
4
4
4
4
4
Item
No.
914G
914H
916E
916M
916N
916P
916R
916AC
920E
Part Name
Hex Nut
Hex Nut
Washer
Washer
Washer
Washer
Washer
Washer
Key
Item
No.
Part Name
Qty.
106
Chemical Barrier Gasket
1
107
Seal Spacer
1
905T
Hex Head Cap Screw
3
916V
Seal Washer
3
See Pages 56 and 57 for Recommended Spare
Parts.
62
Qty.
4
4
4
4
4
4
4
4
4
63
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