1CV Overhaul.pdf

CENTAC

5CII Overhaul Procedures

INGERSOLL-RAND AIR COMPRESSORS

5CII OVERHAUL PROCEDURES

Copyright Notice Copyright 1996, 1999 Ingersoll-Rand Company THE CONTENTS OF THIS MANUAL ARE PROVIDED AS IS AND WITHOUT ANY IMPLIED WARRANTIES WHATSOEVER. Ingersoll-Rand air compressors are not designed, intended, or approved for breathing air applications. Ingersoll-Rand does not approve specialized equipment for breathing air applications and assumes no responsibility or liability for compressors used for breathing air service.

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5CII OVERHAUL PROCEDURES

Table of Contents

Disassembly Procedures .........................................................................................................1 Removal of Stage(s) Components: ......................................................................................1 Removal of the Bull gear From the Casing .........................................................................3 Installation of the Bull Gear into the Casing .......................................................................4 Assembly of the Stage(s): ........................................................................................................5 Impeller/Diffuser Clearance Setting Procedure......................................................................7 Clearance Setting Bracket and Indicator Positioning..........................................................10

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Disassembly Procedures The following is provided as a guide to follow when rebuilding a 5CII centrifugal compressor. The specific details will be outlined during the actual disassembly and assembly procedure conducted with the training machine.

Removal of Stage(s) Components: Before you begin: provide a bench or a work area off the floor where the parts can be inspected and cleaned. If more than one stage will be removed, make sure there is enough room to separate the stages to avoid mixing parts. 1. Tag out all service to the unit. Ensure that there is no power to the control panel. 2. Remove the vibration probe and seal air injection nipple in the plain bearing on the stage(s) that will be disassembled. 3. Remove any service piping to/from the machine and disconnect the tubing and/or wiring to any devices on the cooler housing. If necessary, tag the tubing and/or wiring to facilitate reconnection. 4. Rig for lifting. Make sure that you use an adequate weight handling technique. Then unbolt and remove the cooler housing and cooler. 5. Install the lockbolt in the bull gear. 6. Tighten up on the inactive thrust bearing adjusting screw then measure the impeller volume tip clearance prior to removing the diffuser. This measurement provides an indication of wear and/or erosion. See Figure 1.

Impeller

Impeller Volume tip clearance

Diffuser Impeller back clearance

Impeller pressure tip clearance

Figure 1. Clearance Settings

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5CII OVERHAUL PROCEDURES

7. Remove the diffuser using the following procedure: • Match and mark the top of the diffuser and casing with a felt pen or other suitable marker. •

Remove two or three of the five retaining bolts and install guide studs in their place.

•

Remove the remaining retaining bolts.

•

Evenly jack the diffuser out of the bore using the jackscrews in the holes provided.

•

Use a crane to remove the diffusers and place them on a suitable work surface

8. Back off the inactive thrust bearing adjusting screw one or two turns. 9. Remove the thrust bearing cover and place the cover and bolts on the work bench area. CAUTION

The impeller blade is very sharp. Use caution when handling the impeller. 10. Clean out any accumulation of dirt in the impeller Allen-head bolt to allow full insertion of the wrench. Remove the left hand threaded impeller bolt with an Allen wrench. It is important that this Allen wrench is in good condition. 11. Loosen, but do not remove the thrust collar bolt. 12. Remove the bull gear locking bolt and remove the jackscrews in the thrust bearing if installed. 13. Remove the thrust bearing retaining bolts being careful not to loosen the shims. Place a lint free rag in the oil drain back hole in the bull gear cover to prevent the shims from falling into the oil reservoir. Slightly rotate the thrust bearing so as not to jack on the adjustment area. Install three long jackscrews (M12X1.75 or 1/2 -13, which ever is applicable). Place flat washers or shim stock under the jacking bolts. 14. With someone holding the impeller to prevent it from falling, jack the thrust bearing out evenly. The jacking will pull the impeller out of the pinion. Place the impeller on the workbench. 15. Remove the thrust bearing, collar and pinion as an assembly. Remove the thrust collar bolt and place the assembly in an arbor press, resting on the thrust bearing shell. Install a M16 X 2 stud in the thrust end of the pinion and push the pinion out of the collar. DON'T ALLOW THE PINION TO DROP! Place the parts on the workbench. 16. Verify the seal air injection nipple has been removed. 17. Remove the plain bearing retaining bolts. Use the jackscrew holes provided; evenly jack the plain bearing out of the bore. 18. Remove the seal cartridge snap ring, at the workbench. Use the jackscrew holes provided in the seal cartridge and evenly jack the cartridge out of the plain bearing bore. Place the parts on the workbench.

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19. Inspect the parts for wear and damage. •

• • •

Inspection of the bearings should be done both before and after cleaning to detect any signs of damage. The bearings may be cleaned with safety solvent to remove the oil. If wiping (distortion) of the babbitt has occurred, it will be necessary to replace the bearing. If no distortion is apparent, the bearing can be reused. Any discoloration or varnish may be cleaned by using gray or white Scotchbrite and safety solvent. The pinion, impeller, thrust collar, impeller bolt, thrust collar bolt, and nose cone (if present) must be balanced as a unit. Cleaning of the diffuser can be accomplished with solvents or by glass bead blasting. Replacement of the seal cartridge is necessary if any sign of damage is present, if the carbon seal is cracked, or if the carbon rings ability to move has been affected.

20. Remove cooler from the cooler casing. Keeping the cooler wet will aid in the removal of the cooler. The water acts as a lubricant and keeps soft sludge in the slurry state. The cooler should be cleaned and inspected. 21. Test the air side fins for flexibility. If fins easily break, the cooler should be replaced. 22. Remove the moisture separator screens from the cooler casing. Inspect and clean the screens. Steam cleaning is usually employed for cleaning. 23. Clean and preserve (paint) the casing air passage and the cooler casing water and air passages.

Removal of the Bull gear From the Casing This procedure is done after removal of the stage(s). 1.

Remove the coupling, oil manifold, oil RTD, demister, oil pump and oil hoses. Two heat sources are recommended when removing the coupling hub.

2.

Remove the retaining bolts or nuts from the casing to the baseplate. Use an overhead crane or other means, as necessary, to break the RTV seal and loosen the casing from the baseplate.

3.

Lift the casing off the baseplate. Lay the casing cooler side down on a skid or wooden blocks. Level the casing using a level.

4.

Remove the shaft seal retainer and oil feed line.

5.

Remove the wave spring. Note the wave spring arrangement to ensure proper reinstallation.

6.

Remove the bull gear cover bolts and dowel pins. Use jackscrews to break the gearcase cover free from the gearcase.

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5CII OVERHAUL PROCEDURES

NOTE It is suggested that the last couple of threads be machined off the jackbolts to prevent the bolts from binding up in the cover. 7.

Lift the cover off the casing and stand upright.

8.

Place a 3/8"-16 eyebolt in the bull gear shaft, coupling end. Remove the bull gear and lay on blocking in a clean area. Inspect the bull gear and bearings. Remove and replace the bearings if necessary.

Installation of the Bull Gear into the Casing 1.

Thoroughly clean the RTV/sealant from the faces of casing and cover. Check the oil feed line on the thrust bearing side and clean any blockage from the oil line and spray nozzles.

2.

Install new anti-friction bearings the on bull gear using the following procedure: •

Install the radial type anti-friction bearing on the coupling side.

•

Install the thrust bearing on the oil pump side. Make sure the cage of the thrust bearing (the brass and numbers) faces towards you when viewed from the main oil pump side.

3.

Install the bull gear using the eye bolt that was installed when the bull gear was removed. Use caution to avoid damage to the bearings.

4.

Apply a thin (approximately 1/16 diameter) bead of sealant on the gearcase cover. Route the sealant around the oil galley, oil drain holes, and completely around the cover inside the bolt circle. CAUTION

Do not use excessive sealant. Follow the sealant manufactures instructions.

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5.

Install the gearcase cover using locating studs. Start the dowel pins and tap in place to seat. Use care to not peen over or mushroom the dowel pins. Install the bolts on the cover using a cross bolt pattern.

6.

Install each of the following: the wave spring, a new shaft seal and gasket, and the seal cover.

7.

Tighten the seal cover and reconnect the oil feed line.

8.

Clean the baseplate and bottom of the casing. Install new drain gaskets in the base. Apply RTV/sealant around the oil drain back holes and around the base.

9.

Mount the casing onto the baseplate and tighten the hold down nuts.

5CII OVERHAUL PROCEDURES

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10.

Inspect the oil pump gerotor, key, and spacer for chips and burrs.

11.

Install the oil pump spacer in the casing. Ensure that it fits flush against the casing. Place the gerotor on the shaft with the key. Insure free movement of the gerotor on the shaft. Typical gerotor end clearance is 0.005 to 0.007 . Install the oil pump housing with a new o-ring and bolt down. Reconnect the oil lines.

12.

Install the Oil Demister and reconnect the oil manifold and oil temperature RTD.

The compressor is now ready to accept installation of the stage components.

Assembly of the Stage(s): NOTE In the following procedure, DO NOT use any oil on the parts unless instructed to do so. Lubrication will be provided when the prelube system is started. Lock the bull gear against rotation.

1.

Place the seal in the plain bearing. Use Parker O-ring Lube to lightly lubricate the o-rings. Be careful not to cut the o-rings. Install the retaining ring with the bevel up.

2.

Wipe the seals with isopropyl alcohol using lint free cloths. Lightly lubricate the bearing o-rings with Parker O-ring Lube. Align the seal air injection hole in the bearing with the casing hole and install the plain bearing, use a gasket if applicable in the casing. Tighten the bearing retaining bolts until the lockwashers, if used, just close up.

3.

Install the seal air supply line.

4.

Wipe the pinion with isopropyl alcohol using lint free cloths. Ensure the internal threads are also cleaned. Align (center) the carbon seals by careful insertion of the pinion from the impeller side. After the seal is aligned, insert the pinion into the plain bearing from the motor side. Push the pinion forward until it just touches the plain bearing shell.

5.

Ensure there are no proud spots on the casing or the thrust bearing on the bearing flange seating areas. Stone any suspected proud spot areas. Start the thrust bearing into the casing bore with the oil drain holes pointed down.

6.

Install a long 5/16"-18 bolt into the thrust end of the pinion. •

Install the bearing in the bore until the bearing is near the thrust collar shoulder of the pinion. A LIGHT film of oil on the bearing shell and in the bore will facilitate installing the bearing.

•

Pull the pinion into the bearing by hand, using the long bolt to guide the pinion through the bearing. Use care to not scrape the babbitt.

•

Push the thrust bearing into the bore until the flange is tight against the casing.

•

Check the surface between the casing and the bearing flange with a 0.0015" feeler to ensure there are no proud spots. Re-stone the casing as necessary until the 0.0015 feeler will not pass between the bearing flange and the casing. 

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5CII OVERHAUL PROCEDURES o

7.

Install the bull gear locking bolt. Heat the thrust collar to approximately 200 F. A 100 watt light bulb works fine for this. This takes approximately 20-30 minutes.

8.

Lightly apply Tiolube 70 to the polygon, as recommended in the Field Service Manual. Align the match marks and slide the thrust collar on the pinion. The thrust collar must be slid firmly against the shoulder on the pinion. Use the 5/16 -18 bolt to hold the pinion away from the thrust bearing to avoid damaging the thrust face with a hot thrust collar.

9.

Clean the thrust collar bolt with isopropyl alcohol. Install the thrust collar bolt and tighten until the match marks align. Use a 1/2" box end wrench with the bevel ground off for tightening. Allow the collar to cool, remove the thrust collar bolt and apply one drop of Loctite 271 to the threads. Install and tighten the bolt to the match mark.

10.

Install the vibration probe. Gently seat the vibration probe against the pinion and then back off.

11.

Install the thrust bearing covers temporarily. Use the following procedure to check for leaks: A.

Verify that the seal air piping has been correctly re-installed. Pressurize the seal air system to 7 PSIG. Test the circumference of the vane plates using a soap and water or leak detecting liquid on all stages. Test all bolt and other plate penetrations for air leakage.

B.

Test the seal air inter-lock with the prelube pump starter to assure it is functioning properly. Correct any discrepancy.

C.

Verify all lube oil piping has been correctly installed. Untag and energize controller control power to the prelube pump. Start the prelube pump. Record oil temperature and pressure.

D.

Inspect the lubricating oil system for leaks. Inspect the area of the pinion air seal for any signs of oil migration. Inspect the gull gear casing cover for any signs of oil leakage through the split line.

E.

Allow the system to operate for a minimum of one hour. Thoroughly inspect for leaks after the one-hour run time. Correct any leaks.

F.

Stop the prelube pump at the completion of the satisfactory oil leak test. Deenergize and retag the control power system. Shut off the seal air.

G.

Remove the thrust bearing covers when you are finished with leak checking and continue with the assembly.

12. Install the clearance setting bracket to push and hold the pinion toward the impeller end. See Figures 2, 3, and 4. 13. Lightly apply Tiolube 70 to the impeller polygon, as recommended in the Field Service Manual. Align the match marks and slide the impeller into the pinion. 14. Clean the impeller bolt with isopropyl alcohol. Apply one drop of Loctite 271 on the impeller bolt. Preload the impeller and tighten the bolt until the match marks align. 15. Remove the clearance setting bracket installed in step 12. Pull the rotor assembly toward the thrust end with the thrust bearing. This procedure is intended to get the impeller out of the way of the diffuser.

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16. Install the diffuser, using M10 x 125 mm studs to help facilitate installation. Tighten the bolts until the lockwashers just close. 17. Establish the Impeller/Diffuser pressure tip clearance. See Impeller/Diffuser clearance setting procedure. 18. Ensure the inactive button bearing adjustment screw is backed out. Install the bearing cover. Tighten up the bolts until the lock washers just close up. 19. Tighten the inactive adjustment screw, pushing the rotor assembly toward the diffuser until the screw stops turning.

CAUTION

DO NOT FORCE THE SCREW. Forcing the adjustment screw can damage the inactive button bearing. Back the bolt off 1/4 to 1/3 turn and tighten the lock nut. This action provides for a 0.008 to 0.010 total axial float clearance setting. 20. Install the cleaned moisture separator screens in the cooler casing(s). The fine screen goes in first. To eliminate airflow bypass, ensure both screens fit snugly in the casing I.D. 21. Attach the cooler casing to the compressor casing. Install the: •

o-rings

•

cooler into the cooler casing

•

cooler casing guide pins into the compressor casing

•

cooler casing to the compressor casing

22. Install the inlet and bypass valves, bypass pipe and all instrumentation. Install the vibration probe. Reconnect any wiring and/or tubing to the devices on the casing. 23. Supply seal air and set seal air pressure to 7 to 9 PSIG. Turn on the power to the control panel. This will start the pre-lube pump so that the machine can be safely rolled over by hand. The re-assembly is complete. Adjustment of the vibration probes and other controls will be necessary. Do not connect the motor to the compressor until after correct motor rotation is observed.

Impeller/Diffuser Clearance Setting Procedure NOTE The bull gear locking bolt should be removed prior to performing this procedure.

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5CII OVERHAUL PROCEDURES 1.

Carefully push the rotor assembly toward the diffuser until it touches the diffuser. Holding the rotor assembly against the diffuser, you should be able to pull the thrust bearing shell away from the casing before the thrust bearing contacts the thrust collar.

2.

Check and record the total axial float of the rotor assembly using a dial indicator installed on the thrust collar. This is the distance the rotor can travel between the impeller contacting the diffuser in one direction and the casing in the other direction.

3.

Start the three retaining bolts and jacking screws in the thrust bearing. Install the Clearance Setting Bracket. Install each dial indicator as illustrated in Figure 2. Place two of the indicators on the bearing shell approximately 180° degrees apart. The third indicator is positioned on the thrust collar or in line with the thrust collar bolt, on the clearance setting bracket.

4.

Adjust all of the indicators to zero. Jack out the bearing evenly until it just picks up the thrust collar as indicated by the indicator on the thrust collar or clearance setting bracket. Record the movement of the bearing shell at this point. Jack out the rotor assembly with the thrust bearing until the indicator on the clearance setting bracket is at the required pressure tip clearance. Move the assembly 0.001" at a time on each jackscrew keeping all dial indicators as even as possible. Tap the bearing lightly and often to keep it square in the bore. At 0.005" from the desired clearance, move the assembly 0.0005" at a time until the desired pressure tip clearance is attained.

5.

Read the value of the bearing shell indicators and grind the thrust bearing shims to this thickness.

6.

Use taper feeler gauges to measure and check the impeller or inducer clearance, this is the volume tip clearance. It is the distance between the impeller and the diffuser at the inlet. The clearance should be within 0.002" of center on all sides. The volume tip clearance is set by component design and must not be adjusted in the field. If a volume tip clearance problem is suspected or discovered, contact Customer Service.

7.

Remove the dial indicators and clearance adjusting bracket. Remove the jacking bolts. Install the shims and tighten the thrust bearing bolts.

5CII OVERHAUL PROCEDURES 8.

9

Push the assembly all the way in against the thrust bearing. Set an indicator on the thrust collar bolt and set it to zero. Pull the thrust collar back. This distance is the, remaining axial float. The remaining axial float plus the established pressure tip clearance should equal the total axial float measured in step 3. (Total float = clearance + axial float). Push the rotor assembly toward the diffuser and remove the indicator. NOTE If the remaining axial float plus the established pressure tip clearance does not equal the total axial float determined above, then check the stage components to determine the problem.

9.

Adjust the reverse (inactive) thrust clearance in accordance with the procedure given starting at step 16 in the Assembly of the Stage(s) Procedure.

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5CII OVERHAUL PROCEDURES

Clearance Setting Bracket and Indicator Positioning

Dial mounting fixtures

All thread Jack bolt Dial indicators

All thread in cover bolt hole

Clearance setting bracket 4th Dial if used

SIDE VIEW

Jack bolt

FRONT VIEW

Lock bolt

Jack bolt Stud in bearing cover bolt hole

Lock bolt

Jack bolt Lock bolt Clearance setting bracket

LOCATE DIAL INDICATOR BETWEEN JACK AND LOCK BOLT

3 DIAL INDICATOR CLEARANCE SETTING ARRANGEMENT IS NEEDED TO ASSURE BEARING IS NOT BEING COCKED WHEN IT IS BEING JACKED OUT WHEN SETTING THE PRESSURE TIP CLEARANCE

Figure 2. Clearance setting indicator positioning

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The impeller clearance setting tool can be used at the thrust bearing end of all Centac compressors. All Centac service personnel should have a clearance setting bracket when working on a Centac compressor. See Figure 3. Never attempt to set the clearances without a clearance setting bracket.

1/2

1 1/4

1 1/2

1 1/32

1 7/16

2 9/32

1/2

1

TAP 3/8 - 16 NC

3/8 RADIUS

DRILL 9/16

1/4

TAP 3/8 - 16 NC

2 1/4

8 1/2

1/4

Figure 3. Clearance Setting Tool

NOTE •

The purpose of the spring bracket impeller clearance setting tool is to apply a positive pressure (inward) on the R/A while the thrust bearing is being jacked (outward) for setting the pressure tip clearance. See Figure 4.

•

The tool can be used in an end to end, or reversed, manner as may be required by the Centac model.

•

Adjust bolt length to achieve flat position of tool.

•

Material for tool is a common bar stock.

•

Bracket anchoring bolt (all thread) sized to Centac bearing cover capscrew threads.

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5CII OVERHAUL PROCEDURES

1 1/4 X 3/8-16 ALLENHEADSCREW

2 X 3/8-16 ALLEN HEAD SCREW ANCHORING STUDAND NUT

LOCKNUT

LOCKNUT

TENSION

THRUST COLLAR

CASING

Figure 4. Placement of the clearance setting tool