BBR-3516 Compressor Service Manual (CP)

Compressor Service Manual

Customer : Company Address City/State ZIP Code Phone Fax Email Address Site Location

Product Model No Serial No

Compressor BBR- 3516 CO-BBR-3516

Vol. 2 (J1705)

INTERMECH LTD. 88 Leonard Road, Penrose PO Box 12284, Penrose Auckland, New Zealand Ph 64 (9) 525 2220 Fax 64 (9) 579 3900 Email [email protected]

Page 2 of 79

Compressor Operation & Maintenance Manual

Revisions Record Revision No.

Date August, 2006

Intermech Ltd.

Description of Revision First edition

BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual

Page 3 of 79

Table of Contents 1

GENERAL.....................................................................................................................................6 1.1

2

INTRODUCTION.......................................................................................................................6

SAFETY.........................................................................................................................................8 2.1 2.2

3

GENERAL SAFETY ..................................................................................................................8 MAINTENANCE SAFETY..........................................................................................................9

COMPRESSOR SPECIFICATION..........................................................................................11 3.1 3.2 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.5 3.5.1 3.5.2 3.5.3 3.5.4 3.5.5 3.6 3.6.1 3.6.2 3.6.3 3.6.4 3.6.5

MODEL .................................................................................................................................11 DESIGN SPECIFICATION ........................................................................................................11 MANUFACTURER’S PLATE & LABEL INFORMATION .............................................................11 Specification Plate ..........................................................................................................11 Cylinder Identification Plate ..........................................................................................12 Suction Identification Plate ............................................................................................12 Discharge Identification Plate........................................................................................12 Warning Plate.................................................................................................................13 Rotation Plate .................................................................................................................13 CLEARANCES .......................................................................................................................13 Original Running Clearances.........................................................................................13 Piston Ring Side Clearances / End Gaps........................................................................14 Piston to Cylinder Clearances........................................................................................16 Torque Settings ...............................................................................................................16 Rhino Compressor Tools ................................................................................................18 OPERATING PROCEDURES ....................................................................................................19 Start Up Check List Contents..........................................................................................19 Package Details ..............................................................................................................19 Prior to Starting..............................................................................................................20 After Starting ..................................................................................................................21 Maximum Allowable Working Pressure .........................................................................21 LUBRICATION .......................................................................................................................22 General Description .......................................................................................................23 Oil Specification .............................................................................................................23 Before Starting................................................................................................................24 Top Up With Oil .............................................................................................................24 Primary Starting .............................................................................................................24

3.6.5.1

3.6.6 3.6.7 3.6.8 3.6.9 4

Priming the lubrication system using priming pump........................................................... 25

Oil Filter .........................................................................................................................26 Lube Oil Pressure Adjustment ........................................................................................26 Oil Relief Valve Setting...................................................................................................26 Compression Cylinder Injection Lubrication System .....................................................27

MAINTENANCE........................................................................................................................28 4.1 GENERAL .............................................................................................................................28 4.2 OIL PUMP (CRA-357) & OIL PUMP HOUSING (CRA-352-1)................................................29 4.2.1 Oil Pump Housing Drawing (CRA-352-1) .....................................................................29 4.2.2 Oil Pump Housing (CRA-352-1) Parts List ....................................................................30 4.2.3 Oil Pump Assembly Drawing (CRA-357) .......................................................................31 4.2.4 Oil Pump Assembly (CRA-357) Parts List......................................................................32 4.2.5 Oil Pump Relief Valve Drawing (CRA-333) ...................................................................33 4.2.6 Oil Pump Relief Valve (CRA-333) Parts List..................................................................34 4.2.7 Disassembly – Oil Pump Housing ..................................................................................35 4.2.8 Disassembly – Oil Pump Relief Valve ............................................................................35 4.2.9 Disassembly – Oil Pump.................................................................................................35 4.2.10 Assembly – Oil Pump .................................................................................................36 4.2.11 ............................................................................................................................................36 4.2.12 Oil Pump Relief Valve................................................................................................36

Intermech Ltd.

BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual

Page 4 of 79

4.2.13 Assembly – Oil Pump Housing (CRA-352) ................................................................37 4.3 RHINO CRANKCASE (CRA-3603).........................................................................................38 4.3.1 Rhino Crankcase Drawing (CRA-3603) .........................................................................38 4.3.2 Rhino Crankcase Drawing (CRA-3602) .........................................................................39 4.3.3 Rhino Crankcase (CRA-3603) Parts List........................................................................40 4.3.4 Rhino Crankcase (CRA-3602) Parts List........................................................................40 4.3.5 Taper Lock Bearing Housing Assembly Drawing (CRA-3640) ......................................41 4.3.6 Taper Lock Bearing Housing Assembly Parts List (CRA-3640).....................................42 4.3.7 Rhino Crankcase Filler Bowl Drawing (CRA-820)........................................................43 4.3.8 Rhino Crankcase Filler Bowl (CRA-820) Parts List ......................................................44 4.3.9 Disassembly – Crankshaft (CR-3253) ............................................................................45 4.3.10 Assembly – Crankcase (CRA-3603) ...........................................................................46 4.4 DRIVE END BEARING HOUSING / MECHANICAL SEAL ASSEMBLY (CRA-356)....................49 4.4.1 Drive End Bearing Housing / Mechanical Seal Drawing (CRA-356 RevB)...................49 4.4.2 Mechanical Seal Housing (CRA-356) Parts List ............................................................50 4.4.3 Disassembly / Assembly - Mechanical Seal ....................................................................51 4.5 CONNECTING ROD ASSEMBLY .............................................................................................53 4.5.1 Connecting Rod Assembly Drawing (ROA-8525)...........................................................53 4.5.2 Connecting Rod Assembly Parts List (ROA-8525) .........................................................54 4.6 CROSS HEAD CYLINDER/PISTON (CYXA-6003) ..................................................................55 4.6.1 6” Cross Head / Cylinder Drawing (CYXA-6003) .........................................................55 4.6.2 6” Cross Head / Cylinder (CYXA-6003) Parts List........................................................56 4.6.3 Disassembly - Cross-Head Cylinder/Piston ...................................................................57 4.6.4 Assembly - Cross-Head Cylinder/Piston ........................................................................57 4.7 1ST STAGE CYLINDER/PISTON / PISTON ROD ASSEMBLY ......................................................59 4.7.1 Cylinder Assembly Drawing (CYA-3500-3)....................................................................59 4.7.2 Cylinder Assembly (CYA-3500-3) Parts List ..................................................................60 4.7.3 Disassembly ....................................................................................................................62 4.7.4 Assembly .........................................................................................................................62 4.8 ROD SEAL HOUSING ASSEMBLY ..........................................................................................65 4.8.1 Rod Seal Housing Drawing (SEA-3503).........................................................................65 4.8.2 Rod Seal Housing (SEA-3503) Parts List .......................................................................66 4.8.3 Disassembly ....................................................................................................................67 4.8.4 Assembly .........................................................................................................................67 4.9 2ND / 3RD STAGE CYLINDER/PISTON/PISTON ROD ASSEMBLY ................................................68 4.9.1 Cylinder Assembly Drawing (CYA-3216-4)....................................................................68 4.9.2 3.25”x 1.625” Cylinder Assembly (CYA-3216-4) Parts List ..........................................69 4.9.3 Piston 3.25” x 1.625” Assembly Drawing (PIA–3216-2)...............................................71 4.9.4 Piston 3.25” x 1.625” Assembly (PIA–3216-2) Parts List .............................................72 4.9.5 Disassembly – Final Stage Cylinder / Piston .................................................................73 4.9.6 Disassembly – 2nd Stage Cylinder / Piston ....................................................................73 4.9.7 Assembly- 2nd / 3rd Stage Cylinder / Piston ..................................................................74 4.10 ROD SEAL HOUSING ASSEMBLY SEA-3250.........................................................................76 4.10.1 Rod Seal Housing Assembly Drawing (SEA-3250: Sheet 1)......................................76 4.10.2 Rod Seal Housing Assembly Drawing (SEA-3250: Sheet 2)......................................77 4.10.3 Rod Seal Housing Assembly (SEA-3250) Parts List ..................................................78 4.10.4 Disassembly ...............................................................................................................78 4.10.5 Assembly ....................................................................................................................78 4.11 COMPRESSOR VALVES .........................................................................................................79 4.11.1 Removal .....................................................................................................................79 4.11.2 Installation .................................................................................................................79

Table of Figures Figure 1 Plan and Elevation of Three-Stage Compressor____________________________________7 Figure 2 Specification Plate _________________________________________________________11 Figure 3 Cylinder Specification Plate __________________________________________________12 Figure 4 Suction Identification Plate __________________________________________________12 Figure 5 Discharge Identification Plate ________________________________________________12 Figure 6 Warning Plate_____________________________________________________________13

Intermech Ltd.

BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual

Page 5 of 79

Figure 7 Rotation Plate _____________________________________________________________13 Figure 8 Compressor Tools__________________________________________________________18 Figure 9 Oil Circulation Schematic ___________________________________________________22

Table of Tables Table 1 Specification Chart__________________________________________________________11 Table 2 Original Running Clearance __________________________________________________13 Table 3 Piston Ring End Gaps _______________________________________________________14 Table 4 Piston Ring Side Clearances __________________________________________________15 Table 5 Piston to Cylinder Clearances _________________________________________________16 Table 6 Torque Settings_____________________________________________________________17 Table 7 The Maximum Allowable Working Pressure ______________________________________21

Intermech Ltd.

BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual

1 1.1

Page 6 of 79

General Introduction The Rhino compressor has been developed specifically for CNG/NGV with the following features : Gas tight pressurised crankcase, up to 40 bar (600 psig). Hoerbiger valves for specific performance and reliability. Double row spherical roller main bearings. Heavy duty crankcase. High strength crankshaft, 100-80-3 ductile iron, 89mm (3.5" journals. Full flow, filtered, pressurised lubrication. Generous integral cross-head piston bearing surface. Standardized design, 22 - 200 kW (30 - 270 hp), 0.5-30 bar, (8 - 435psig) inlet pressure. High quality oil flooded mechanical crankcase seals. Double acting two, three or four stage design. Exclusive low friction cylinder treatment.

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 7 of 79

Compressor Operation & Maintenance Manual

Figure 1 Plan and Elevation of Three-Stage Compressor

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 8 of 79

Compressor Operation & Maintenance Manual

2 2.1

Safety General Safety

!!! WARNING !!! COMPRESSED GAS IS A HIGHLY DANGEROUS SUBSTANCE READ AND UNDERSTAND THIS SECTION OF MANUALS IT IS ESSENTIAL FOR THE SAFE OPERATION OF EQUIPMENT 2.1.1. Systems must be entirely vented before repair or maintenance is carried out. 2.1.2. The installation, operation, maintenance and repair shall be carried out only by qualified personnel and in accordance with the corresponding regulations for operation and safety. 2.1.3. No smoking or naked lights within 10m of any gas installation. 2.1.4. Do not adjust, remove or bypass any protective device. 2.1.5. Rotating machine parts represent a special danger. Covers and guards must not be removed whilst the machine is operating. 2.1.6. Persons operating the compressor should use hearing protection. 2.1.7. Do not store flammable materials e.g. oily rags near the compressor unit or engine drive. 2.1.8. Supply pipework and other components, which may not be included in scope of supply, must be suitable for the respective working pressure. 2.1.9. If necessary they have to be tested and protected by a pressureunloading device. 2.1.10. Electrical cable must be Flameproof and must not be linked, or allowed to contact rotating parts.

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 9 of 79

Compressor Operation & Maintenance Manual

2.2

Maintenance Safety

!!! WARNING !!! COMPRESSED GAS IS A HIGHLY DANGEROUS SUBSTANCE. BEFORE DISMANTING ANY PART OF THE COMPRESSOR, ENSURE THAT THE UNIT IS COMPLETELY DEPRESSURED 2.2.1. Maintenance and repair may be carried out only on the shutdown and entirely vented compressor unit. If necessary isolate all storage systems and blow-down all condensate traps and heat exchanger collectors. Open all manual drain valves. 2.2.2. Isolate the equipment electrically by pad-locking the main switch in the "OFF" position and fixing a corresponding warning sign. 2.2.3. Only use original spare parts and recommended products for maintenance and repair works on the compressor unit. 2.2.4. Never do work that will produce heat, like welding near oil or gas systems. Before working on oil or gas tanks empty them and clean them carefully eg. by a steam jet or purge with nitrogen. 2.2.5. During maintenance and repair work observe strict cleanliness. Keep impurities away, by covering dismounted parts and free openings with a clean rag, paper or adhesive tape. 2.2.6. After having finished the works be sure that no tools, loose parts or cleaning rags have been left on or in the compressor unit, or near the engine air cleaner. 2.2.7. Do not use easily flammable solving agents for cleaning of parts, until the unit has cooled thoroughly. After the use of solving agents carefully rinse the parts and clean them with compressed air. 2.2.8. Be very careful, use eye protection, when working with compressed air for cleaning equipment. 2.2.9. After modification or repair work on pressure vessels and safety equipment, such as relief valves, all work must be tested and accepted by the inspection authority concerned. 2.2.10. The switchboard may be opened only by qualified and authorized persons. Even if the main switch is set to the "OFF" position, the poles of the switch and feed cables of the terminal strip are alive. Therefore do not touch anything on the switchboard, and do not carry out work, with the mains current supply is not disconnected. Before starting work check if the system is entirely free of power. Intermech Ltd.

BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual

Page 10 of 79

2.2.11. Do not touch bare wires and live (current-carrying) parts, when the electrical system is energized. 2.2.12. After modification or repair work to compressor, and before power is supplied to machine, always manually turn compressor over by hand to ensure compressor is running free. 2.2.13. Intermech takes no responsibility for personal injury or damage on the unit, caused by the non-observance of the safety precautions during handling, operation, maintenance or repair of compressor units or other equipment.

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 11 of 79

Compressor Operation & Maintenance Manual

3 3.1

Compressor Specification Model This package utilises the BBR-3516 compressor. First stage Second stage Final stage

3.2

3-1/2” Double Acting cylinder 3-1/4” Single Acting cylinder 1-5/8” Single Acting cylinder

Design Specification DESCRIPTION STROKE ROD LOAD, COMPRESSION ROD LOAD, TENSION FRAME HORSEPOWER MAX. INTERNAL PRESSURE WEIGHT, APPROXIMATE RPM OIL PUMP CAPACITY SUMP CAPACITY

IMPERIAL UNITS 3.25 inches 10,000 lbs 10,000 lbs to 270 hp 600 psi 1900 lb to 1800 rpm 6 gpm @ 1600rpm 4.5 gallons

Table 1 Specification Chart 3.3 3.3.1

Manufacturer’s Plate & Label Information Specification Plate

Figure 2 Specification Plate

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 12 of 79

Compressor Operation & Maintenance Manual

3.3.2

Cylinder Identification Plate

Figure 3 Cylinder Specification Plate 3.3.3

Suction Identification Plate

Figure 4 Suction Identification Plate 3.3.4

Discharge Identification Plate

Figure 5 Discharge Identification Plate

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 13 of 79

Compressor Operation & Maintenance Manual

3.3.5

Warning Plate

Figure 6 Warning Plate 3.3.6

Rotation Plate

Figure 7 Rotation Plate Note : Rotation direction is anti-clockwise looking at the compressor from the oil sight glass side. 3.4 3.4.1

Clearances Original Running Clearances Original Running Clearances

Minimum

Maximum

Connecting rod thrust (side clearance)

0.010”

0.015”

Crankpin bearing (con-rod big end)

0.002”

0.004”

Connecting rod bushing to wrist pin

0.0015”

0.0035”

Crosshead to wrist pin

0.0015”

0.002”

Oil pump impellor assembly end clearance

0.003"

0.005"

Crosshead to guide

0.007”

0.010”

Drive end metering plate to crankshaft

0.002”

0.004”

Table 2 Original Running Clearance

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 14 of 79

Compressor Operation & Maintenance Manual

3.4.2

Piston Ring Side Clearances / End Gaps

Ring Gaps Ring Material Cast Iron 1.5 1.625 1.75 3 3.25 3.5

Clylinder Size

3.75 4.25 4.5 4.75 6 6.5 8 8.25 8.5 10

Straight Cut 45º Cut Straight Cut 45º Cut Straight Cut 45º Cut Straight Cut 45º Cut Straight Cut 45º Cut Straight Cut 45º Cut Straight Cut 45º Cut Straight Cut 45º Cut Straight Cut 45º Cut Straight Cut 45º Cut Straight Cut 45º Cut Straight Cut 45º Cut Straight Cut 45º Cut Straight Cut 45º Cut Straight Cut 45º Cut Straight Cut 45º Cut

Carbon Teflon *

Max

Min

Max

Min

Max

0.004 0.003 0.004 0.003 0.004 0.003 0.006 0.004 0.006 0.004 0.006 0.004 0.006 0.005 0.007 0.005 0.007 0.005 0.008 0.005 0.009 0.006 0.010 0.007 0.011 0.008 0.012 0.008 0.012 0.008 0.014 0.010

0.014 0.013 0.014 0.013 0.014 0.013 0.016 0.014 0.016 0.014 0.016 0.014 0.016 0.015 0.017 0.015 0.017 0.015 0.018 0.015 0.019 0.016 0.020 0.017 0.021 0.018 0.022 0.018 0.022 0.018 0.024 0.020

0.042 0.030 0.046 0.032 0.049 0.035 0.082 0.058 0.089 0.063 0.096 0.068 0.103 0.072 0.116 0.082 0.123 0.087 0.129 0.091 0.163 0.115 0.176 0.125 0.216 0.153 0.223 0.158 0.230 0.163 0.270 0.191

0.052 0.040 0.056 0.042 0.059 0.045 0.092 0.068 0.099 0.073 0.106 0.078 0.113 0.082 0.126 0.092 0.133 0.097 0.139 0.101 0.173 0.125 0.186 0.135 0.226 0.163 0.233 0.168 0.240 0.173 0.280 0.201

0.011 0.008 0.012 0.008 0.013 0.009 0.020 0.014 0.022 0.015 0.023 0.016 0.025 0.017 0.028 0.019 0.029 0.021 0.031 0.022 0.038 0.027 0.041 0.029 0.050 0.035 0.052 0.036 0.053 0.038 0.062 0.044

0.021 0.018 0.022 0.018 0.023 0.019 0.030 0.024 0.032 0.025 0.033 0.026 0.035 0.027 0.038 0.029 0.039 0.031 0.041 0.032 0.048 0.037 0.051 0.039 0.060 0.045 0.062 0.046 0.063 0.048 0.072 0.054

Table 3 Piston Ring End Gaps

Intermech Ltd.

Peek

Min

BBR-3516 Compressor Service Manual

Page 15 of 79

Compressor Operation & Maintenance Manual

Side Clearance

Table 4 Piston Ring Side Clearances

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 16 of 79

Compressor Operation & Maintenance Manual

3.4.3

Piston to Cylinder Clearances Clearances

Minimum

Maximum

Crosshead piston to guide

0.008"

0.010"

8.0" - 10.0" Dia cylinder

0.035"

0.040"

6.0" - 6.5" Dia cylinder

0.030"

0.035"

5.0" - 5.25" Dia cylinder

0.025"

0.030"

4.125" – 4.75" Dia cylinder

0.020"

0.025"

3.5" - 4.0" Dia cylinder

0.018"

0.022"

2.75" – 3.25" Dia cylinder

0.015"

0.020"

2.0" – 2.5" Dia cylinder

0.013"

0.018"

1.25" - 1.75" Dia cylinder

0.016"

0.025"

Table 5 Piston to Cylinder Clearances

3.4.4

Torque Settings Torque Settings

Size

Type

Torque ft-lb

Piston Nut (8” to 8-1/2” Piston)

1-1/8” - UNF

3" - 3-1/2" Piston

1" – UNF

-

200

Piston Rod to Crosshead Lock Nut

1" – UNF

Rod

300

Piston Rod to Crosshead

1" – UNF

-

300

Final Stage Cylinder to C.E.Cylinder

¾" – UNC

Stud

125

Final Stage Cylinder to C.E.Cylinder

¾" – UNF

Stud

106

Final Stage Head

¾" – UNF

Stud

140

Cylinder Head. 10"

¾" – UNF

Stud

96

Cylinder Head. 6" Thru 8"

¾" – UNF

Stud

96

Crosshead Cylinder To Crankcase

¾" – UNF

Stud

105

Compression Cylinder To Crosshead Guide

¾" – UNF

Stud

112

Crankcase Inspection Cover

5/8" – UNC

Cap Screw

92

Valve Lantern Jacking Screw

5/8" - UNF

Socket Set Screw

80

Crankcase Mounting Bolts

5/8" - UNC

Hex Bolts

80

Cylinder Head. 4-½" thru’ 3-1/2”

5/8" - UNC

Cap Screw

51

Final Stage Discharge Valve Cover

½" – UNF

Cap Screw

50

Cylinder Head. 3-1/4" thru’ 3”

½" – UNC

Cap Screw

51

Valve Covers

½" – UNC

Cap Screw

45

Oil Filter Housing

½" – UNC

Cap Screw

53

Split Flange Clamps

½" – UNC

Bolt

45

Conrod Bearing Cap

½ " - UNF

Cap Screw

62

Drive Bearing Housing

½" – UNC

Cap Screw

45

Intermech Ltd.

150

BBR-3516 Compressor Service Manual

Page 17 of 79

Compressor Operation & Maintenance Manual

Torque Settings

Size

Type

Torque ft-lb

Oil Pump Housing to Crankcase

½" – UNC

Cap Screw

45

Final Stage Piston Retaining Nut

½" – UNF

-

30

Rod Seal Housing to Cylinder

½" – UNF

Cap Screw

45

Rod Seal Housing to Cylinder

7/16" - UNF

Cap Screw

40

6-1/2” First Stage Piston

7/16" - UNF

Cap Screw

27

Tandem Piston (5-1/4") to Crosshead

3/8" – UNC

Cap Screw

25

Tandem Piston (3" to 3-1/2") to Piston Rod Lock Bolt

3/8" - UNF

Cap Screw

27

Split Flange Clamps

3/8" - UNF

Cap Screw

20

Gudgeon Pin End-CapRetaining Bolt Nut

3/8" UNF

Bolt / Nut

30

Mechanical Seal Retainer

5/16 " -UNC

Cap Screw

15

Bearing Cover Plate

5/16" - UNC

Cap Screw

15

Oil Pump Housing Seal Cover

5/16" -UNC

Cap Screw

15

Oil Pump Retainer

5/16" –UNC

Cap Screw

17

Final Stage Piston Retaining Plate

5/16" – UNC

Cap Screw

22

Piston “Power Nut” Locking Screw (10” Piston)

5/16” – UNF

Grub Screw

12

Rod Wiper Retainer Plate

5/16” – UNF

Cap Screw

18

Piston Rod Balance Nut Lock Screw (Power Nut type)

5/16" UNF

Grub Screw

12

Piston Rod Balance Nut Lock Screw (Standard Balance Nut)

¼" UNF

Grub Screw

6

Piston Rod Locking Screw

¼" UNF

Grub Screw

6

Table 6 Torque Settings

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 18 of 79

Compressor Operation & Maintenance Manual

3.4.5

Rhino Compressor Tools

Figure 8 Compressor Tools

Intermech Ltd.

BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual

3.5

Page 19 of 79

Operating Procedures

!!! WARNING !!! COMPRESSED GAS IS A HIGHLY DANGEROUS SUBSTANCE. BEFORE DISMANTLING ANY PART OF THE COMPRESSOR ENSURE THAT THE UNIT IS COMPLETELY DEPRESSURED 3.5.1

Start Up Check List Contents

3.5.2

Package Details Compressor Model Serial Number Motor/Engine Model Motor Rated Speed

: : : :

Packager

:

Package Unit Number Date Package Shipped Start Up Date Commissioning Engineer

: : : :

Customer

:

Location

:

Local Service Agent

:

Local Service Agent Telephone Number

:

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 20 of 79

Compressor Operation & Maintenance Manual

3.5.3

Prior to Starting

Yes

ALIGNMENT RUN OUT

FAC E

OD

DIAL INDICATOR

1 Do you have the Intermech Manual(s), special tools & spares? 2 Check the Performance Data Sheet for design limitations; eg Rod loads, RPM, discharge temperature. 3 Check the Performance Data Sheet for optimum running conditions. 4 Set the Fault Switches according to these conditions. 5 Have all the Intermech Pre Start-up Checks, as outlined in the Commissioning Procedure, been carried out? 6 Has the Electrical Pre Start-up Checks, as outlined in the Commissioning Procedure, been carried out? 7 Is the Installation complete to the satisfaction of the Commissioning Engineer? 8 Has the Warranty Document been completed? 9 Are the customer & operators familiar with the equipment's Operating Instructions? 10 Check that no damage has occurred to the Package during transportation. 11 Is the correct grade and quantity of oil available on site (at least 20 litres - 5 imp. gallons)? 12 Check the oil level in the compressor. 13 Has all the lubrication oil pipework been primed with oil? 14 Is there Methanol or Isopropyl Alcohol available on site (at least 20 litres - 5 imp. gallons)? 15 Check the coupling bolt torques. 16 Has the compressor coupling alignment been checked (maximum allowable tolerance 0.005" (0.127mm)? Record dial indicator readings: 17 Has the gas inlet pipework been cleared of dirt, slag, rubbish, etc? 18 Check the Cooler Fan for obstructions. 19 Has the Compressor been turned over by hand prior to initial start-up?

Intermech Ltd.

BBR-3516 Compressor Service Manual

No

Page 21 of 79

Compressor Operation & Maintenance Manual

3.5.4 After Starting

Yes

No

1 Did oil pressure come up immediately? 2 Are there any strange noises or shaking in the compressor? 3 Are there any oil leaks? 4 Have all safety/fault functions been tested? 5 If the compressor driver (prime mover) is an electric motor, check the current draw with the compressor under full load.

3.5.5

Maximum Allowable Working Pressure The Maximum Allowable Working Pressure is defined as the maximum continuous pressure for which the manufacturer has designed the equipment (or any part to which the term is referred), when handling the specified fluid at the specified temperature. All Rhino Compressors Cylinders have a Maximum Allowable Working Pressure (MAWP), this and the hydrostatic test pressure with test date are stamped on the end of every cylinder. Any relief valves will be set to operate at not more than the maximum allowable working pressures but not less than the values listed below. Rated Discharge Pressure

Relief Valve Margin Above Rated Discharge

Psig

Bar

Pressure

-14.7 to 150 151 to 2500

-1 to 10 10+ to 170

15psi (1 bar) 10 %

2501 to 3500

170+ to 240

8%

3501 to 5000*

240+ to 345

6%

Table 7 The Maximum Allowable Working Pressure * For related discharge pressures above 5000 psig (345 bar), the relief valve setting shall be agreed upon between the purchaser and Intermech Limited.

Rated Discharge Pressure is defined as the highest pressure required to meet the conditions the purchaser specifies for the intended service. Maximum allowable working pressure shall exceed the rated discharge pressure by at least 10 percent or 25psi (1.7 bar), whichever is greater.

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 22 of 79

Compressor Operation & Maintenance Manual

3.6

Lubrication

Figure 9 Oil Circulation Schematic

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 23 of 79

Compressor Operation & Maintenance Manual

3.6.1 General Description The lubricating system is based on a pressurised crankcase with mechanical seals. Pressurised oil is fed right through the crosshead thrust face. Oil is picked up via a mesh strainer, through the oil pump, then monitored by a relief valve, back to the oil pickup, pumped through the oil cooler and then through a full flow filter. The filter is located within the pressurised crankcase inside the filter cap. From the filter the oil enters the auxiliary drive end crankshaft seal cavity. From the seal cavity the oil then passes into the crankshaft and is fed through to the crank pin journals. Oil is fed up the con-rod to the gudgeon pin bearing and into the gudgeon pin itself where it passes into the crosshead bushes and to the thrust face of the crosshead. Also from the seal cavity oil passes through an internal pipe to the main drive end where it enters the drive seal cavity, cooling the mechanical drive seal and then relieving back into the sump. The main drive bearing is fed from the seal cavity through a close metering clearance plate. The front bearing is fed from the crankshaft through a smallmetered hole from the oil filter cavity. 3.6.2 Oil Specification Listed below are some of the INTERMECH approved oils. The customer must consult INTERMECH during the oil selection process.

SAE 40 Oils Approved Caltex RPM 150 Shell Corena H 150 BP Energol RC 150

SAE 30 Oils Approved Caltex RPM 100 Shell Corena H 100 BP Energol RC 100

For ambient temperatures above 50degF (10degC), SAE 40 compressor oil should be used. For ambient temperatures below 50degF (10degC), SAE 30 compressor oil should be used.

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 24 of 79

Compressor Operation & Maintenance Manual

Note : •

The compressor has a capacity of 3.5 imp gallons (15 litres).

•

Synthetic oils should not be used.

3.6.3 Before Starting 1. Check that the oil filter is fitted and tightened using a filter wrench. 2. Ensure that the oil filter housing is securely in place. 3. Check compressor crankcase oil level.

3.6.4 Top Up With Oil 1. Remove the oil cap on top of the crankcase using the oil cap removal tool. 2. Fill the oil filler bowl with the correct oil. The oil filler bowl has a 1.25 litre capacity. 3. Re-instate the oil cap using the oil cap tool. 4. The oil within the filler bowl will drain into the crankcase. 5. After approximately 60 seconds, check the oil level in the sight glass. 6. If necessary, repeat steps 1 through 5 until the oil level in the crankcase reaches the correct level. 7. The correct oil level is midway up the top sight glass (when the compressor is stopped). 8. The minimum oil level is midway up the bottom sight glass (when the compressor is running). 9. Ensure that the oil cap securely in place after topping up crankcase. 3.6.5

Primary Starting If the compressor package has a built in electric pre-lube pump, oil pressure builds up automatically before the compressor starts. If there is no electric prelube pump, a priming pump must be used to prime the compressor lubrication system before initial start up eg. at time of commissioning. If the compressor has been shut down for an extended period, the lubrication system should be primed when restarting. If the compressor package is supplied without a built in electric pre-lube pump, a priming pump is supplied as part of the special tools kit.

Intermech Ltd.

BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual

Page 25 of 79

3.6.5.1 Priming the lubrication system using priming pump. Pump oil through until the oil pressure gauge registers approximately 30 psi. Continue to prime the system for another 15 seconds after oil pressure reaches 30 psi. IMPORTANT: After replacing the oil filter element or draining any oil from the oil cooling system, it is important to prime the compressor oil system.

Intermech Ltd.

BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual

3.6.6

Page 26 of 79

Oil Filter Service Period : Oil and oil filter elements should be changed every 1500 hours. If regular quality viscosity checks or oil analyses are done with satisfactory results, then longer periods of 3000 hours may be justified. CAUTION: Do not use other than original oil filter element, as this will void all warranty. Equivalent oil filters are not necessarily satisfactory and may not have similar seals, pressure rating or internal valves.

3.6.7 Lube Oil Pressure Adjustment There are two relief valves in the crankcase. The first is situated in the oil pump housing and is set at 65psig to protect the oil filter element. The second is situated in the rear main bearing housing and is set at 50 - 55psig. This is to relieve the oil from the seal housing and to ensure that the rear seal is cooled.

3.6.8

Oil Relief Valve Setting

Instructions

Cautionary Notes

Theory 1/.

There are two oil pressure relief valves fitted to the Rhino compressor. One is located in the oil pump housing the other in the flywheel bearing housing (mechanical seal housing). Both oil pressure relief valves are adjustable by way of an Allen headed cap screw located on the bottom edge of these housings.

The oil pressure relief valve in the flywheel housing must be fitted with a lighter spring than that used in the relief valve in the oil pump housing.

The relief valve in the flywheel bearing housing should lift first to maintain desired oil pressure.

This ensures that there is oil pressure at all parts of the lubrication system, and that oil flows through the mechanical seal cavity (aids in cooling)

Setting the Oil Pressure 2/.

Screw both oil pressure adjusting screws in completely and back off about ¼ of the

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 27 of 79

Compressor Operation & Maintenance Manual

Instructions

Cautionary Notes

total adjustment 3/.

Start the compressor

4/.

Unscrew the Oil Pressure adjusting screw at the oil pump housing until the oil pressure drops to 65psi

5/.

Unscrew the Oil Pressure adjusting screw at the fly wheel housing until the oil pressure is 55psi

6/.

Monitor the oil pressure

7/.

If the oil pressure drops below 45psi then adjust both screws up by one full turn

8/.

Unscrew the flywheel housing relief screw until the oil pressure is 50psi

The Oil Pressure should be high (>65psi)

Oil Pressure will reduce as the oil temperature increases. Adjust the oil pump housing first, then the flywheel housing relief.

3.6.9 Compression Cylinder Injection Lubrication System 1. The function of the injection lubrication system is to lubricate piston rings on compression pistons. 2. The 2 main components of the injection lubrication system are the Mechanical lubricator pump and the Oil divider (distribution) block. 3. The compressor crankshaft drives the lubricator pump. 4. Oil from the lubricator pump is delivered to the oil divider (distribution) block. 5. The function of the divider block is to deliver oil to all stages of compression and to rod seal housings. . 6. The oil is delivered through individual tubes and discharged through check valves into each compression cylinder and to each rod seal housing. 7. A flow (proximity) switch mounted on the divider block monitors divider block activity. 8. There is also an orange coloured cycle indicator mounted to the divider block for visual monitoring of divider block 9. See Fault Repair section of Compressor Package manual for set up and repair procedure.

Intermech Ltd.

BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual

4

Page 28 of 79

Maintenance

!!! WARNING !!! COMPRESSED GAS IS A HIGHLY DANGEROUS SUBSTANCE. BEFORE DISMANTLING ANY PART OF THE COMPRESSOR ENSURE THAT THE UNIT IS COMPLETELY DEPRESSURED 4.1

General The major components of the compressor are the crankcase, the crankshaft and bearings, the connecting rods and wrist pins, the crosshead cylinders and pistons, the 1st, 2nd and 3rd stage cylinders and pistons and the oil pump. Drilled oil passages & a fitted oil gallery circulate lubricating oil from the oil pump to each of the main bearings and crankshaft. Whenever working on the unit ensure that absolute cleanliness, using lint free cloths, is observed. When the inspection cover is removed and/or the internal components are exposed, ensure that these parts are kept covered except when actually working on them. Be sure to protect the exposed mating surfaces from mechanical damage at all times. On gas engine powered units remove centre coupling to ensure compressor cannot turn over during maintenance. On electric motor powered units switch off & lock out the electric circuit to the motor during maintenance.

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 29 of 79

Compressor Operation & Maintenance Manual

4.2 4.2.1

Oil Pump (CRA-357) & Oil Pump Housing (CRA-352-1) Oil Pump Housing Drawing (CRA-352-1)

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 30 of 79

Compressor Operation & Maintenance Manual

4.2.2

Oil Pump Housing (CRA-352-1) Parts List

Item Number Part Number

Description

Quantity

1

CNC-0508

Cap screw 5/16" UNC x 1"

6

2

CR-3554

Seal Cover Cap

1

3

ORN-7151

O-Ring (Nitrile)

1

4

CR-3521

Oil Pump Housing Cover

1

5

8 HP50N

7/8"UNF Plug

3

6

CRA-333

Pressure Relief Valve (refer Item 16 also)

1

7

ORN-7117

O-Ring (Nitrile)

2

8

CR-3611

Sight Glass

2

9

ORN-7020

O-Ring (Nitrile)

2

10

CR-3622

Sight Glass Retainer

2

11

ORN-7119

O-Ring (Nitrile)

2

12

CR-3541

Oil Restrictor Plate

1

13

ORN-7228

O-Ring (Nitrile)

1

14

ORN-7270

O-Ring (Nitrile)

1

15

ORN-7271

O-Ring (Nitrile)

1

16

CR-3336

Spring Pressure Relief Valve (Strong)

1

17

CRA-357

Oil Pump Assembly

1

18

8-10 F5BU

1/2" Tube x 7/8"UNF Straight Connector

1

19

8 FNU

1/2" Blanking Cap - Ferulok

1

20

CR-3524

Wear Plate

1

21

KNC-0404

Cap Screw CSK ¼” UNC

1

22

12 F5BU-M

7/8"UNF Straight Tube Connector

2

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 31 of 79

Compressor Operation & Maintenance Manual

4.2.3

Oil Pump Assembly Drawing (CRA-357)

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 32 of 79

Compressor Operation & Maintenance Manual

4.2.4

Oil Pump Assembly (CRA-357) Parts List

Item Number Part Number

Description

Quantity

1

CR-3571

Hex Drive Key (6mm)

1

2

CR-3582

Thrust Ring

1

3

CR-358

Oil Pump Driven Gear

1

4

CR-357

Oil Pump Driver Gear

1

5

CR-3575

Oil Pump key

1

6

CR-360

Oil Pump Bush

1

7

CR-3591

Oil Pump Retainer

1

8

CNC-0508

Cap screw 5/16"UNC x 1"

1

9

CRA-3579

Oil Pump Impellor Assembly

1

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 33 of 79

Compressor Operation & Maintenance Manual

4.2.5 Oil Pump Relief Valve Drawing (CRA-333)

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 34 of 79

Compressor Operation & Maintenance Manual

4.2.6

Oil Pump Relief Valve (CRA-333) Parts List

Item Number Part Number 1

CR-3335

2

Description

Quantity

Valve Plunger

1

Spring (see CRA-352-1 or CRA- 358 for part no.) O-Ring Retainer

1

3

CR-3333

4

ORN-7114

O-Ring (Nitrile)

1

5

BUN-114

Back-up Ring (Nitrile)

1

6

NNF-08

Nut 1/2"UNF

1

7

CR-3331

Valve Retainer Nut

1

8

CR-3339

Adjustment Screw

1

Intermech Ltd.

1

BBR-3516 Compressor Service Manual

Page 35 of 79

Compressor Operation & Maintenance Manual

4.2.7 Disassembly – Oil Pump Housing 1. Refer drawing # CRA-352-1 in section 4.2.1 2. Before dismantling, ensure compressor is completely de-pressured. 3. Drain oil from crankcase. 4. Remove ½” capscrews (15 off) that hold the oil pump housing in place. 5. Carefully remove oil pump housing.. 6. Check condition of all o-rings about the oil pump housing sealing face. 7. Check condition of sight glass o-rings. Replace if necessary. 8. Remove seal cover cap (CR-3554) and check condition of oil restrictor plate (CR-3541) & O' ring (ORN-7228). Replace if necessary. 9. Remove pressure relief valve assembly (CRA-333). See procedure below. 4.2.8 Disassembly – Oil Pump Relief Valve 1. Refer drawing # CRA-333 in section 4.2.5. 2. Remove relief valve adjustment screw. 3. Screw ½” UNF Capscrew from special tools into o-ring retainer (CR-3333). 4. Use screw to remove O-Ring retainer. 5. Relief valve plunger and spring will drop out of oil pump housing. 6. Check condition of O-Rings; spring; etc. 4.2.9 Disassembly – Oil Pump 1. Refer drawing # CRA-357 in section 4.2.3 2. Remove the oil pump housing from crankcase as described in section 4.2.2 3. Check condition of oil pump drive gear (CR-357) & oil pump drive key (CR-3575) on crankshaft. 4. Remove oil pump driven gear (CR-356) and hex drive key (CR-3571). Check condition. 5. Remove oil pump retainer (CR-3591) 6. Check condition of oil pump bush (CR-360) and thrust ring (CR-3582). 7. Remove oil pump impellor assembly (CR-3579) and check for signs of wear. 8. Remove Wear Plate (CR-3524) and check sign for wear, if necessary replace with new.

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 36 of 79

Compressor Operation & Maintenance Manual

4.2.10 Assembly – Oil Pump

Instructions 1. 2. 3.

4.

5.

6.

Clean and oil all components Insert oil pump impeller and rotor into its pocket. Check clearance between impellor / rotor assembly and oil pump retainer. See Clearance chart 3.4.1 Oil the pump rotor with medium – heavy oil and fit retainer. Torque cap screws to 17 ft-lb. Fit oil pump driven gear and 6 mm hex drive key to oil pump and check for ease of rotation of oil pump. Locate thrust washer in gear. Rotate driven gear to check freedom of movement.

Cautionary Notes Refer CRA-352-1 and CRA-357

Use Plastigauge between impellor assembly and oil pump retainer to check clearance.

4.2.11 4.2.12 Oil Pump Relief Valve

Instructions 1. 2. 3.

Fit new o-ring and back-up ring to o–ring retainer. Fit oil pressure relief valve plunger, spring & o-ring retainer. Fit relief valve adjustment screw

Intermech Ltd.

Cautionary Notes Apply grease to o-rings Take care not to damage o-rings when inserting retainer. Adjust spring tension to ¾ of full travel of adjustment screw. OIL PRESSURE ADJUSTMENT MUST BE CARRIED OUT AFTER OVERHAUL OF RELIEF VALVE. Refer sections 3.6.7 & 3.6.8

BBR-3516 Compressor Service Manual

Page 37 of 79

Compressor Operation & Maintenance Manual

4.2.13 Assembly – Oil Pump Housing (CRA-352)

Instructions 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Fit o-ring (ORN-7228) to bronze restrictor (CR-3541) Fit bronze restrictor into oil pump housing Fit seal cover cap and torque to17 ft-lb. Fit o-rings to sight glasses. Fit sight glasses; sight glass retainers and o-rings. Fit o-rings to oil pump housing. Fit oil pump drive gear drive pin into crankshaft. Slide the oil pump driver gear over the crankshaft to line up with key. Fit oil pump housing assembly. Fit retaining screws and tighten to correct torque.

Intermech Ltd.

Cautionary Notes

Apply grease to o-rings

Grease o-rings.

This will be a firm slide fit. Ensure that oil restrictor plate remains in place when carrying out this process. See Torque Setting Chart (section 3.4.4)

BBR-3516 Compressor Service Manual

Page 38 of 79

Compressor Operation & Maintenance Manual

4.3

Rhino Crankcase (CRA-3603)

4.3.1 Rhino Crankcase Drawing (CRA-3603)

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 39 of 79

Compressor Operation & Maintenance Manual

4.3.2

Rhino Crankcase Drawing (CRA-3602)

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 40 of 79

Compressor Operation & Maintenance Manual

4.3.3 Rhino Crankcase (CRA-3603) Parts List

Item Number Part Number

Description

Quantity

1

CR-3603

Taper Locking Bearing Crankcase

1

2

CRA-3602

Lubrication Assembly

1

3

CR-3253

Crankshaft Rhino 3.25” Stroke

1

4

CRA-356

Drive End Cover Assembly

1

5

CRA-3640

Taper Locking Bearing Housing

1

6

BRS-9052C4

Spherical Roller Bearing

1

7

CRA-328

Filter Cap Assembly

1

8

FIE-Z178

Filter Element

1

9

CR-3311

Spigot Oil Filter

1

10

SSC-0505

Socket Set Screw 5/16” UNC x 5/16”

1

11

CR-3254

Main Drive Key

1

12

PNR-M0420

4 x 20 Roll Pin

1

13

CNC-0812

Cap screw 1/2”UNC x 1.5” lg

32

14

CNC-0612

Cap screw 3/8”UNC x 1.5” lg

8

15

1/8-HHP-S

Hollow Hex Plug 1/8” NPT

2

16

1-HHP-S

Hollow Hex Plug 1” NPT

4

17

ORN-7114

O-Ring 114

2

18

ORN-7156

O-Ring 156

1

4.3.4 Rhino Crankcase (CRA-3602) Parts List

Item Number Part Number

Description

Quantity

1

CR-329

3/4" Tube

1

2

ORN-7117

O-ring (Nitrile)

3

3

CRA-820

Oil Filler Bowl Assembly

1

4

CNC-1012

Cap screw 5/8"UNC x 1-1/2"

6

5

CRA-352

Oil Pump Housing Assembly

1

6

PFP-16

1"NPT Dry seal Plug

1

7

CRA-332

Oil Pick-Up Assembly

1

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 41 of 79

Compressor Operation & Maintenance Manual

4.3.5 Taper Lock Bearing Housing Assembly Drawing (CRA-3640)

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 42 of 79

Compressor Operation & Maintenance Manual

4.3.6 Taper Lock Bearing Housing Assembly Parts List (CRA-3640)

Item Number

Part Number

Description

Quantity

1

CR-3641

Bearing Housing

1

2

CR-3642

Taper Locking Wedge Block

1

3

SSF-0608

Set Screw 3/8"UNF x 1" long

4

4

CNF-0412

Capscrew 1/4"UNF x 1.5" Lg.

12

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 43 of 79

Compressor Operation & Maintenance Manual

4.3.7 Rhino Crankcase Filler Bowl Drawing (CRA-820)

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 44 of 79

Compressor Operation & Maintenance Manual

4.3.8 Rhino Crankcase Filler Bowl (CRA-820) Parts List Item Number Part Number

Description

Quantity

1

1/4 HP-S

1/4"NPT Plug

1

2

CR-821

Top Plate

1

3

CNC-0628

Capscrew 3/8" x 3-1/2"

4

4

CR-8221

Filler Bowl

1

5

CPE-06

Circlip External 3/8"

1

6

ORN-7010

O-Ring Nitrile

2

7

ORN-7011

O-Ring Nitrile

4

8

VAN-073

Seal Teflon

1

9

CR-803

Spring

1

10

CR-805

Regulating Piston

1

11

ORN-7218

O-Ring Nitrile

1

12

ORN-7137

O-Ring Nitrile

1

13

CR-806

Vent Plug

1

15

CR-807

Spring Seat

1

16

ORN-9151

O-Ring Nitrile 90

1

17

FIE-090

Woven Stainless Steel Mesh

1

18

ORN-7266

O-Ring Nitrile

1

19

CPE-10E

Circlip External 5/8"

1

20

CPI-M72

Circlip Internal 72mm

2

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 45 of 79

Compressor Operation & Maintenance Manual

4.3.9 Disassembly – Crankshaft (CR-3253) 1. Before dismantling, ensure compressor is completely de-pressured. 2. Remove the drive coupling. 3. Remove the crankcase top cover. 4. Remove cylinder assemblies as described in this section. 5. Remove the oil pump housing and oil pump as described in 4.2 6. Remove the mechanical seal assembly as described in 4.4. 7. Remove mechanical seal drive pin from crankshaft. 8. Remove the oil pump end crankshaft main bearing retainer plate. 9. Refer to Taperlock Bearing Housing drawing in section 4.3.5. This shows crankshaft oil pump end Bearing Sleeve arrangement. With crankshaft installed in crankcase Taperlock Sleeve (item # 2 ) is locked in place over top of Bearing Housing (item # 1). The bearing is locked inside Bearing Housing. The Taperlock Sleeve is what locks the bearing in place. 10. To remove the crankshaft, the Taperlock Sleeve must be pushed off the Bearing Housing. Jacking screws are provided for this purpose. 11. Once the Taperlock Sleeve is free from the Housing the crankshaft bearing can be slid from the Bearing Housing. 12. The best way to remove the crankshaft from the crankcase is to stand the crankcase on its end (oil pump end). 13. Carefully lift the crankshaft from the drive end of crankcase. 14. Once the crankshaft is out, remove the crankshaft main bearing retaining circlip from the drive end bearing housing. Remove the drive end bearing housing from the crankshaft and bearing. 15. Check the main bearings for wear. Replace if necessary. To remove bearings use a hydraulic ram puller.

Intermech Ltd.

BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual

Page 46 of 79

4.3.10 Assembly – Crankcase (CRA-3603)

Crankcase Assembly Procedures Clean inspect and oil all components

Ensure 1/8 Dry Seal plugs are fitted into 2 locations on crankshaft.

(*)

I. Fitting Main Bearing to Crankshaft

Heat bearings for 2 hrs to 110oC Place ∅160 internal circlip over drive end of crankshaft and slide bearing onto this journal. C3 Type. Minimum bearing clearance 0.0015” 3 When the drive end bearing is cool enough so that it is locked onto the crankshaft, stand the crankshaft on the drive end and fit the main bearing to the oil pump end of crankshaft. C4 Type. Minimum bearing clearance 0.0015” II. Assemble Drive End Bearing Housing 1 Fit the O ring (ORN-7240) into the grove on the bronze metering plate and lightly lubricate with grease 2 Press metering plate into the metering plate retainer. 3 Assemble oil pressure relief value into its hole, by inserting the shuttle, spring then retainer (with O ring fitted then backup ring), locate in place with retaining bolt and adjust screw. 4 Fit plug (8HP50N-S) to bottom drilling and hollow hex head plug to (6HP50N-S) into outer seal cover face. 5 Tap 1/8 x ¾”long roll pin into the hole at top face of bearing diameter bore. 6 Place metering plate/retainer assy inside bore of CR-3531 housing so that the roll pin locates in the hole in the retainer. 1 2

7

Ensuring that it is hard against the crankshaft shoulder. This is best achieved by having the crankshaft in a vertical position. (*)

From the side that has the lead in chamfer

(*)

All items to be lubricated before assembly. USE LIGHT SPRING. CR-3334

(*)

Ensure the Hollow Hex Plug is inserted below flush.

(*) (*)

Fit this housing assembly to the crankshaft and locate with circlip, which is to be fitted to the groove inside CR3531 housing.

(*)

III. Install Crankshaft into Crankcase 1 2

The crankcase is to be clean and inspected for damage Insert oil tube into bottom of crankcase. Fitted O ring in recess on end of tube.

Intermech Ltd.

(*) Ensuring plastic hose is fitted over the tube between bulkheads and webs of crankcase. BBR-3516 Compressor Service Manual

(*)

Compressor Operation & Maintenance Manual

Page 47 of 79

Crankcase Assembly Procedures 3

4

Fit O rings (ORN-7270 + ORN-7271) into groove and flywheel housing and corner of flywheel housing and lightly grease, and O ring (ORN-7206) into oil relief valve recess on face of housing. Fit both pieces of bearing carrier as one unit into crank case Sit on back and lower Crank Case / Drive housing assembly into crank case

(*)

Tighten cap screws to 25 Ft-lbs Tighten ½” cap screws that hold drive housing in place to 45 Ft-lbs

Sign as torqued Sign as torqued

Lower crankcase back onto mounting feet From inside crankcase tap outer bearing race fully back towards oil pump end of crankcase. Set DTI on outer race of bearing From outside Tap the outer race of bearing towards drive end housing. Note: distance outer race moves. Shift outer race to center point plus 0.004” further apart. Once bearing clearance is reduced by Tighten ¼” cap screws in rear bearing 0.001” screw in 4 x SSF0608 set screws cover to 3.5 ft-lbs and nip. Tighten ¼ Clamp bolts in bearing carrier to 9.5 Ft/lbs Minimum bearing clearance 0.002” Tighten ¼ cap screws in bearing carrier to 12 ft/lbs 5 6 7

Check O Rings in recess. Mark cap screws as torqued with a dab of colored lacquer; or permanent marker. Check rotation for freedom movement

Sign as torqued Sign as torqued Sign as torqued (*) (*)

IV. Fitting Oil Pump Housing assembly 1

Oil Pump Housing assembly to be assembled as per assembly procedure.

2

Oil pickup filter assembly is fitted from the inside of the crankcase. Its tube is passed through from inside the crankcase to protrude through the recess and be flush with end of crankcase. This is to be expanded into the hole so as to lock it permanently in position.

Intermech Ltd.

Procedure number: PRA-008 (Oil Pump Housing CRA-352-1 Assembly) This needs to be carried out prior to installing CRA-3640

BBR-3516 Compressor Service Manual

(*)

Page 48 of 79

Compressor Operation & Maintenance Manual

Crankcase Assembly Procedures 3

Fit 2 O-rings to crankcase ORN-7114

Ensure O-rings are fitted to oil pump bearing housing boss (ORN-7270 & ORN-7271), and sight glass retains (ORN-7119) and teflon thrust washer is on the face of oil pump gear.

(*)

4

Fit pin key into crankshaft and slide the oil pump driver gear over the crankshaft to line up with key.

This will be a firm slide fit. Ensure that this gear is correctly located against restrictor plate.

(*)

5

Fit O rings to end of oil tube & oil pickup (in recesses provided) and at oil filter feed drillings on face of crankcase and ease oil pump housing (CRA-352) over crankshaft and into is correct position against crankcase. Torque cap screws to 45 ft-lb and mark as torqued.

Ensure that the crankshaft does not push out of its seat, the restrictor inside oil pump housing.

6

(*)

V. Oil Filter Installation 1 2

3

Fit socket set screw to left hand side hole beside oil spigot Insert oil filter spigot and nip to the bottom of its thread. Lubricate seal on oil filter with a thin film of grease and screw onto spigot. Tighten firmly hand tight. Grease lightly the O-ring on the oil filter cover and fit to crankcase. Torque cap screws to 60 ft. lb, and mark as torqued.

Use Loctite 243

ASSEMBLED BY:

Screw grub screw into filter housing with Loctite 271

(*)

Use O-ring 7156

(*)

SIGNATURE:

DATE:

COMMENTS:

Intermech Ltd.

BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual

4.4

Page 49 of 79

Drive End Bearing Housing / Mechanical Seal Assembly (CRA-356)

4.4.1 Drive End Bearing Housing / Mechanical Seal Drawing (CRA-356 RevB)

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 50 of 79

Compressor Operation & Maintenance Manual

4.4.2 Mechanical Seal Housing (CRA-356) Parts List

Item Number Part Number

Description

Quantity

1

CNC-0510

Cap screw 5/16” UNC x 1-1/4” lg.

6

2

CR-3286

Seal Gland Plate (Burgmann)

1

3

ORN-7246

O-Ring (Nitrile)

1

Lip Seal

1

Hex Plug Dry Seal type

2

Mechanical Seal Assembly

1

5 6

SEL8010510 6HP50N-S

7

SEMH7N/80-00

8

CR-3531

Mechanical Seal and Bearing Housing

1

9

ORN-7271

O-Ring (Nitrile)

1

10

ORN-7270

O-Ring (Nitrile)

1

11

CR-3302

Oil Metering Plate

1

12

ORN-7239

O-Ring (Nitrile)

1

13

CR-3301

Oil Metering Plate Retainer

1

14

BRS-9052

Self Aligning Bearing

1

15

CPI-160

Circlip Internal (160 dia. Groove)

1

16

CRA-333

Pressure Relief Valve assembly

1

17

PNR-0212

Roll Pin 1/8” dia x ¾” lg.

1

18

CR-3334

Spring –Pressure Relief Valve (Weak)

1

19

ORN-7206

O-Ring (Nitrile)

1

20

4-F5BU-S

21

Straight Thread Tube Connector ¼” T x 7/16”UNF

1

4 HP50N-S

Hollow Hex Plug 7/16”UNF O-Ring seal

1

22

PNR-M0425

Anti-Rotation Pin 4mm dia. x 25mm lg

1

23

CR-3259

Anti-Rotation Pin

1

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 51 of 79

Compressor Operation & Maintenance Manual

4.4.3 Disassembly / Assembly - Mechanical Seal

Instructions

Cautionary Notes

REMOVAL 1 2

Remove drive coupling “spider”. Remove coupling hub from compressor by firstly removing the flange from the hub then sliding the hub off the shaft. The flange will probably need to be jacked off using jacking screw holes provided on the flange. Once the flange is removed, the hub will need to be spread a little using a screwdriver to allow the hub to be slid off easily.

3 4

Remove key from shaft. It is important to protect mechanical seal faces from damage while removing / installing. Heavy paper or thin card must be wrapped around crankshaft before mechanical seal gland housing (CR-3286) is removed. Rotate compressor crankshaft until drive keyway is at the top.

5

6 7

Remove mechanical seal gland housing from drive end bearing housing. Remove dynamic part of seal (Silicon Carbide Ring) along with Spring Assembly.

8

Check condition of drive pin (CR-3259)

9

Clean out drive end bearing housing where mechanical seal is located.

Before removing the flange, check the distance between the hub on the motor and the hub on the compressor. The distance should be 117.0mm + or – 0.15mm. After installing the new mechanical seal and refitting the coupling hub to the shaft, the distance between the hubs should equal this distance (see coupling hub drawing attached). Slide card onto crankshaft through lip seal cavity up to crankshaft shoulder.

This ensures that the mechanical seal drive pin is at the top and cannot fall out when Spring Assembly is removed. To do this, 2 “wire pullers” should be hooked behind Spring Assembly 180 deg apart. The Spring Assembly / Silicon Carbide Ring can then be removed as an assembly. Ensure that protective card is wrapped around crankshaft while removing this assembly. Drive pin can be removed using pliers. Take care when doing this. The pin can drop out and fall into the cavity at the bottom of the mechanical seal housing.

INSTALLATION 1

Slide spring assembly onto the shaft

Intermech Ltd.

BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual

Instructions

2

3 4

ensuring that the drive pin slot at back of Spring Assembly slides into place over the drive pin. Fit dynamic (rotating) part (Silicon Carbide Ring) of the mechanical seal into place against the spring assembly. There will be resistance from the dynamic ring o-ring. Lightly oil o-ring. Push dynamic ring into place using thumbs. Note there are 2 tabs which locate dynamic ring in spring assembly. Remove protective paper / card from shaft. Fit the non-rotating part of the seal into gland housing.

5

Fit the gland housing complete with bronze ring.

6 7 8

Tighten gland plate screws. Slide the coupling hub into place on shaft As detailed above, it is most important to have correct distance between the motor hub and the compressor hub. Lightly clamp the hub to the shaft by tightening the cap screws on the hub. Fit Coupling Flange and tighten cap screws. Check that distance between coupling hub “flanges” is correct. Ensure that drive coupling hub locking bolts are tightened to correct torque. Re-fit coupling “spider”

9 10 11 12 13

Intermech Ltd.

Page 52 of 79

Cautionary Notes

Take care not to damage the seal face. Use protective card wrapped around crankshaft as described above.

As above, there will be resistance from the static ring o-ring. Lightly oil o-ring. Push static ring into place using thumbs. Drive slot at back of static ring must locate with drive pin. Ensure that the faces of the mechanical seal parts are dry ie. free of oil.

This will stop the hub moving when the flange is fitted. The distance must be 117mm.

BBR-3516 Compressor Service Manual

Page 53 of 79

Compressor Operation & Maintenance Manual

4.5

Connecting Rod Assembly

4.5.1 Connecting Rod Assembly Drawing (ROA-8525)

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 54 of 79

Compressor Operation & Maintenance Manual

4.5.2 Connecting Rod Assembly Parts List (ROA-8525)

Item Number

Part No.

1

CNF-0824

Capscrew 1/2"UNF x 3" Lg

4

2

RO-1252

Bush 2.5" Gudgeon

1

3

RO-85251

Con-Rod

1

4

RO-904

Shell Bearing (Big End)

1

5

RO-905

Pin 3/16" dia x 3/4" lg - Silver Steel

2

Intermech Ltd.

Title

Qty.

BBR-3516 Compressor Service Manual

Page 55 of 79

Compressor Operation & Maintenance Manual

4.6

Cross Head Cylinder/Piston (CYXA-6003)

4.6.1 6” Cross Head / Cylinder Drawing (CYXA-6003) (CYXA-6003 for Low Pressure side and High Pressure side)

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 56 of 79

Compressor Operation & Maintenance Manual

4.6.2 6” Cross Head / Cylinder (CYXA-6003) Parts List Item Part Number Number

Description

Quantity

1

ROA-8525

Con-rod Assembly

1

2

CYX-6451

X-Head Cylinder

1

3

PIX-6062

6" Cross-head Piston

1

4

RO-2534

Gudgeon Pin 2.5"

1

5

RO-2535

End-plate for Gudgeon Pin

2

6

BNF-0644

Bolt 3/8"UNF x 5-1/4"

1

7

NNF-12

Nut 3/4"UNF

6

8

NNF-C06

Nut 3/8"UNF Cone Lock

1

9

ORN-7262

O-Ring (Nitrile)

1

10

PNR-0405

Roll Pin 1/8" dia. x 5/16"

2

11

STN-1224

Stud 3/4"UNF x 3"

6

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 57 of 79

Compressor Operation & Maintenance Manual

4.6.3 Disassembly - Cross-Head Cylinder/Piston 1. Decompress and degas the compressor. 2. Remove low pressure compression cylinder assembly (ref.4.7) and / or high pressure cylinder assembly (ref.0) as per procedures detailed in this section. 3. Remove oil filler bowl (CRA-820 section 4.3) assembly from top of crankcase. 4. Remove big end cap from Conrod. 5. Remove cross head piston assembly complete with Conrod. 6. Remove gudgeon pin end plate (RO-2535) retaining bolt (BNF-0644). 7. Slide Gudgeon pin out of piston and Conrod. Take note of top of Conrod and top of crosshead piston. (Conrod serial # is always facing the top) 8. If removing both high pressure throw and low pressure throw crosshead pistons, take note of which crosshead belongs to high pressure throw and which belongs to low pressure throw. When reassembling, they cannot be mixed up. 9. Check condition of big-end bearing shells. 10. Remove cross head cylinder from crankcase. 11. Check the condition of the bore, i.e. check for score marks and measure inside diameter. 4.6.4

Assembly - Cross-Head Cylinder/Piston

Instructions 1. 2. 3. 4. 5.

All components to be cleaned and oiled before assembly Fit o-ring (ORN-7262) into corner of cross head cylinder Slide cross head cylinder over studs. Tighten nuts to correct torque. See Torque Setting Chart (section 3.4.4)) Position the con-rod (ROA-8525) inside the cross head piston (con-rod serial # to the top). Align gudgeon pin holes and fit gudgeon pin.

Intermech Ltd.

Cautionary Notes Check for damage Lightly grease o-ring Orientate so that the radiused cut out on cross head skirt is adjacent to crankshaft counterweight. Check clearance of crankshaft counterweight on skirt of cylinder. Ensure that high pressure side cross head piston is fitted to high pressure throw and low pressure side cross head piston is fitted to low pressure throw. NOTE: Both, the top of the crosshead piston and the bottom of the cross head piston have oil retention grooves. In 1 side only, there are oil holes drilled into the grooves. The side of the piston that

BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual

Instructions

6. 7. 8.

9.

10.

11. 12.

Fit Gudgeon end plates (RO-2535) and retain with bolt (BNF-0644) and lock nut (NNF-C06). Fit big end bearing shells to con-rod and end-cap. Slide con-rod / cross-head piston assembly into cross-head cylinder.

Check bearing shell to crankshaft clearance by placing Plastigauge strip between end-cap bearing shell and crankshaft journal then tightening end-cap bolts to correct torque. After checking clearance, lubricate bearing shells and crankshaft bearing journal. Then re-fit bearing cap and tighten retaining bolts to correct torque. Check for freedom of rotation If Cross-head piston is new, check crosshead piston to cross-head cylinder clearances. Check using feeler gauges at points indicated in sketch.

Intermech Ltd.

Page 58 of 79

Cautionary Notes has oil holes goes to the thrust side of the crosshead guide i.e. Thrust side on the high pressure throw is at the top and thrust side on the low pressure throw is at the bottom. Locknut torque = 30 ft-lb

Ensure that con-rod serial # faces the top. Ensure that cross-head piston lubrication holes face the top for high pressure throw and face downwards for low pressure throw. Do not rotate crankshaft with plastic gauge fitted or faulty readings will result.

See Torque Setting Chart (section 3.4.4)

BBR-3516 Compressor Service Manual

Page 59 of 79

Compressor Operation & Maintenance Manual

4.7

1st Stage Cylinder/Piston / Piston Rod Assembly

4.7.1 Cylinder Assembly Drawing (CYA-3500-3)

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 60 of 79

Compressor Operation & Maintenance Manual

4.7.2 Cylinder Assembly (CYA-3500-3) Parts List Item

Part Number

Title

1

CYXA-6003

X-Head Cylinder Assembly Hollow Gudgeon

1

2

CY-3500

Cylinder 3.5"

1

3

PI-3500

3.5" Double Acting Piston

1

4

RIS-3030

Piston Support Ring

1

5

HE-3500-2

Head 3.5"

1

6

ROP-3200

Piston Rod

1

7

RIC-35D438

3-1/2” Sealing & Rider Ring

1

8

Vls-3200

Valve Lantern (Suction)

2

9

VAS-602357-M

Suction Valve '60'

2

10

RIC-354532

Compression Ring 3.5”

2

11

VLD-3500

Valve Lantern (Discharge)

2

12

GKV-07006530

Gasket Aluminium (60RX)

2

13

HE-3031

Valve Cap

4

14

HE-4553

Cover (Suction Port)

1

15

5151HK-32

2" Split Clamp (Parker)

2

16

HE-4555

Cylinder Stub (Split Flange) 2" - Weld

1

17

HE-4554

Cap (Split Flange)

1

18

ORV-7230

O-Ring (Viton)

5

19

GKV-07006510

Gasket Aluminium (60RX)

2

20

ORV-7236

O-Ring (Viton)

1

21

VAD-602357-M

Discharge Valve `60’

2

22

NNF-12

Nut ¾”UNF

6

23

ORN-7258

O-Ring (Nitrile)

1

24

ORV-7228

O-Ring (Viton)

2

25

RPN-087

Jam Nut Assembly 0.875”

1

26

-

-

-

27

RPN-100

Jam Nut Assembly 1”

1

28

CNC-0812

Cap screw ½"UNC x 1.5" Lg.

32

29

CNC-0816

Cap screw ½"UNC x 2" Lg.

8

30

Gkv-10009010

Gasket Aluminium

1

31

CNC-1216

Cap screw ¾"UNF x 2" Lg.

6

32

STN-1224

Stud 3/4"UNF x 3" UNC

6

Intermech Ltd.

Quantity

BBR-3516 Compressor Service Manual

Page 61 of 79

Compressor Operation & Maintenance Manual

Item

Part Number

Title

33

SEA-3503

Seal Assembly 3.5”

1

34

SEB-3554

Seal Housing Ring for 3.5” D.A. Cylinder

1

35

ORV-7154

O-Ring (Viton)

1

Intermech Ltd.

Quantity

BBR-3516 Compressor Service Manual

Page 62 of 79

Compressor Operation & Maintenance Manual

4.7.3 Disassembly 1. Remove inlet filter vessel. 2. Remove 1st stage discharge pipe. 3. Remove first stage cylinder head. 4. Remove first stage piston centre lock nut. 5. Unscrew first stage piston using the special tool provided. 6. CAUTION: When unscrewing the piston, ensure that the piston rings do not get caught in head end valve pockets. To prevent this occurring, roll over the machine until first stage piston is approximately in middle of stroke. Then unscrew the piston. 7. Slide piston complete with piston rings from cylinder. 8. Check condition of the bore, i.e. check for score marks and check bore diameter. 9. Check condition of piston rings. 10. Remove 3/4" UNF cylinder retaining nuts at crosshead cylinder. 11. Carefully slide cylinder off piston rod. 12. CAUTION: Take care when lifting the cylinder off the piston rod. Rod Packings are easily damaged. The cylinder must be lifted off the rod without any force (up; down or sideways) being placed on the rod while lifting the cylinder off. 13. Inspect piston rod for damage. 14. Before removing piston rod, take note of distance from top of rod to top of balance nut. 15. Loosen balance nut locking screws. 16. Loosen balance nut (use special tool provided). 17. Remove piston rod. 4.7.4

Assembly Instructions

1

Screw balance nut onto piston rod.

2

Screw piston rod and balance nut assembly into X-head piston until balance nut makes contact with top of X-head piston.

Intermech Ltd.

Cautionary Notes

Set distance between top of rod and top of balance nut to the same distance as it was before rod was removed.

BBR-3516 Compressor Service Manual

Page 63 of 79

Compressor Operation & Maintenance Manual

Instructions

Tighten balance nut to 300ft-lb

5 8 9

Tighten balance nut locking grub screws Fit o-ring (ORN7268) into groove on compression cylinder face. Fit tapered rod seal guide (special tool # TL-0061 - see section 3.4.5.) over end of piston rod. Slide cylinder assembly over rod and onto spigot of cross head cylinder. Tighten retaining nuts to correct torque (See Torque Setting Chart section 3.4.4). Remove rod seal guide from piston rod. Fit the piston to piston rod (without piston rings). Tighten piston to 125 ft-lb. Fit gasket and o-ring to head. Fit head to cylinder and tighten retaining screws to correct torque. Check piston HE and CE clearances at top and bottom of stroke respectively.

10

11 13 14 15

If head-end and crank-end clearances are incorrect. compression cylinder will need to be removed and piston rod position changed in X-head piston Remove cylinder head and piston. Check that piston ring side clearances and end-gaps concur with clearances detailed in Table 3 Piston Ring End Gaps) Fit piston rings to piston. Slide piston support ring onto rod. Oil piston rings generously and ease into cylinder. Screw piston onto rod. Torque to 200 ft lb. using special tool provided (special tool # TL-0059 - see section 3.4.5.) Screw piston nut onto rod & torque to 130 ft lb.

Intermech Ltd.

Cautionary Notes

Use special tool # TL-0060 (see section 3.4.5.) Tighten until Allen key twists out of shape. Lightly lubricate o-ring. Lightly oil outside of guide. Ensure that cylinder is right way up i.e. Discharge valves towards drive motor.

Ensure that piston support ring is placed in position on rod before fitting piston.

Use feeler gauges fed through HE & CE valve pockets to check clearances. HE clearance should be 2/3 of total clearance. CE clearance should be 1/3 of total clearance.

Orientate piston ring end-gaps, 180 deg to each other. Ensure crank is at bottom of throw. Take care not to damage rings. Roll over machine until piston is at top of stroke for final torquing of piston

BBR-3516 Compressor Service Manual

Page 64 of 79

Compressor Operation & Maintenance Manual

Instructions

Cautionary Notes

16

Tighten grub screws .

Use Loctite 222 on grub screws..

17

Fit head to cylinder and tighten retaining screws to correct torque.

Ensure that bevelled areas of head are in line with valve pockets (i.e. in vertical position).

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 65 of 79

Compressor Operation & Maintenance Manual

4.8

Rod Seal Housing Assembly

4.8.1 Rod Seal Housing Drawing (SEA-3503)

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 66 of 79

Compressor Operation & Maintenance Manual

4.8.2 Rod Seal Housing (SEA-3503) Parts List Item Part Number Number

Description

Quantity

1

SEC-3503

3.50” Seal Cup

1

2

SEB-4625

Seal Block

1

3

CNF-0506

Cap screw 5/16”UNF x ¾” lg.

8

Pressure Breaker

1

BTU Seal

2

Cap screw ½”UNF x 1-3/4” lg.

6

4 5 6

SER-1805-P1U SER-1805BTUU CNF-0814

7

ORN-7106

O-Ring (Nitrile)

2

8

ORV-7239

O-Ring (Viton)

1

9

SEB-4040-H

Seal Block with Hole

1

10

ORMV-706030

O-Ring (Viton) 70x60x3

1

11

ORV-7236

O-Ring (Viton)

1

12

SEC-4252-2

3-1/2” x 3-1/4” Wiper Seal Retainer

1

13

SEW-1805-RTV

RTV Seal 0.1 Wiper

1

14

SEB-4041

Seal Block Face

1

15

BRB-040

Sealing Plug

4

16

PNR-0204

Roll Pin 1/16” dia. x ¼” lg.

2

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 67 of 79

Compressor Operation & Maintenance Manual

4.8.3 Disassembly 1. Remove Wiper Seal Retainer (Item 12), Wiper (Item 13) & Seal Block Face (Item 14) 2. Remove BTU Rod Seals (Item 5), Seal Blocks (Item 2 & 9) and Pressure Breaker (Item 4). 3. Check condition of all Rod Wipers, Seal Blocks, Rod Seals, Pressure Breakers, O-Rings, etc. 4. Remove Seal Cup Retaining Screws (Item 6). 5. Remove Seal Cup (Item 1) from compression cylinder. 6. Check condition of O-rings. 4.8.4

Assembly 1. Place Pressure Breaker (Item 4) into Seal Cup. 2. Place Seal Block (Item 2) and first BTU Rod Seal into Seal Cup. Ensure that Seal Block Alignment Pin (Item 16) locates correctly in hole in Seal Cup. Ensure that Rod Seal is correct way up. 3. Place Seal Block with hole (Item 9) and second BTU Rod Seal into Seal Cup. Ensure that Seal Block Alignment Pin (Item 16) locates correctly. 4. Fit O-Ring (Item 10) and Seal Block Face (Item 14). 5. Fit RTV Wiper Seal (Item 13) into Seal Cup. 6. Fit Wiper Retainer (Item 12). Torque cap screws to 18ft/lb. 7. Fit O-rings to Seal Cup. Ensure that O-rings are lubricated. 8. Fit aluminium gasket (part of cylinder assembly) to cylinder then fit Seal Housing assembly to cylinder. Torque Seal Housing Retaining Screws to 45ft/lb.

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 68 of 79

Compressor Operation & Maintenance Manual

4.9

2nd / 3rd Stage Cylinder/Piston/Piston Rod Assembly

4.9.1 Cylinder Assembly Drawing (CYA-3216-4)

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 69 of 79

Compressor Operation & Maintenance Manual

4.9.2 3.25”x 1.625” Cylinder Assembly (CYA-3216-4) Parts List Item Number

Part Number

Description

1

CY-3250-2

Cylinder 3.25" D.A.

1

2

CY-2751

Cylinder Final Stage

1

3

CYXA-6003

X-Head Cylinder Assembly, Hollow Gudgeon

1

4

HE-3045

Head Final Stage

1

5

ROPA-3216

Piston Rod Assembly

1

6

SEA-3250

Seal Assembly

1

7

HE-4553

Cover (Suction port)

1

8

HE-3031

Valve Cap

1

9

PIA-3216-2

Piston Assembly (3.25” x 1.625”)

1

10

HE-4558

Cylinder Stub (Split Flange) 1-1/2”NPT

1

11

Li-1625

Cylinder Liner

1

12

¼” HHP-S

Hollow Hex Plug ¼”NPT

1

13

VAD-602359-M

Discharge Valve `60’

1

14

VAS-602359-M

Suction Valve `60’

1

15

VLD-3201

Valve Lantern (Discharge)

1

16

VLS-3201

Valve Lantern (Suction)

1

17

GKS-7670

Gasket stepped for 30R1/54C Valve

1

18

GKV-04503511

Gasket Aluminium for VAC-54 series

1

Gasket for VAC-54 series (steel)

1

Valve Lantern (Discharge)

1

19

GKV-07006310S

Quantity

20

GKV-07006510

21

GKV-07006510

22

5151HK-16

1" Split Clamp

2

23

HE-4557

Thermowell Cap (Split Flange)

1

24

HE-1758

Weld Adapter (for 1” Split Flange)

1

25

ORV-9219

O-Ring (Viton)

2

26

ORV-7228

O-Ring (Viton)

2

27

ORV-7230

O-Ring (Viton)

2

28

ORV-9230

O-Ring (Viton)

4

29

ORV-7232

O-Ring (Viton)

1

30

ORV-7236

O-Ring (Viton)

1

31

ORN-7258

O-Ring (Nitrile)

1

32

VAC-546015

Concentric Valve

1

33

5151HK-32

Split Clamp 2”

2

Intermech Ltd.

Valve Lantern (Discharge

2

BBR-3516 Compressor Service Manual

Page 70 of 79

Compressor Operation & Maintenance Manual

Item Number

Part Number

Description

Quantity

34

NNF-12

Nut ¾”UNF

6

35

NNFR-12

Nut Reduced Hex. ¾”UNF

6

36

CNF-0610

Cap screw 3/8”UNF x 1-1/4” lg.

8

37

CNC-0816

Cap screw ½”UNC x 2” lg.

8

38

CNC-0812

Cap screw ½”UNC x 1-1/2” lg.

32

39

STN-1274

Stud ¾”UNF x ¾”UNF x 9-1/4” lg.

6

40

STN-1224

Stud ¾”UNF x 3”UNC

6

41

SEB-3254

Seal Housing Ring for 3-1/4” D.A. Cylinder

1

42

ORV-7153

O-Ring (Viton)

1

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 71 of 79

Compressor Operation & Maintenance Manual

4.9.3 Piston 3.25” x 1.625” Assembly Drawing (PIA–3216-2)

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 72 of 79

Compressor Operation & Maintenance Manual

4.9.4 Piston 3.25” x 1.625” Assembly (PIA–3216-2) Parts List Item Part Number Number

Description

Quantity

1

RIC-324432

Compression Ring 3-1/4”

1

2

RIC-324435

Sealing Ring 3-1/4"

2

3

RIC-328Q31

Rider Ring 3-1/4”

1

4

RIR-168L31

Rider Ring 1-5/8”

1

5

RIC-164455

Sealing Ring 1-5/8"

2

6

RIC-162252

Compression Ring 1-5/8”

3

7

CNC-0508

Cap screw 5/16”UNC x 1” lg.

5

8

PI-3250-2

Piston 3-1/4” HP

1

9

RIS-3030

Piston Support Ring

1

10

ROPW-1502

Retaining Plate

1

11

SSF-0404

Socket Set Screw (Grub) ¼”UNF x ½” lg.

2

12

PI-1625

Piston 1-5/8”

1

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 73 of 79

Compressor Operation & Maintenance Manual

4.9.5 Disassembly – Final Stage Cylinder / Piston 1. Remove final stage discharge pipe and 2nd stage separator. 2. Remove final stage head (HE-3045) 3. Remove final stage concentric valve. 4. Remove final stage cylinder. 5. Unscrew final stage piston retaining plate screws (CNC-0508). 6. Remove final stage piston. 7. Check condition of final stage piston rings and piston. 8. Check condition of final stage cylinder liner. 9. Check condition of final stage cylinder O-Ring (ORV-7232) 4.9.6 Disassembly – 2nd Stage Cylinder / Piston 1. Remove 2nd stage discharge pipe and 1st stage separator. 2. Remove 2nd stage piston locking screw (CNF-0508) 3. Unscrew piston from piston rod using special tool provided (special tool # TL-0059 - see section 3.4.5.). CAUTION: When unscrewing the piston, ensure that piston rings do not get caught in head end valve pockets. To prevent this occurring, roll over the machine until piston is approximately in middle of stroke. Then unscrew the piston. 4. Remove 2nd stage cylinder retaining nuts. 5. Carefully slide cylinder assembly off piston rod. CAUTION: Take care when lifting the cylinder off the piston rod. Rod Packings (seals) are easily damaged. The cylinder must be lifted off the rod without any force (up; down or sideways) being placed on the rod while lifting off. 6. Before removing piston rod, take note of distance from top of rod to top of balance nut. 7. Loosen balance nut locking screws. 8. Loosen balance nut using special tool provided (TL-0060). 9. Remove piston rod. 10. Check condition of piston rod.

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 74 of 79

Compressor Operation & Maintenance Manual

4.9.7 Assembly- 2nd / 3rd Stage Cylinder / Piston

Instructions

1

Fit balance nut to piston rod.

2

Fit piston rod to X-head piston.

3

Tighten balance nut to 300 ft-lbs using special tool provided. (TL0060) Tighten balance nut locking screws.

4 8 9 10 11

12 13 15 16 18 19 20 21

22 23 24

Fit o-ring (ORN-7258) to bottom of cylinder. Fit tapered rod seal guide (special tool # TL-0061 - see section 3.4.5.) special tool) over end of piston rod. Slide cylinder assembly over rod and onto spigot of cross head cylinder. Tighten retaining nuts 125 ft-lbs Check that 2nd stage piston ring side clearances and end-gaps concur with clearances detailed in Table 3 Piston Ring End Gaps Fit piston rings to piston. Remove rod seal guide from piston rod. Oil piston rings generously and ease into cylinder. Screw piston onto rod. Torque to 180 ft lb. using special tool provided. Lock piston in place by tightening centre locking screw to 27 ft-lbs. Fit final stage piston and lock in place using retaining plate. Tighten retaining plate screws to 22 ft-lbs. With retaining plate screws tight, the final stage piston should be free to move (“float”) Check that final stage piston ring side clearances and end-gaps concur with clearances detailed in Table 3 Piston Ring End Gaps) Fit piston rings to piston. Oil piston rings generously. Fit o-ring (ORV-7232) into groove in bottom of final stage cylinder.

Intermech Ltd.

Cautionary Notes

Set distance between top of rod and top of balance nut to the same distance as it was before rod was removed. Screw rod in until balance nut meets Xhead piston.

Tighten until Allen key twists out of shape. Lightly oil outside of guide. Ensure that cylinder is right way up i.e. discharge valves towards drive motor.

Orientate piston ring end-gaps, 180 deg to each other. Ensure crank is at bottom of throw. Take care not to damage rings. Roll over machine until piston is at top of stroke for final torquing of piston Use Loctite on cap screw. If piston is tight, bottom “flange” of piston will need to be lapped.

Orientate piston ring end-gaps, 180 deg to each other. Ensure o-ring is greased.

BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual

25 26

Slide final stage cylinder over piston. Fit concentric valve bottom gasket (GKS-7670) to final stage cylinder.

27

Fit concentric valve top inner gasket (GKV-04503511) to valve and top outer gasket (GKV-07006310-S) to valve recess in final stage head. Fit concentric valve to final stage head. Slide final stage head over studs onto final stage cylinder. Tighten head retaining nuts to 140 ftlbs

28 29 30

Intermech Ltd.

Page 75 of 79

Ensure that cylinder is right way up.

Ensure that valve gaskets remain in place.

Tighten head nuts incrementally starting at approximately 80 ft-lbs increasing torque by 10 ft-lbs at a time until full torque is reached.

BBR-3516 Compressor Service Manual

Page 76 of 79

Compressor Operation & Maintenance Manual

4.10

Rod Seal Housing Assembly SEA-3250

4.10.1 Rod Seal Housing Assembly Drawing (SEA-3250: Sheet 1)

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 77 of 79

Compressor Operation & Maintenance Manual

4.10.2 Rod Seal Housing Assembly Drawing (SEA-3250: Sheet 2)

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 78 of 79

Compressor Operation & Maintenance Manual

4.10.3 Rod Seal Housing Assembly (SEA-3250) Parts List Item Part Number Number

Description

Quantity

1

SEC-3250

Seal Cup

1

2

SEB-4625

Seal Block

1

3

SEB-4041

Seal Block Face

1

4

CNF-0506

Cap screw 5/16”UNF x ¾” lg.

8

5

ORV-7234

O-Ring (Viton)

1

Pressure Breaker

1

BTU Seal

2

RTV Seal 0.1 Wiper

1

6 7 8

SER-1805-P1U SER-1805BTUU SEW-1805-RTV

9

CNF-0814

Cap screw ½”UNF x 1-3/4” lg.

6

10

ORN-7106

O-Ring (Nitrile)

2

11

ORV-7238

O-Ring (Viton)

1

12

BRB-040

Sealing Plug

4

13

SEB-4040-H

Seal Block with Hole

1

14

ORMV-706030

O-Ring (Viton) - 70x60x3

1

15

SEC-4252-2

Wiper Seal Retainer

1

16

PNR-0204

Roll Pin 1/16” dia x ¼”

2

4.10.4 Disassembly Use same procedure as for 1st Stage Rod Seals (see section 4.8)

4.10.5 Assembly Use same procedure as for 1st Stage Rod Seals (see section 4.8)

Intermech Ltd.

BBR-3516 Compressor Service Manual

Page 79 of 79

Compressor Operation & Maintenance Manual

4.11

Compressor Valves

4.11.1 Removal 1. Decompress and degas the compressor. 2. Loosen valve cap screws. Note: Do not totally remove the valve cover bolts. Unscrew bolts to a point where the valve cover can be moved outwards to a position where the valve cap o-ring seal is clear of the valve pocket. This will allow residual gas in the valve pocket to escape. 3. Remove valve cap retaining bolts and valve cap. 4. Remove valve lantern ring. 5. Use the valve tool provided to extract the valve. 6. Remove valve gasket. 7. Check condition of valve gasket and valve cap o-ring. 8. Check condition of valve. 4.11.2 Installation 1. Ensure that valve is in good condition before re-installing. Re-kit valve as required by maintenance schedule. Replace complete valve if required. 2. Fit valve with new gasket. Smear Anti-seize grease on valve gasket before installing valve. 3. Fit lantern ring. Ensure that valve and lantern are correctly located in valve pocket. 4. Fit valve cover with new o-ring if required. Ensure that o-ring is greased. 5. Tighten valve cover bolts evenly to the correct torque setting.

Intermech Ltd.

BBR-3516 Compressor Service Manual