WRVT 510

$ffiMVEGH

MANUAL GAS & REFRIGERATION COMPRESSOR

ffi

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COI.IPRESSOR SERYICE HAHUAL

INDEX TO SECTIOH

Page Ho.

G

Section

1

Foretrord

Section

?

Description

2

2.1 Compressor 2.2 Compression Cycle 2.3 Gas System ?.4 0il System 2.5 0ils Section

I

Section

3

4

$

Section

5

6

3

4q ,t4 r5 6

Instal I ation

3.1 Ai ignment of Compressor Coupl ings 3.2 Alignment Tolerance 3.3 Dowe11 ing 3.4 Piping 3.5 External Arrangement Draw'ings First Start Up 4.1 First Start 4.2 Use of Compressor as a vacuum pump Normal Start Normal Stop

7

Precautions During Shut

.l .Z 7.3 7 .4 7.5 7

$ Section

B

9

General

.1 .2 9.3 9.4

s

L?

12,13

Dmrn 15 15

16

i6 16 L7 1B

Comments

Dismantl ing Compressor for l'lajor 0verhauls Re-Assembly Compressor after 0verhaul Compressor General Arrangements

19

19,20 20,21 ?2,?3

Special Instructions 9

ln IU

,10 ,11

T4

General Comments Preparation for Annual Inspection Djsmantl ing Procedure for Annual Inspection Check i ng C1 earances Re-Assembly after Annual Inspection

9

c^^+:^JtJl.-LIUII

g

0verhaul

8.1 B.? 8.3 8.4 Section

B

i{ai ntenance

7

B

o

14

6.1 Procedure on Shut Down 6.2 Inhibiting 0i1s Section

7

I

Hormal 0peration

5.1 5.2 Section

a

J

Torque Spec i fi cati ons P rocedure f or F i tt'i ng Lockrvashers Special Tool Li st Component l,Jei ghts

Lq

Compressor Recommended Spares Li st

L/

25

26

Spares

10.1

Page

1

COMPRESSOR SERVICE MANUAL

-0

SECTION

1-

FOREWORD

READ CAREFULLY BEFOtrE INSTALLING AND STARTING

YOUR

COMPRESSOR

These instructions have been prepared to ensure that your compresSor gives lorrg and satisfactory service. The entire manual should be read before reverlrng to any one section for specilrc inf ormation One copy should be given to the personnel responsible for installing and operating the compressor.

a +

ts

s

All requests for information. services or spares should be directed

to:-

HOWDEN CCM PRESSORS LIM ITED SERVICE DEPARTMENT, 133 BARFILLAN DRIVE, G LASGOW G52 1 BE

Telephone Number. 041 -BBZ 3346 ROCOMP Telex Number'.778711

-

Ail enquiries should be accompanied by the Howden Contract Number and the Compressor Serial Number, taken from the nameplate on the side of the compressor body. B

Page

2

SECTION

?.1

2-

DESCRIPTION

cot-tPREss0Rs

0il injected Screw Compressor is a positive disp'lacement, capacity conirolled, oil flooded rotary machine.

a

The Howden

Compression is achieved by the meshing shafts housed in a casing.

of

two

hel'ical rotors on para'I1e1

The accurately mach'ined helical rotors are called Male and Female. The male (driving) rotor has four lobes which mesh with six flutes in the female (driven) rotor, both rotors having the same outside djameter. Each rotoris supported by two plain white metal thjck walled journal bearings fitted adjacent to the compression chamber.

As the lubricating or'l is at discharge pressure plus 30 the bearinEs act as shaft seals within the compressor.

I

-$

p.s.i Q xg/cnZ)

Rotor end thrust is accomodated by a balance piston on the male rotor and tilting pad thrust bearings on both male and female rotors.One side of the bal ance pi ston 'is subject to o'i'l pressure (gas outl et pressure pl us 30 p.s.i), the other side is at suction pressure and therefore the balance piston opposes the normal rotor end thrust and assists the thrust bearing loading on the male rotor. The male rotor has lobes of approximate'ly circular arc sections formed helically along the rotor length and these mesh with corresponding flutes on the female rotor. When the interlobe space aiong the rotor iength is fi11ed, the rotation of the rotors moves the end of the I obes past the 'i nl et port, so seal 'i ng the i nterl obe space. As the rotors continue to rotate the intermeshing of the lobes on the discharge side of the compressor progressively reduces the space occupied by the gas causing compress'ion. Compression continues until the interlobe becomes exposed to the outlet port in the casing and gas is discharged. See Secti on 2.?

-

Capac'ity controi is achieved by means of a slide valve in the casing operated by a piston in a hydraulic cyf inder mounted on the compressor.

B

is

actuated by lubricating oi1, fed from the compressor lubricating oi1 manifold, to one or other side of the ptston, moving the slide valve and altering the point jn the rotor length at which compression begins. Th'is allows internal gas recirculation, thus controlf ing the capacity from 100% down to 10% with approximately proportjonate saving in

The Piston

p

owe

r.

Various methods of hydraulic cy1 inder control are available and the appropriate literature provided by the compressor set supplier, should studied before carry'ing out any work on this equipment.

2.2

be

COI{PRESSIOH CYCLE

Fig 1. Gas js drawn in to fill the interlobe space between adiacent I obes

Fig 2. As the rotors rotate the interlobe space moves Past the inlet port so sealing the j n ter'l obe space.

.^

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B

Page

3

uur1r ^LJJUn

SECTION

JLKI ILE-

Z-

ru\KUf\L

DESCRIPTIOI{

Fig 4.

Fig 3. Continued rotation progressively reduces the space occupied by the gas causing

_t&

compression

2.3

DESCRIPTION OF GAS SYSTEI'{ FOR REFRIGERATI0?{ C0MPRESS0R SET(Fig 5)

I &

l.{hen

the interl

obe

space becomes exposed to the outlet port the gas is di scharqed

A

STAI{DARD

.

is drawn into the compressor throuqh a non-return valve and then a strainer fitted directly on the inlet flange and discharged into an oil tank/separator. The non-return valve is necessary to prevent the compressor be'i ng 'motoreC' 'in the reverse d'i rect'ion when i t 'is stopped wi th h'igh gas pressure at the outl et.

Gas

If necessary a second non-return val ve is positioned at the outlet of the tank to prevent the entry of gas or 1 i quid refri gerant. Primary separation of the oil mjxed with the gas is achieved in the tank, secondary separation takes place in a wi re mesh el ement separator positioned close to the tank outlet

In some separator designs the wire mesh is repl aced by a separator cartridge.

oil drains'into the oil tank. A further secondary separator vessel may also be fitted where a very high separation efficiency i s requi red. The oil separated i s usual 1y dra ined into the compressor through a small bore pipe which can be fitted with a protective filter and an i sol ati ng va1 ve.

The separated

&

s

2.4

DESCRIPTIOH OF OIL SYSTEI'{ FOR A STAHDARD REFRIGERATI0N C0MPRESS0R SET (Fig 5)

0i1 at outlet pressure is

drawn from the tank by the oi1 pump, passed through a cooler and micronic filters to the manifold where it is fed to the bearings, balance piston, shaft seal, compression chamber and hydraul actuator.

IC

liquid refrigerant iniection is used there is no oil cooler. A differential pressure relief valve in the system before the filters, majntains a manifold pressure in the range of 30 p.s.i (2 Xg7crTl1. !{hen the compressor operates on a continous duty, duplex micronic filters may be fitted, allowing one f ilter e1ement to be changed while the other is in

1.{hen

n^^-:+i^vPcr qLruil-

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Approved I ubrj cati ng oi I s

Section

2'u

for refri

gerati on compressors are I i sted under oage

4

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Page

5

-G 2.5

BECOMMENDED LUBRICATING OILS. Details of recommended oils are given in (Fig.6) and (Fig. 7). dependanl on application APPROVED LUBRICANTS - REFRIGERATION COMPRESSORS

Fis

6

AMMONIA AND R22 vrsco

MATiUIAC IURER

srTY s

No.l

PE

CtFrC

H€LI XACO/C

A LT

E

X

IPT 68

68

67

t.3

310

48.5

o.901

o.437

-

34

-42

183

CLAVUS 68

68

68

7.3

Jr5

4

8.5

o.895

o.4 39

-30

24

111

68

6?

6.3

285

o.902

0.440

-60

68

65

7.4

300

8.6

o.89s

o.4 39

34

207

63

250

45

o.895

o.438

-34

-44

r90

0.9?0

o 433

-36

-54

183

o.925

0.450

-40

48

168

o

a9B

o 438

33

o c31

o 430

Y

E

(1

200"

wF68 ERIC

$

4

ICEMATIC

299

56

5.9

245

SUN

uNls{-) 4GS

59

5.8

268

4

CULF

ESKTTO 6B

68

300

.18 5

cH EVRON

6ALF

6g

CASTROL

o

PO

IIJT

C

204

E

300

B

5"Cl

(caUKg

l 5"Cl

(

F

OL

RC

ARCTIC MOBIL

FLASH

ro00c

68

SO

cLos € o

POINT

100"c

Z

ES

rLASH

POINT

40"c

GRAVIT

CAPELI.A rE

POUR

HEAT

GRADE' €ri

S

P€crFrc

R€OWO( )o

rso

B.P

s

CENTISTOKES

| {7E

s

ll 2) 3)

5

5.5

6.7

68

3.8

305

212

-48

200

'

The vrscosriy ol lhese olls,s between ISO 46 g'trCe and ISO 6B qrarle Kcal,'tg'C.1 Bru/lb"F.1 I9K,/trg"C The exisleoce ol lhis l;st does not erclude the use ol olher o,ls. bul arO.oval lo( o,ls not included above musl 1

be oblained [.om

Howden Compressors Lld . before use

APPROVED LUBRICANTS - REFRIGERATION COMPRESSORS R12 PROPANE AND PROPYLENE (\/here discharge pressure exceeds 1OO psia - (7.O31 Kg/cm^) See Note 1 Belor^r

Fig 7

VISCOSiTY MANUFACTURER

CENIISTOKES

TYPE

s

REDWOOO NO.1

B

C

RAD€

40. c

lo0'c

GCS C ORE

1

508

I

IEXACO

SYMLUsE sA€ 1 40

ESSO

rG

150

150

144

21

22

CULT

sN6 TS

150

POINT

Kcal/(g'C

oc

l 060

o.44

39

235

148

650

r26

1.060

o44

40

259

180

7AO

155

1

054

o.4 6

30

2e0

150

158

690

i o.1

1.0a9

o.+4

33

240

r50

161

?2

695

106

1.012

048

29

150

150

23

670

104

1 008

0.44

40

255

?2

230

150

695

FLASH

126

ALPHA

CASIROL

closEo

POIN T

630

{1

50CI

GLYCOYLE r,10BlL

POUR

EAT

H

200"F

NA

SilELL

P€CIFIC

oo'c

l

EN€RCOL

BP

S

(15.C1

rso

$

ECTFTC

P

GRAVITY

26

610

1 067

-

rr, r6s il 2) J)

A

(g/cm') amneral o,l {forn F,g6mayLeuse'J lOOFSIA{7Oll m,rec *,1h no.mal m,riefal o,1s ln meTi,slaGe planl5 !11 slaget musl lhe'elore 6or be must polyqtycol llu,ds aod ihese tubrlcanl, afe u5e a CoiYgltcol liurd NH) V,sccs,ty o{ und,luted lubrrcanl !; e on rn,riat s1a.ti is 5i9^,l,cantly h,ghe, lhao lha! ol .acommeoded m ner.l orlt lo' R22 and neaalsJ,i *he^ des,g.,ng lrrb:rc;rrcn syster-s a g oil tur.p molor, , lier otessute dloi ..,.tia--.lece la. !h,s rrcrg3rec v!9ac't\,r: !r'releds.hareep,eseere,slesrthan

.. ,i l!

at

't 1 .,: ,.1,'a- - ]

5l

' Ihe v,scos,tv ol lh,5 orl rs bel*e4n

rJ lL'a

I:,::"4 ISO 150 gr3'Je 3'd ISO 22O g'ade

B

Page

6

-te COMPRESSOR SERVICE MANUAL

SECTION 3 3.1

-

INSTALLATION

ALIGNMENT OF COMPRESSOR COUPLINGS

The couplings supplied vrith this compressor must be aligned using the method described below as follows:lf a compressor only is supplied the coupling alignments tolerance ligures can be seen under

Section 3.2. lf a compressor set is supplied, the coupling alignment tolerances and any special instructions regarding allowances for expansion or movement during running will be sio*n on the General Arrangement Drawing and must be adhered to. During aliinment checks both half couplings should be rotaied together from 0o to 900, lg0o, 27oo aad 3600 and readings of radial and facial alignment recorded. Turning both half couplings together ensures that readings are recorded at the same point on each hJlf coupling, thus eliminating the effect of any irregularities on the outside diameters. or faces of the half

*e .$'A

coupling. Commence alignment by setting the faces of the coupling halves parallel in the vertical plane. The units will nov; be parallel in the horizontal ptane a"no further adjustment to obtain the correct centre heights, will require equal si-rinrrning under each foot of tie unit being adlusted. The units are now positioned vertically and horizontally. Further adjustment to obtain the correct coupting gap, radial and facial alignment, will only require movement of one unit on the existing shim slze. Coupling gap dimensions should be set with the couplings held in a repeatable position, i.e hard together or hard apart. This ensures that each coupli"ng half is removed to the same axial position as each check is made. The actual coupling gap should be correct when the shafts are in their normal running condition lf the combined float of the driving and driven shaft exceeds the coupling gap tolerance, the value and direction of float to? Ootn shafts will be shown on the General Arrangement Drawing When setting the gap the axial f Ioat of each shaft shoutd be determined and the,.hard toEether,, or "hard apart" dimension calculated

Example:-

e q

Compressor directly driven by a turbine Compressor Shaft Ftoat 0.002" (0.05mm) Turbine Shaft Float 0.010" (0.250mm)

Normal running posrtion of compressor shaf i is towards the turbine and the turbine normally runs thrusting tovrards the compressor. Bequired Gap 0.125" (3.175mm)

if the gap is checked with the couplings "hard apart" it should be 0.i25,,(3.175mm) + 0.010 (0.250mm) for Turbine shaft Float and + 0.002'; (0.05mm) for Compressor Shaft Float i e.

0 137" (3.475mm).

lf the gap is checked rvith the couplings "hard together" it should be 0.125"'(3.175mm). NOTE:

lf a "limited f Ioat" coupling is used w'ith an electric motor whose shaft has no thrust gap must be correct rvith the rnotor shaft on its magnetic centre ln this instancebearing the the faclal alignment check should be mace rotating the,ii-lverihaif coupiing oniy, as ihe orive (motor) hrlf e clrplin3 i: ncl lccatecj :xialiy oi pi-ufcri.Li';, Ly a "cioublc cioox'nretirocj which avorc.Js tire problem of repeated axial position"

$

rl

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{6

3.2 Flg

ALIGNMENTTOLERANCE

8

The maximum acceptable lrne-up tolerance for couplings on compressor installations is as follows:_ Radial Tolerance

Eccentncity = !/. T l.R. on circumference

p

RADIAL TOLERANCE

----' FACE TOLER

Applicaticn Motor to Gearbox or Compressor, i.e. couplings operating up to 3,6O0 r.p m. Gearbox to Compressor, i.e. couplings operating above 3,600 r.p.m.

A) B)

I s

Radial Toierance

B)

Face Tolerance

0.15 mm (0.00,6")T l

R

A)

T.l.R. 0.005 mm/cm dia. of coupling.

0.10 mm (0.0O4")T.t

R

B)

T.l.R. 0.0005"/inch dia. of coupling.

T.l.R. denotes Total lndicator Reading oblained by clockgauqe.

3.3 DOV/ELLING Only one unit of any assembly vrill be dowelled before despatch. Dowels should be fitted to ease re-alignment when components are removed for overhaul. 3.4 PIPING

Before installing the piping, the compressor inlet and outlet ports should be inspected to nsure no did is present. AII plping should be supported so lhai no strain is transmitted to the compressor casings. The piping should be inspected for cleanliness before installation. As each pipe is connected to the cornpressor, the coupling alignment should be checked to ensure that no alteration has taken place. lf alignment has altered, the compressor is being strained and the piping supports must be e

a

dju sted.

It is not sufficient merely to re-align the drive unit as this will not correct the strain being imposed on the compressor. oii injected i'efrigeration compi'essors inusi have a suction

sirainer lternianrntlr,, f lttcC direcil.,,cr-- iitc ccirpre ssoi- iriiei.

-B

Paqe

B

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BE6'SE

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_

COI'IPRESSOR

Y

SECTIOH

9.i

9-

SERYICE

I{ANUAL

SPECIAL I}ISTRUCTIO}IS

ToRQUE SPECIFICATI0T{S

Torque specifications are FrG 104

detai 1 ed per Tabl e Fi g. 104.

as

T0RqUE SPECIFICATIOHS FOR FASTEHERS OH

HRVT51O COI.PRESSOR

PART NO.

I

DESCRIPTlON

IORQUE

Lbs.FT

G16032

Slotted Cheese Head Screw 68A x 1 1/4" 1G

4

G24102

Hex Nut

M30

G24103

Hex Nut

M24

G2501

Hex Socket Head Cap Screw N0.10

liBB 583 41

1

UNC

I

G250 37

x 5/8"

Kg.l'1

164 BO

LG.

Hex Socket Head Cap Screw l{o.10 UNC

x 3/8" LG.

G26002

Hex Socket Set Screw (Grub Screw) with Cup Pojnt

G26006

Steel Hammer Drive Screw No.6 1/4" LG

G26030

Hex Socket Head Cap Screw MB x 20 rLUc

)1 LL

? J

Hex Socket Head Cap Screw M24 x

583

BO

M24

583

BO

l'116

t71

t+

G26037

45 G26038

LG

Hex Socket Head Cap Screw

70

x

LG

ry B

?

G260 39

Hex Socket Head Cap Screw

45

LG

G27002

Hex Head Screw Ml6

x 50 LG

777

?4

G27012

Hex Head Screw M30

x

120

liBB

tb4

GZ70l3

Hex Head Screw ll24

x

B0

G270

Hex Head Screw M10

x 30 LG

15

G270i6

Hex Head Screw 1124 x 60

G?7017

Hex Head Screw M24

G27018

liex l{ead Screvr 1"120 x 50

LG

BO

LG

4i

LG

x 70 LG tG

BO

30J

BO

1/ n

47

G2800

I

Stud

1430

to Drawi ng LCV332l/A

1

G2800

2

Stud

t'124

to

583

Drawi ng LCV332l/B

6

IBB

154 BO

P

age

24

COI{PRESSOR

sEcTI0N 9

!9.?

PROCEDURE FOR

FITTII{G

-

SERYICE

HANUAL

SPECIAL IHSTRUCTIoHS

LOCKI{ASHERS

This instruction applies to all lockwashers used on Howden Compressors for the purpose of reta'ining'in pos'ition the locknuts locating the bearings, thrust collars, pistons etc. A typical example of the items concerned is shown below

(rtg.

105).

v

**11 il II U

Fi 9.105

Fis lO5

Assemt-rly Method:

-

In all cases where this type of lockwasher is used the components must be assembled without the lockwasher and torqued to the prescribed value. The locknut must then be removed, the lockwasher d'ipped in oil and placed on

the shaft, the locknut replaced and aga'in torqued to the pr^escribed value. This assembly process limjts the amount of relative movement between the locknut and the lockwasher under torque, and avoids the possibility of the inner tang being damaged.

9.3

SPECIAL TOOLS FOR THE

COI'{PRESSOR

Tools can be provjded as deta'i1ed per (fig.106) for ease of dismantling/assembiy however, they are not a mandatory requirement. Fig.106 t

'ilRVT510

LIST OF SPECIAL

TOOLS

i oescnrPlroN I I

socrEr

sPANNER

-

Bo HH LocKlluT

socrrr

saANNER

-

100

MM

LocKNUT

I I I

I sEr on ltrrntc socrrrs coupntsiNe to ttt'i, to MM I I zo ulr, z+ NN :o ltu socrErs plus nnrcHrr I I I ExtrNsioN enRs to" a s" I srr or RLLnN rrvs compRrstNe - o Ftlt, B tltt, to ttM I I I rz rru, zq H[1

No

I

stooieJ

I

ennr

s10015J I I

I I I

3

-Pacle ^z-'

COI'IPRESSOR

SECTIO}I

B

9.4

9-

SERYICE

SPECIAL IHSTRUCTIONS

COMPOHEIT I{EIGHTS FOR I{RYTs1O COI.IPRESSOR

l,leights detailed below to allow correct

I coueourur

t t

t

Nnr-r

I

r'rarr

I

COYER 1

tB6

ROTOR

RoToR covER

sucr roN -BRG '( 2 of f )'

rrmnlr

RoroR

covER

DISCHARGE-BRG THRUST HSG

I

(2

I2.OFF) OFF)

nrv 'niRUSr'PLATE (z

orr) -

I

rHnusr sPACTR (z orr) rHnusr colLAR (2 oFF)

I

runusr Pi-ATE "('2 oFF)

I

I

-

Inolusrrrucnnic(zorr)

9

t

1053

BALANCE PISTON

l-

q

zw

I

RoToR

FEMALE

'

-2652-

cASTNG

OUTLET

I

wrrcHT-(Kg)

I

l .ourlrr cASING rNlrr

lifting facilities to be used"

I

RoToR

I

I'IAHUAL

-'

-

]

j -- -g,e 4:B I

1 ''zs'6.2 1i0 -

I ersroru noo I

PrsToN

l

ncrunroR

I

sToP

CYLINDIR END COVER

i

srr

scRrils

rHnusr eacs

iie

I

I

I

'

I

516

cvt- t runrn

I slroe vALYE I sL rrr vALVr sToP

I I

-

I

I

I

) I

"'

257 cc JJ 200

ct

-#\

Hage r0