Intermech BBR-6015-2 Service Manual Download Page 1

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Compressor Service Manual

Customer :

Company

Origin Energy

Address

1 King William Street

City/State

Adelaide, South Australia

ZIP Code

5000

Phone

+61 8 8217 5211 (reception)

Fax

+61 8 8217 5768 (reception)

Email Address

[email protected]

Site Location

East Perth Bus Depot, Kensington Street,
East Perth, Western Australia, 6004

Product

Compressor BBR- 6015-2 Vol. 2 (J1563)

Model No

CO-BBR-6015-2

Serial No

R4837; R5081

INTERMECH LTD.

88 Leonard Road, Penrose
PO Box 12284, Penrose
Auckland, New Zealand
Ph

64 (9) 525 2220

Fax

64 (9) 579 3900

[email protected]

Summary of Contents for BBR-6015-2

Page 1: ...7 5768 reception Email Address ReceptionKWS originenergy com au Site Location East Perth Bus Depot Kensington Street East Perth Western Australia 6004 Product Compressor BBR 6015 2 Vol 2 J1563 Model N...

Page 2: ...REVISIONS RECORD Revision Date Changes Additions Issued 1 March 2006 New edition...

Page 3: ...Start Up Check List Contents 21 3 5 2 Package Details 21 3 5 3 Prior to Starting 22 3 5 3 Prior to Starting 22 3 5 4 After Starting 23 3 5 5 Maximum Allowable Working Pressure 23 3 6 LUBRICATION 24 3...

Page 4: ...TON CYXA 6004 59 4 7 1 X Head Cylinder Assembly CYXA 6004 59 4 7 2 X Head Cylinder Parts List CYXA 6004 60 4 7 3 Disassembly Cross Head Cylinder Piston 61 4 7 4 Assembly Cross Head Cylinder Piston 61...

Page 5: ...__________________________________________________________15 Figure 9 Compressor Tools__________________________________________________________20 Figure 10 Oil Circulation Schematic _________________...

Page 6: ...oller 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...

Page 7: ...Page 7 of 85 1 1 1 Compressor General Arrangement BBR 6015 2 Figure 1 Plan and Elevation of Four Stage Compressor Intermech Ltd BBR 6015 2 Compressor Service Manual...

Page 8: ...Page 8 of 85 1 1 2 Compressor GA X Section BBR 6015 2 Figure 2 X Sectional Plan A A Intermech Ltd BBR 6015 2 Compressor Service Manual...

Page 9: ...art Number Description Quantity 1 CRA 3603 Crankcase Assy 1 2 LUB BBR SB 6015 RHINO Compressor Lubricator Assembly 1 3 CYA 6046 3 6 x 4 5 Cylinder Assembly 1 4 CYA 3015 1 Cylinder Assy 3 25 x 1 5 MT V...

Page 10: ...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 ope...

Page 11: ...ng 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 compr...

Page 12: ...wer 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 b...

Page 13: ...cation DESCRIPTION IMPERIAL UNITS STROKE 3 25 inches ROD LOAD COMPRESSION 10 000 lbs ROD LOAD TENSION 10 000 lbs FRAME HORSEPOWER to 270 hp MAX INTERNAL PRESSURE 600 psi WEIGHT APPROXIMATE 1900 lb RPM...

Page 14: ...Plate Figure 4 Cylinder Specification Plate 3 3 3 Suction Identification Plate Figure 5 Suction Identification Plate 3 3 4 Discharge Identification Plate Figure 6 Discharge Identification Plate Interm...

Page 15: ...s 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...

Page 16: ...005 0 015 0 082 0 092 0 019 0 029 Straight Cut 0 007 0 017 0 123 0 133 0 029 0 039 45 Cut 0 005 0 015 0 087 0 097 0 021 0 031 Straight Cut 0 008 0 018 0 129 0 139 0 031 0 041 45 Cut 0 005 0 015 0 091...

Page 17: ...Page 17 of 85 Side Clearance Table 4 Piston Ring Side Clearances Intermech Ltd BBR 6015 2 Compressor Service Manual...

Page 18: ...t 1 UNF Rod 300 Piston Rod to Crosshead 1 UNF 300 Final Stage Cylinder to C E Cylinder UNC Stud 125 Final Stage Cylinder to C E Cylinder UNF Stud 106 Final Stage Head UNF Stud 140 Cylinder Head 10 UNF...

Page 19: ...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 Retain...

Page 20: ...Page 20 of 85 3 4 5 Rhino Compressor Tools Figure 9 Compressor Tools Intermech Ltd BBR 6015 2 Compressor Service Manual...

Page 21: ...OMPLETELY 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 Sta...

Page 22: ...ocument 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 gra...

Page 23: ...st pressure and 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...

Page 24: ...Page 24 of 85 3 6 Lubrication Figure 10 Oil Circulation Schematic Intermech Ltd BBR 6015 2 Compressor Service Manual...

Page 25: ...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 se...

Page 26: ...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 glas...

Page 27: ...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...

Page 28: ...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 t...

Page 29: ...ation 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...

Page 30: ...ng 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 remov...

Page 31: ...Page 31 of 85 4 2 Oil Pump CRA 357 Oil Pump Housing CRA 352 1 4 2 1 Oil Pump Housing Drawing CRA 352 1 Intermech Ltd BBR 6015 2 Compressor Service Manual...

Page 32: ...ght 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 OR...

Page 33: ...Page 33 of 85 4 2 3 Oil Pump Assembly Drawing CRA 357 Intermech Ltd BBR 6015 2 Compressor Service Manual...

Page 34: ...ex 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 Ca...

Page 35: ...Page 35 of 85 4 2 5 Oil Pump Relief Valve Drawing CRA 333 Intermech Ltd BBR 6015 2 Compressor Service Manual...

Page 36: ...tity 1 CR 3335 Valve Plunger 1 2 Spring see CRA 352 1 or CRA 358 for part no 1 3 CR 3333 O Ring Retainer 1 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...

Page 37: ...tion 4 2 5 2 Remove relief valve adjustment screw 3 Screw 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...

Page 38: ...ven gear and 6 mm hex drive key to oil pump and check for ease of rotation of oil pump Locate thrust washer in gear 6 Rotate driven gear to check freedom of movement 4 2 11 Oil Pump Relief Valve Instr...

Page 39: ...es sight glass retainers and o rings 6 Fit o rings to oil pump housing Grease o rings 7 Fit oil pump drive gear drive pin into crankshaft 8 Slide the oil pump driver gear over the crankshaft to line u...

Page 40: ...Page 40 of 85 4 3 Rhino Crankcase CRA 3603 4 3 1 Rhino Crankcase Drawing CRA 3603 Intermech Ltd BBR 6015 2 Compressor Service Manual...

Page 41: ...Page 41 of 85 4 3 2 Rhino Crankcase Drawing CRA 3602 Intermech Ltd BBR 6015 2 Compressor Service Manual...

Page 42: ...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 N...

Page 43: ...Page 43 of 85 4 3 5 Taper Lock Bearing Housing Assembly Drawing CRA 3640 Intermech Ltd BBR 6015 2 Compressor Service Manual...

Page 44: ...ts 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...

Page 45: ...Page 45 of 85 4 3 7 Rhino Crankcase Filler Bowl Drawing CRA 820 Intermech Ltd BBR 6015 2 Compressor Service Manual...

Page 46: ...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 P...

Page 47: ...f 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 Be...

Page 48: ...etering plate retainer From the side that has the lead in chamfer 3 Assemble oil pressure relief value into its hole by inserting the shuttle spring then retainer with O ring fitted then backup ring l...

Page 49: ...arance 0 002 Tighten cap screws in bearing carrier to 12 ft lbs Tighten cap screws to 25 Ft lbs Tighten cap screws that hold drive housing in place to 45 Ft lbs Once bearing clearance is reduced by 0...

Page 50: ...ump housing CRA 352 over crankshaft and into is correct position against crankcase Ensure that the crankshaft does not push out of its seat the restrictor inside oil pump housing 6 Torque cap screws t...

Page 51: ...Page 51 of 85 4 4 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 6015 2 Compressor Service Manual...

Page 52: ...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 Groo...

Page 53: ...thin card must be wrapped around crankshaft before mechanical seal gland housing CR 3286 is removed Slide card onto crankshaft through lip seal cavity up to crankshaft shoulder 5 Rotate compressor cr...

Page 54: ...ng Push static ring into place using thumbs Drive slot at back of static ring must locate with drive pin 4 Fit the gland housing complete with seal Ensure that the faces of the mechanical seal parts a...

Page 55: ...Page 55 of 85 4 5 Connecting Rod Assembly 4 5 1 Connecting Rod Assembly Drawing ROA 8525 Intermech Ltd BBR 6015 2 Compressor Service Manual...

Page 56: ...ROA 8525 Item Number Part No Title Qty 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 Ste...

Page 57: ...Page 57 of 85 4 6 Cross Head Cylinder Piston CYXA 6003 Low Pressure Throw 4 6 1 X Head Cylinder Assembly CYXA 6003 Intermech Ltd BBR 6015 2 Compressor Service Manual...

Page 58: ...PIX 6062 6 Cross head Piston CI SDF Coating 1 4 RO 2534 Gudgeon Pin 2 5 1 5 RO 2535 End plate for 2 5 Gudgeon 2 6 BNF 0644 Bolt 3 8 UNF x 5 1 4 lg 1 7 NNF 12 Nut 3 4 UNF 6 8 NNF C06 Nut 3 8 UNF Cone...

Page 59: ...Page 59 of 85 4 7 Cross Head Cylinder Piston CYXA 6004 High Pressure Side 4 7 1 X Head Cylinder Assembly CYXA 6004 Intermech Ltd BBR 6015 2 Compressor Service Manual...

Page 60: ...PIX 6081 6 Cross head Piston Heavy Version 1 4 RO 2534 Gudgeon Pin 2 5 1 5 RO 2535 End plate for 2 5 Gudgeon 2 6 BNF 0644 Bolt 3 8 UNF x 5 1 4 lg 1 7 NNF 12 Nut 3 4 UNF 6 8 NNF C06 Nut 3 8 UNF Cone N...

Page 61: ...ring 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 7 4 Assembly Cross Head Cylinder Piston Instructions...

Page 62: ...head piston lubrication holes face the top for high pressure throw and face downwards for low pressure throw 9 Check bearing shell to crankshaft clearance by placing Plastigauge strip between end cap...

Page 63: ...Page 63 of 85 4 8 1st 2nd Stage Cylinder Piston Piston Rod Assembly 4 8 1 Cylinder Assembly X Section CYA 6046 3 Intermech Ltd BBR 6015 2 Compressor Service Manual...

Page 64: ...Page 64 of 85 4 8 2 Cylinder Assembly Exploded View CYA 6046 3 Intermech Ltd BBR 6015 2 Compressor Service Manual...

Page 65: ...lit Flange 2 Weld 1 17 HE 6047 3 Pipe Flange 1 18 RIR 60A431 6 Rider Ring 1 19 RIC604532 6 x 1 4 x 5 16 Compression Ring 2 20 RIC453311TF 4 5 Cast Iron Compression Ring 4 21 RIO453311 4 5 Oil Scraper...

Page 66: ...Page 66 of 85 Item Number Part Number Title Quantity 38 ORV 7238 O Ring Viton 7238 1 Intermech Ltd BBR 6015 2 Compressor Service Manual...

Page 67: ...Page 67 of 85 4 8 4 Cylinder Head Assembly Drawing HEA 6000 Intermech Ltd BBR 6015 2 Compressor Service Manual...

Page 68: ...PEEK 1 3 VAD 886584 P Discharge Valve 88CRXK PEEK 1 4 VLS 8802 Suction Valve Lantern Ring 1 5 VLD 8802 Discharge Valve Lantern Ring 1 6 HE 6044 88RX Valve Cap 2 7 GKV 10009410 Gasket aluminium 88CRXK...

Page 69: ...piston rings have correct end gaps and side clearances refer piston ring clearance table in section 3 4 2 7 Fit 1st and 2nd stage piston rings to piston 8 Ensure that the piston rings are well oiled o...

Page 70: ...tighten power nut locking screws to correct torque see Torque Setting chart section 3 4 4 13 Fit new 1st stage head o ring 14 Reinstate 1st stage head 15 Tighten head retaining screws nuts to correct...

Page 71: ...Page 71 of 85 4 9 3rd 4th Stage Cylinder Piston Piston Rod Assembly 4 9 1 Cylinder Assembly X Section CYA 3015 1 Intermech Ltd BBR 6015 2 Compressor Service Manual...

Page 72: ...Page 72 of 85 4 9 2 Cylinder Assembly Exploded View CYA 3015 1 Intermech Ltd BBR 6015 2 Compressor Service Manual...

Page 73: ...n 1 15 SEB 3054 Seal Housing Ring 1 16 VLD 3001 Valve Lantern Discharge 1 17 SEA 3060 3 00 Seal Assembly 1 18 5151HK 16 1 Split Clamp 2 19 5151HK 32 2 Split Clamp Parker 2 20 NNF 12 Nut 3 4 UNF 6 21 C...

Page 74: ...UNF x 9 1 4 Lg 6 38 ROPA 3280 Piston Rod Assembly 1 39 VAC 544180 Concentric Valve 1 40 GKV 04503511 Gasket Aluminium for VAC 54 Series 1 41 GKV 07006310 S Gasket for VAC 54 Series Steel 1 42 GKS 767...

Page 75: ...Page 75 of 85 4 9 4 Piston Rod Assembly Drawing ROPA 3280 Intermech Ltd BBR 6015 2 Compressor Service Manual...

Page 76: ...Rod Assembly ROPA 3280 Item Number Part Number Description Quantity 1 ROP 3217 2 Piston Rod 1 2 PIX 3203 Balance Weight Lock Nut 1 3 SSF 0404 Socket Set Screw Grub UNF x lg 2 Intermech Ltd BBR 6015 2...

Page 77: ...Page 77 of 85 4 9 6 Piston 3 0 x 1 5 Assembly Drawing PIA 3015 2 Intermech Ltd BBR 6015 2 Compressor Service Manual...

Page 78: ...3002 3 0 HP Piston 1 4 RIC152252 Compression Ring 1 50 6 5 RIC154455 Sealing Ring 1 5 2 6 RIC304432 Compression Ring 3 00 1 7 RIC304435 Sealing Ring 3 00 2 8 RIR158L31 1 5 Rider Ring 1 9 RIR308G31 Ri...

Page 79: ...vided 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 unt...

Page 80: ...side clearances and end gaps concur with clearances detailed in Table 3 Piston Ring End Gaps Fit piston rings to piston Orientate piston ring end gaps 180 deg to each other Remove rod seal guide from...

Page 81: ...linder Ensure o ring is greased Slide final stage cylinder over piston Ensure that cylinder is right way up Fit concentric valve bottom gasket GKS 7670 to final stage cylinder Fit concentric valve top...

Page 82: ...Page 82 of 85 4 10 Rod Seal Housing Assembly SEA 3503 4 10 1 Rod Seal Housing Assembly 3 00 SEA 3060 Intermech Ltd BBR 6015 2 Compressor Service Manual...

Page 83: ...4 CNF 0506 Capscrew 5 16 UNF x 0 75 Lg 8 15 PNR 0204 1 16 x 1 4 Roll Pin 2 16 ORV 7232 O Ring Viton 7232 1 4 10 3 Disassembly 1 Remove Wiper Seal Retainer screws Item 14 2 Remove Wiper Seal Retainer I...

Page 84: ...O Ring between Seal Blocks Cups item 9 and Seal Block Face Item 14 7 Fit Wiper Seal into Wiper Seal Retainer 8 Fit Wiper Retainer Item 13 Torque cap screws to 18ft lb Intermech Ltd BBR 6015 2 Compres...

Page 85: ...ovided 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...

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