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SUNDYNE

LMC 341F COMPRESSOR

Instruction and Operation Manual

August 2007

Effective:

August

2007

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Summary of Contents for LMC 341F

Page 1: ...SUNDYNE LMC 341F COMPRESSOR Instruction and Operation Manual August 2007 Effective August 2007 Visit our website at www sundyne com ...

Page 2: ... period Sundyne s sole obligation shall be limited to alteration repair or replacement at Sundyne s expense F O B Factory of parts or equipment which upon return to Sundyne and upon Sundyne s examination prove to be defective Equipment and accessories not manufactured by Sundyne are warranted only to the extent of and by the original manufacturers warranty Sundyne shall not be liable for damage or...

Page 3: ...stalling the Suction and Discharge Piping Guidelines 6 Seal Environment Control System 7 Baseplate Grouting 9 Horizontal Unit Gearbox Support Bracket 9 Driver and Coupling 9 2 LUBRICATING OIL SYSTEM 9 3 START UP 13 Compressor Control During Start Up 14 Run In of the Compressor 14 4 SERVICING 15 Regular Maintenance 15 5 MAINTENANCE OF THE SEALS AND PROCESS END DISASSEMBLY 16 Tandem Seal Configurati...

Page 4: ...DISASSEMBLY 30 7 INSPECTION OF DISASSEMBLED HARDWARE 44 8 CHECKING AND SETTING HIGH SPEED SHAFT END PLAY 48 9 GEARBOX AND PROCESS END REASSEMBLY 50 Gearbox Auxiliary Hardware Installation 53 10 TROUBLESHOOTING 54 11 OPERATION 57 12 SPARE PARTS 58 13 SUNDYNE COMPRESSOR WARRANTY 62 Critical Start up Checklist 62 Lock out Tag out Guidelines 64 SINGLE SEAL ARRANGEMENT 65 DOUBLE SEAL ARRANGEMENT 66 TAN...

Page 5: ... and accessories are specifically designed and tested for use with these products to ensure continued product quality and performance Sundyne cannot test all parts and accessories sourced from other vendors incorrect design and or fabrication of such parts and accessories may adversely affect the performance and safety features of these products Failure to properly select install or use authorized...

Page 6: ...ogram be followed prior to altering the equipment Locks or tags must be provided to warn employees that equipment is temporarily unavailable Once all work has been completed the person installing the lock or tag must remove it according to company procedure Testing Equipment Prior to performing a test on newly installed maintained or repaired equipment all personnel in the immediate area must be w...

Page 7: ...rial number This manual contains the following sections 1 Installation Describes how to install the compressor and how to store it until you install it 2 Lubricating Oil System Provides the following information how to prepare the gearbox for start up how the lubricating oil system works and specifications for gearbox lubricants 3 Start up Provides a procedure for starting and controlling the comp...

Page 8: ...iately It contains a subsection on each of the following Introduction This provides a brief description about the compressor and how it is used Inspection As soon as you receive the compressor inspect it thoroughly Short term Storage If the unit will be installed within 6 months follow these procedures Long term Storage If the unit will not be installed within 6 months follow these procedures Suct...

Page 9: ...iary items are properly included 3 Check the gearshaft carefully Seal drag may cause it not to turn freely at first This is normal But if the gearshaft binds it may be damaged or it may need adjusting Short term Storage 1 day to 6 months 1 If the compressor is to be stored near strong chemicals or salt water protect it immediately To do this follow steps 5 through 11 from the long term storage pro...

Page 10: ...antee the quality of the equipment during and after the storage period An Extended Warranty will be null and void if the proper equipment preparation is not maintained Installing the Suction and Discharge Piping Guidelines Step 1 Clean the suction line Step 2 Install a strainer to protect the impeller from damage by mill scale welding slag or other foreign particles Step 3 Make sure that the pipin...

Page 11: ...vity and should be regulated by a valve or orifice on port 2 It is also acceptable to provide a buffer into port 2 and regulate by a valve or orifice out of port 7 The buffer system must be in operation prior to starting the compressor Refer to compressor specification sheet for specific buffer requirements A buffer gas may also be used between tandem seals to reduce process leakage when buffer co...

Page 12: ...eals must vent case drain port 1 to atmospheric pressure and allow it to gravity drain properly Otherwise oil could contaminate the outboard gas seal This port can be attached to a flare line but should not have back pressure in excess of 5 psi ...

Page 13: ...e design attaching the two pieces to provide adjustability in the field during field installation alignment A shim 1 4 thickness preferred should be placed under the bracket and alignment completed The bracket should then be drilled and pinned 3 8 minimum pin diameter in two locations to prevent possibly shifting of the bracket during operation of the unit Driver and Coupling Lock out starting swi...

Page 14: ...f the oil Operating of gearboxes with oxidized lubricant should be avoided Synthetic oils possess different characteristics than conventional mineral oils which make them desirable for various extreme conditions such as high and low temperature operation Synthetic oils offer very low pour points high temperature oxidation stability and a higher viscosity index The operation of Sundyne equipment in...

Page 15: ...2 Sequence 1 Sequence 2 Sequence 3 25 0 max 50 0 max 25 0 max Note No other additives are recommended Recommended ISO VG 46 gearbox lube oil specifications Gravity API 28 37 Pour Point C F 7 20 max Flash Point C F 204 400 min Viscosity cSt at 40 C cSt at 100 C SUS at 100 F SUS at 210 F 41 4 to 50 6 6 5 min 217 to 260 48 8 min Viscosity Index 95 min ISO Viscosity Grade 46 Color ASTM D 1500 2 0 Neut...

Page 16: ...ed to stabilize temperature The oil filter is a disposable pleated paper element type Gearbox oil and filter should be changed every six months Optional Lube Oil System Auxiliaries A LUBE OIL PRIMING KIT A pre lube system is required on units operating at high speed high pressure or high horsepower conditions It is also mandatory with the use of certain auxiliary equipment The kit consists of a mo...

Page 17: ...pening With wet sump compressors add oil as necessary until the oil level stabilizes at the top of the bull s eye in the sight glass With dry sump check oil level at reservoir sight glass Start the auxiliary lubricating pump and run it until the oil reaches the correct pressure and temperature Add oil as necessary until the oil level stabilizes 3 4 of the way from the bottom of the sight glass All...

Page 18: ...nd maintain stable operation C Start the first stage unit and maintain design flow to both units D When sufficient pressure is being produced to overcome system back pressure the check valve will open and the units will be on stream E Close the bypass valve being sure that the flow to the compressor is above the surge point Parallel Operation Check valves must be placed in the discharge piping of ...

Page 19: ...rbox will cause excess foaming and overheating and should be avoided at all times Oil may be added to the external reservoir of the dry sump gearbox at the fill port Oil Pressure The correct oil pressure from the main pump of the gearbox depends on the configuration of the bearings and the characteristics of the lubricating oil used In the normal operation the oil pressure supplied to the gearbox ...

Page 20: ...ressurized otherwise reverse pressure may cause the inboard seal to fail Item numbers refer to the numbers in Reference D gearbox module drawings The following procedures apply to all configurations of the Sundyne LMC BMC compressors Refer to the specification sheet to determine the specific configuration and optional equipment included in your unit Parenthetical numbers in the text correspond to ...

Page 21: ...s to the gearbox bearing plate 102 Using the turnbuckles lift the gearbox and seal housing from the compressor casing Exercise care to prevent damage to the impeller Place the gearbox on a suitable support with the impeller inclined upward BMC Units Remove bolts 909D securing the coupling guard Remove the coupling guard Disengage both ends of the spacer coupling and remove the floating shaft Attac...

Page 22: ...a right hand thread impeller bolt full emission impeller shown Compressors that utilize clockwise impeller rotation when viewed from the inlet have left hand thread impeller bolts and counterclockwise rotating impellers have right hand thread bolts Step 3 Remove impeller 2 It may be necessary to pry under the impeller and cover 15 to loosen it from the shaft Pry on opposite sides of the impeller s...

Page 23: ...e 51a NOTE Tandem Seal Arrangement shown here See Reference C Seal Arrangement Drawings for single and double arrangements Step 2 Remove hex head cap screws 905E washers 916A and remove lower mechanical seal 60A of the tandem seal arrangement from the seal housing ...

Page 24: ...20 Step 3 Remove spacer sleeve 60A Step 4 Remove o ring 936J Step 5 Remove upper seal rotating face 51C Use two small screw drivers to lift up the rotating face ...

Page 25: ...ve the hex head cap screws 905A lock washers 154AT flat washers 916AG and seal washers 916S from seal housing 30 Step 7 Install two 3 4 eye bolts approximately 180 from each other through the seal housing flange face ...

Page 26: ...ength chain hooks to lift seal housing off the gear box Step 9 Turn seal housing 30 over so you can see the upper Tandem seal and remove the Thermal Barrier Gasket 87A It may help to have to people on hand to help rotate seal housing ...

Page 27: ...ebuilt by replacing the carbon seal nose o ring and springs providing retainer is not damaged or heavily worn A seal repair kit is available contact your customer representative or the factory Replace or lap the seal rotating face if the wear track is rough or worn to a depth greater than 0002 inch Step 12 Remove spacer sleeve 50B from high speed shaft Note o ring 936J will be lifted off high spee...

Page 28: ...for the impeller and diffuser are recorded and supplied as part of the final data package Step 5 The Impeller to Diffuser Cover Alignment Procedure Align the impeller 2 with the diffuser cover 15 as follows The Impeller to Diffuser Cover Alignment Procedure requires multiple assemblies of the stacked rotating elements mounted on the end of the high speed shaft assembly The procedure is attempted a...

Page 29: ...ffuser cover 15 With the high speed shaft A130 extending upward slide on the gearbox mating ring 51D and then the following parts For double seals assemble the upper shaft sleeve 50B the process mating ring 51C the lower shaft sleeve 50A the impeller spacer 15C and the impeller 2 For single seals assemble the shaft sleeve 50 the process mating ring 51A the impeller spacer 158C and the impeller 2 F...

Page 30: ...cover without the o ring on to the seal housing 30 5L Reinstall the impeller using the same procedure described in step 5e above 5m Measure the distance between the top of the impeller shroud and the diffuser cover 15 per Figure 5 1 The impeller shroud should extend 000 030 beyond or above the diffuser cover with the gearbox upside down This is the E dimension in Figure 5 1 If the shroud height is...

Page 31: ...requirements is as follows Step 2 Refer to Figure 5 1 The seals seal housing diffuser cover and impeller must be installed on the gearbox The diffuser must be bolted into the compressor case 1 Step 3 Using electrical solder make a ring that is slightly smaller in diameter than the impeller blade diameter Place the solder ring on the diffuser and center it around the inlet eye Use tape to hold the ...

Page 32: ...28 Figure 5 1 Compressor Cross Section and Clearances ...

Page 33: ...ts Install four of the compressor casing nuts 914A and tighten This step is necessary to compress the PTFE O Ring 935C and maintain the proper final impeller to diffuser clearance Step 13 Remove the gearbox assembly from the case and remove the hex nuts that were used as spacers Retorque three screws 906D to proper torque values Step 14 Reassemble the compressor with another solder ring and rechec...

Page 34: ...to obtain proper torque value 6 Gearbox Disassembly Note In order to disassemble gearbox it is necessary to complete steps 1 through 16 of Maintenance of the Seals and Process End Disassembly Step 1 If you have not drained the oil from the gearbox you should do so now Remove hex head cap screws 905E and lock washers 916A from the gearbox seal flange Step 2 Remove gearbox seal 60C It is helpful to ...

Page 35: ...bon seal nose o ring and spring providing the retainer is not damaged or heavily worn Step 4 Remove o ring 936P Step 5 Remove rotating face 51D Use two small flat blade screw drivers to help lift rotating face out of pocket in the gearbox taking care not to damage the gearbox seal o ring chamfer Inspect the rotating face for any cracks chips or grooves If any cracks or chips are present replace th...

Page 36: ...B Use hoist to lift the upper gearbox housing 101B away from the other gearbox housings It is a good idea to look into the upper gearbox housing 101B and watch to see if the input shaft assembly A120 roller bearing outer race and rollers stay with the upper gearbox housing 101B If the bearing does stay with the upper gearbox housing 101B the mechanic should try to keep the bearing from falling out...

Page 37: ... top of the shaft and lift straight up and away from the bearing plate 102 The lower outer race and rollers from the input shaft assembly A120 will be in the bearing plate 102 Pull the outer race and rollers out of the bearing plate 102 and keep with the input shaft assembly A120 Step 9 Install two 5 8 eye bolts into the top face of the bearing plate 102 The mechanic will use these to lift the bea...

Page 38: ...n fitting 944C with a wrench NOTE If dry sump design unit will not have an internal lube pump and sump tube Step 10 b Then hand spin the nut free Pull the sump tube 173 out of the compression fitting 944C Step 11a Remove compression fitting 944C Loosen the fitting with a wrench ...

Page 39: ...Step 13 Remove socket head cap screws 905BU 10 24 x 2 5 long screw from the lube pump assembly A160 There are two screws that hold the lube pump in place and two screws that hold the lube pump together If by chance when removing 905BU you loosen the shorter screws replace immediately and move to the next screw on the lube pump assembly A160 Note If gearbox is of dry sump configuration then a space...

Page 40: ... pump assembly A160 around in the bearing plate 102 Note with the dry sump gearbox a spacer with O ring seal is installed instead of the lube pump Step 15 a Using the 1 4 20 screws in step 14 turn the lube pump assembly around in either CCW or CW rotation so you can see the o ring 936Z in the hole in the bearing plate 102 where the 2 0 x 3 4 pipe nipple 944B was inserted ...

Page 41: ...assembly A160 from the bearing plate 102 To achieve this the mechanic must grasp the top of the lube pump shaft with their fingers and pull straight up and out on that shaft Remove the pressure relief valve 175 from the top of the bearing plate 102 Inspect the pressure relief valve 175 for any foreign matter If any particles or sludge is found replace with a new pressure relief valve 175 Remove 1 ...

Page 42: ...ring plate 102 If the bearing plate 102 is not lifted evenly it will catch the upper high speed journal bearing 151B on the high speed shaft A130 and possibly damage the shaft or the bearing Step 18 Remove the bearing plate 102 from the lower gearbox housing 101A Make certain you use the 5 8 eye bolts to lift ...

Page 43: ...s or dings or any unusual wear replace the upper high speed journal bearing with a new item 151B If the upper high speed journal bearing checks good tag the bearing as upper high speed journal bearing 151B This will help insure it does not become mixed up with the lower high speed journal bearing Inspect the thrust washer 155B If there are any burns or rubs replace the thrust bearing 155B Step 19 ...

Page 44: ...40 Step 20 Remove the high speed shaft A130 Step 21 Remove socket head cap screws 905AA from lower idler journal bearing 151C ...

Page 45: ...ournal bearing 151C Step 23 Remove lower idler journal bearing Use a bearing puller Thread two screws 1 4 20 into the two top holes in the lower idler journal bearing 151C Screw the jack bolt on the bearing puller down against the 1 0 socket and then jack pull the bearing out of its location Inspect the top thrust face and the interior of the lower idler journal bearing If there are any burns rubs...

Page 46: ...ions are found replace the thrust washer with a new item 155A Step 25 Remove the lower high speed bearing 151A by tapping with a soft mallet on the bottom of the bearing Inspect the lower high speed journal bearing for any rubs unusual wear marks or scratches If anything appears abnormal replace the lower high speed journal bearing 151A with a new item If the bearing checks out good then tag beari...

Page 47: ...ter of the upper idler journal bearing with the 1 2 square drive pointing toward the thrust face of the upper idler journal bearing 151D Step 31 Remove the upper idler journal bearing 151D Use a bearing puller Thread two 1 4 20 screws into the top of the upper idler journal bearing Insert the bearing puller into the upper idler journal bearing with the jack screw located against the 1 2 square dri...

Page 48: ...is pressed onto the idler shaft A140 If the thrust face on this gear is burned or scored replace this gear If there are nicks or dings in the thrust face lightly stone or hone and polish these areas back to the original surface Step 10 Inspect the internal lube pump A160 o ring seal groove If there are any nicks or dings in this area polish or hone them back to the original surface If this cannot ...

Page 49: ...eed to be relapped to factory specification of two light bands flatness or 00002 If this specification cannot be met replace the high speed shaft A130 Step 16 Inspect the high speed shaft A130 thrust surfaces If these show abnormal wear burns gouges deep circular scratches or wear patterns replace the high speed shaft A130 with a new assembly Step 17 Lubricate all other parts thoroughly with light...

Page 50: ...earing 400 HP Gearbox Only Maximum clearance for replacement 0 0085 inches 22 mm Lower Idler Bearing Shaft Clearances Maximum clearance for replacement 0 0063 inches 16 mm Input Shaft Upper Bearing Input Shaft Lower Bearing ...

Page 51: ...learance for replacement 0 0055 inches 14 mm Tilting Pad Thrust Bearing and High Speed Shaft Clearances Maximum clearance for replacement 0 0055 inches 14 mm Tilting Pad Radial and High Speed Shaft Clearances Maximum clearance for replacement 0 0055 inches 14 mm ...

Page 52: ... end play must be 015 002 inch If end play is not within this limit calculate the shim thickness required to place the shaft within the proper end play Select the required thickness shim using 158 series shim spacer sizes Do not install shims below the lower bearing Step 6 Remove the alignment bolts 909C and the C clamps from the bearing plate 102 and lower gearbox housing 101A Now remove the bear...

Page 53: ...cal Seal 1 4 20 x 12 9 5 102 in lbs 11 11 5 N m 905G Double Seal with Spacer 1 4 20 x 3 4 95 102 in lbs 11 11 5 N m 914A Case Nuts 3 4 10 250 275 ft lbs 340 375 N m 914A Case Nuts 7 8 9 300 330 ft lbs 405 445 N m 905A Seal Housing to Gearbox 3 8 16 x 1 3 4 35 40 ft lbs 47 54 N m 905P Separator 1 4 20 x 5 8 95 102 in lbs 11 11 5 N m Pumps Compressors NACE Compliant Steel Screws Bolts BG Material To...

Page 54: ...g 944B and 944C into the bearing plate 102 Step 9 Install pipe plugs as required and relief valve 175 into bearing plate 102 Step 10 Install upper high speed journal bearing 151B into bearing plate 102 and upper thrust washer 155B Use Vaseline to hold upper thrust washer in place Step 11 Set high speed shaft A130 end play NOTE SHIM BEHIND THE UPPER HIGH SPEED JOURNAL BEARING ONLY TO ACHIEVE 015 00...

Page 55: ...specified torque value from chart see Table 8 1 Step 24 Install input seal 115 over input shaft assembly A120 and press into upper gearbox housing 101B seating the input seal 115 firmly against the locating shoulder in the upper gearbox housing 101B Step 25 Turn the complete gearbox assembly over so the high speed shaft A130 is pointing vertically toward the ceiling Step 26 Install the rotating fa...

Page 56: ...1A over high speed shaft A130 Step 44 Install impeller bolt 3 into high speed shaft A130 Step 45 Install impeller 2 over impeller bolt 3 Step 46 Install impeller bolt 3 Step 47 Tighten impeller bolt 3 to correct torque specification see Table 8 1 Step 48 Install initial fill pipe 951D 947L 924RF into upper gearbox housing 101B Step 49 Install vent pipe 951C 947D 186 into upper gearbox housing 101B...

Page 57: ...iate thermocouple locations The thermocouples are typically installed in the thrust position of the upper bearing 151B and in the radial position of the lower bearing 151A Step 2 Vibration Probes Install x y vibration probes in the lower bearing probe bracket attached to bearing 151A Install keyphasor probe in the upper bearing probe bracket after installation of the bearing plate Refer to Bentley...

Page 58: ...performance curve The driver shaft is rotating in the wrong direction Make sure that the drive shaft is rotating in the direction shown by the arrow on the compressor gearbox The suction pressure is low Check the Sundyne specification sheets Recirculation from the discharge to the inlet is excessive Check the flow through the external piping such as the bypass The molecular weight is not that for ...

Page 59: ...on Excessive discharge pressure pulsation Flow rate too low surge Increase flow rate through compressor Add controlled bypass to suction if necessary Defective flow control valve Check control valve Change of gearbox automatic transmission fluid color from normal color to milky pink or yellow Gearbox oil contaminated with water or process fluid Inspect gearbox heat exchanger for leakage Check for ...

Page 60: ...The wear pattern on the rotating faces of the seal is not uniform Lightly lap the surfaces on the shaft sleeve and the impeller hub that contact the rotating face of the seal to remove high spots Install new seal faces Do not remove more than 0 005 in 0 12mm from any surface The rotating face of the seal is cracked or broken This may have been caused by damage at the assembly or by heating due to ...

Page 61: ... the total head output to the system The reduction of inlet pressure correspondingly decreases inlet gas density and thus power consumption Suction throttling also has the advantage of slightly lowering the compressor surge point Discharge Throttling Discharge throttling is control by means of a valve placed at the compressor discharge A constant speed compressor will always operate on its design ...

Page 62: ...ontrol The control of two or more compressors operating in parallel would appear to be relatively simple More than likely though no two compressors ever operate identically across their flow range To produce identical discharge pressures one compressor could be operating at a different flow than the unit in parallel with it As a result the control system would have to include a separate flow contr...

Page 63: ... shown on the Bill of Material which is included with each compressor shipment preferred method or list each part by item number as listed in this manual part name and compressor model Specify quantities desired Order parts from your Fluid Handling representative or directly from Sundyne Corporation at one of the following locations Sundyne Corporation Phone Number 1 303 940 2989 14845 West 64th A...

Page 64: ...L LOWER 1 1 2 60B DS TS SE04AD21F SEAL UPPER 1 1 2 ALL RKORC311FUC O RING 1 2 2 NOTES 1 Options SS Single Seal DS Double Seal TS Tandem Seal 2 Class 1 Minimum recommended spare parts necessary to perform a startup and inspection of a new unit Class 2 Minimum recommended spare parts necessary to cover 1 2 years of normal service Class 3 Minimum recommended spare parts necessary for critical service...

Page 65: ...320 WASHER THRUST UPPER 0 0 1 51D ALL RJ09AA21SD RING MATING 1 1 1 60C ALL SE04AA53A SEAL ASSY GEARBOX 1 1 1 936ZG ALL 14 057UC O RING 2 4 4 936P ALL 14 055UC O RING 2 4 4 936T ALL 14 324UC O RING 2 4 4 936TQ ALL 14 324UC O RING 2 4 4 936TT ALL 14 324UC O RING 2 4 4 936Y ALL 14 322UC O RING 2 4 4 936YA ALL 14 322UC O RING 2 4 4 936ZF ALL 14 323UC O RING 2 4 4 A130 ALL SH01AY05E1L0 SHAFT ASSY HIGH ...

Page 66: ...Mark System where applicable This document incorporates information relevant to the Machinery Directive 89 392 EEC It should be read prior to the use of any of our equipment Individual maintenance manuals which also conform to the EU Directive should be read when dealing with specific models SAFETY WARNING Sundyne Compressors manufactures centrifugal process gas compressors to exacting Internation...

Page 67: ... the compressor with the suction valve completely open while throttling the discharge valve to bring the compressor to the design operating point 3 Variable speed as applicable Start the compressor with the suction valve and the discharge valve open Check the pressure in the system If it exceeds the surge point of the compressor see the specification sheet and the performance curve you will need a...

Page 68: ...ng bolted threaded connections tight a Compressor flange bolts b Seal environment piping and port connections c Cooling water connections to heat exchanger if applicable d Gearbox oil drain plug e Compressor case drain plug Reference B Lock out Tag out Guidelines Follow Your Companies Lock Out Tag Out Procedure When Servicing Sundyne Compressors Never remove a lock or tag applied by someone else A...

Page 69: ...65 SINGLE SEAL ARRANGEMENT ...

Page 70: ...66 DOUBLE SEAL ARRANGEMENT ...

Page 71: ...67 TANDEM SEAL ARRANGEMENT ...

Page 72: ...68 Reference D Phoenix Compressor Gearbox Cross section Drawing Phoenix Gearbox Module Drawing GB01AY01 ...

Page 73: ...69 Phoenix Compressor Gearbox Cross Sectional View ...

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Page 75: ...71 PHOENIX GEARBOX MODULE DRAWING GB01AY01 ...

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Page 82: ...45 W 64th Avenue Arvada Colorado 80007 USA 1 303 425 0800 FAX 1 303 425 0896 www sundyne com Sundyne Europe Dijon Longvic France 33 0 3 80 38 33 00 FAX 33 0 3 80 38 33 66 Sundyne Nikkiso 27 10 Ebisu 2 Chome Shibuya Ku Tokyo 150 0013 Japan 81 3 3444 6475 FAX 81 3 3444 6806 ...

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