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FORM 220.11-NM2 (602)

37

YORK INTERNATIONAL

FIG. 9 –

COMPRESSOR TOOLS
(DEPENDING ON MACHINE SIZE)

FIG. 11 –

COUPLING WRENCH APPLICATION
FOR LOOSENING THE COUPLING NUT
AT DRIVE SHAFT

FIG. 10 –

COUPLING GUARD

LD07322

LD07323

00622VIP

4

TABLE 9 – COMPRESSOR TOOLS

ITEM

DESCRIPTION

QTY

TOOL KIT

1

1

WRENCHES

1

2

WRENCH SUPPORT

1

3

GUIDE PIN

4

4

SNAP RING PLIERS

1

5

SNAP RING PLIERS

1

6

MAIN SHAFT WRENCH

1

7

SNAP RING PLIERS

1

8

THREAD COMPOUND

1

9

HEX CAP SCREW

3

10

HEX CAP SCREW

4

11

OIL PUMP (HAND)

1

12

STUD GUIDE BEARING

HOUSING

4

13

SLEEVES AND

MANDRELS

1

«
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35
36
37
38
39
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Summary of Contents for Turbomaster M Series

Page 1: ...INSTALLATION OPERATION AND MAINTENANCE SERIES M TURBOMASTER COMPRESSORS Supersedes 220 11 NM1 366 Form 220 11 NM2 602 SERIES M TURBOMASTER COMPRESSORS 00617VIP ...

Page 2: ...enced materi als This individual shall also be familiar with and com ply with all applicable governmental standards and regu lations pertaining to the task in question SAFETY SYMBOLS The following symbols are used in this document to alert the reader to areas of potential hazard CAUTION identifies a hazard which could lead to damage to the machine damage to other equipment and or en vironmental po...

Page 3: ... these documents to the equip ment in question If there is any question in the mind of operating service personnel as to the applicability of these documents then prior to working on the equip ment they should verify with the owner whether the equipment has been modified and if current literature is available Diffuser Enhancement M 2 38 A 7 First Stage Impeller Width Designation Nominal Casing I D...

Page 4: ...YORK INTERNATIONAL 4 FORM 220 11 NM2 602 TABLE OF CONTENTS SECTION 1 Description of System and Fundamentals of Operation 7 SECTION 2 Installation 11 SECTION 3 Operation 14 SECTION 4 Service 32 ...

Page 5: ...ts 19 5 AOP Differential Coltrol Settings 29 6 COP Low Oil Differential Safety Settings 29 7 Oil Pressure Switch Tubing Sizing 30 8 Maintenance Requirements for YORK Multistage Centrifugal Compressors 33 9 Compressor Tools 37 10 Shaft Seal Parts 39 11 Typical Shaft Seal Installation Height Dimension 40 12 Clearances 46 13 Screw Sizes for Pulling Drive End Journal Bearing 46 14 General Bolt Torques...

Page 6: ...embling Shaft Seal Collar 40 16 Seal RingAssembly 40 17 Removing Drive End Journal BearingAssembly 42 18 Removing Drive End Oil Seal Assembly 42 19 Exploded View PRV and Oil Seal Assembly 43 20 Oil Reservoir 47 21 Discharge End Bearing and Oil Pump Assembly Exploded View 48 22 CheckingAlignment of Oil Pump 49 23 Removing the Oil Reservoir 50 24 Exploded View Oil Reservoir and Oil SealAssembly 51 2...

Page 7: ...rough a speed increaser reducer Ro tation must always be driven counter clockwise facing the shaft end FUNDAMENTALS OF OPERATION AND MACHINE COMPOSITION This family of compressors has great flexibility in ap plication and the materials of construction will vary based upon the design operating requirements for which it was selected Casing material can be cast iron nodu lar iron or cast steel depend...

Page 8: ...fluid to be directed to an atmo spheric drain trap cast into the leg of the main casing Bolt Patterns Due to the varied application of this compressor fam ily there can be differences in the bolting and the pat terns of the bolting There will be more bolts utilized in the external patterns when the compressor is designed for a higher design working pressure There can be variations on the internal ...

Page 9: ...FORM 220 11 NM2 602 9 YORK INTERNATIONAL FIG 2 TYPICAL COMPRESSOR CROSS SECTIONAL VIEW LD07317 1 ...

Page 10: ...xer cise caution when preparing to service or remove parts from the system Be sure to wear eye protection to avoid any possible splash hazards The compressor contains many close clearance areas and heavy parts which can result in situations where fingers or other extremities may be pinched crushed or even severed Care should be taken when lifting or moving any parts to be sure that any extremities...

Page 11: ... conditions can result in very low temperatures which can be damaging to equipment personnel 1 Conduct the pressure test in accordance with de sign parameters outlined in the application data sheet The compressor s atmospheric shaft seal may leak excessively if the shaft seal reservoir has not been filled with oil 2 Iftheatmosphericshaftsealisleaking chargethecom pressorshaftsealreservoirwiththeap...

Page 12: ...ing temperatures carefully Compressors that utilize refrigerant cooled oil coolers may not be oper ated if there is no source of coolant available C Check that the oil cooler s is functioning prop erly D Check the compressor lubrication system see DAILY OPERATION E The compressor discharge temperature must not exceed the limits specified in the applica tion data sheet for the application or the sa...

Page 13: ...26 EA ADD L 500 100 27 22 2 STAGE 10 500 2 750 230 190 38 EA ADD L 1 300 350 90 75 2 STAGE 25 000 5 000 630 500 55 EA ADD L 3 000 1 000 250 200 TABLE 3 APPROXIMATE COMPONENT WEIGHTS FOR SERIES M COMPRESSORS CASING ID GRAY IRON DUCTILE IRON STEEL INCHES LBS LBS LBS PRV HOUSING 350 350 575 25 26 OIL SUMP HOUSING 650 650 810 PRV HOUSING 900 900 1 230 38 OIL SUMP 1 715 1 715 2 165 HOUSING PRV HOUSING ...

Page 14: ...n Figure 4 Since suction gas enters the first stage impeller 1 at suction pressure and leaves the high stage impeller 2 at discharge pressure the pressure differential becomes progressively greater between the inlet and the discharge of each impeller The inlet areas of the impellers are only affected by suction pressure of that stage while the sides of the impeller are subjected to the higher impe...

Page 15: ...FORM 220 11 NM2 602 15 YORK INTERNATIONAL FIG 3 TYPICAL PRIMARY COMPRESSOR GAS FLOW LD07318 3 ...

Page 16: ...YORK INTERNATIONAL 16 FORM 220 11 NM2 602 FIG 4A MAJOR COMPONENTS LD07319 Operation ...

Page 17: ...FORM 220 11 NM2 602 FORM 220 11 NM2 602 YORK INTERNATIONAL YORK INTERNATIONAL 17 17A FIG 4B CUT A WAY VIEW MODEL 255 COMPRESSOR LD07817 3 ...

Page 18: ... application For this reason it is very difficult to tabulate all clearance values for all applications Form 160 71 M can be used for two stage water chilling application The infor mation in that document should not be applied to any other application unless verified on the application data sheet 1 Check for proper clearance between all stationary and rotating parts 2 Inspect the stationary compon...

Page 19: ...08 SPRING SHAFT SEAL 109 WASHER SPRING RETAINING 110 SEAL O RING 111 RING SHAFT SEAL 112 SCREW MACHINE FLAT HD 113 RING RETAINING SEAL 115 DOWEL PIN 116 NUT HEX 150 ROTOR ASSEMBLY 151 DIFFUSER DISK VANE 152 DIFFUSER VANE ENTRANCE 153 SCREW CAP HEX HD 154 DEVICE PRE ROTATION 155 RING RETAINING 156 RING LABYRINTH SEAL EYE SEAL 1ST 157 RING LABYRINTH SEAL EYE SEAL 2ND 158 COVER BAL PISTON SEAL 159 RI...

Page 20: ...s nor mal and does not indicate a problem Leakage rates are dependent upon coupling size shaft rotational speed and oil reservoir sump pressure Larger diameter and FIG 6 EXPLODED VIEW OF ATMOSPHERIC SHAFT SEAL higher shaft speeds will result in more leakage through the seal faces Since oil leakage to the atmospheric side of the shaft seal is collected in the drain trap a leaking shaft seal can be ...

Page 21: ...he oil reservoir hous ing 5 and flows to the space around the shaft between the thrust bearing 6 and the discharge end main bear ing 8 From this space part of the oil passes through the main bearing 8 toward the impellers and the re mainder passes to the load surface of the thrust bearing inboard surface of oil pump and outboard surface of thrust bearing Oil passes through the discharge end main b...

Page 22: ...YORK INTERNATIONAL 22 FORM 220 11 NM2 602 FIG 7 OIL PIPING SCHEMATIC FOR SERIES LUBRICATION SYSTEM PRIOR TO 1970 LD07320 Operation ...

Page 23: ...FORM 220 11 NM2 602 23 YORK INTERNATIONAL FIG 8 OIL PIPING SCHEMATIC FOR PARALLEL LUBRICATION SYSTEM AFTER 1970 3 LD07321 ...

Page 24: ...ssor D Start all system auxiliaries E If the compressor is motor driven be sure the pre rotation vanes are closed to unload the mo tor during starting Some systems are equipped with a safety switch which automatically pre vents the compressor motor from starting un less the vanes are closed The starting require ments for a single shaft gas turbine are more severe and a special start up procedure i...

Page 25: ...e jet nozzle body is controlled by cooling the oil 7 Opening the pre rotation vanes and cooling of the oil by the oil cooler will both reduce oil foaming and oil pressure fluctuations 8 Be sure the water valves to the oil cooler are wide open and that the design flow of water is passing through the cooler It may be necessary to throttle water to the coolers when the compressor is to op erate at re...

Page 26: ...r to Replacing Oil Filter Element Compressors on which the oil reser voir pressure can fall below atmo spheric should be equipped with a shaft seal oil pressure gauge and regu lating valve 4 Adjust the regulating valve to maintain a seal pres sure of 2 to 5 psi at minimum suction pressure The actual seal oil pressure will vary with suction pres sure and the pre rotation vane position closing the v...

Page 27: ...op valve 24 ahead of the oil filter 3 should never be closed except while servicing the auxiliary oil pump or charging oil 2 During normal operation the auxiliary oil pump suc tion 21 and discharge valves 20 should be open to permit proper automatic pump operation The other pump connection should be closed 3 The Hand Automatic Switch should be set at Au tomatic during operation except as noted inA...

Page 28: ...e pump discharge connection to the oil charging valve located at the end of the compres sor oil sump Be sure the connections are rated for the design pressure of the system Do not com pletely tighten the connection at the charging valve until all of the air is forced out and oil is forced out by pumping a few strokes of the pump This fills the lines and prevents air from being pumped into the syst...

Page 29: ...il pump differential control switch is ac tuated by the pressure differential between the oil res ervoir and the main oil pump discharge sensing the out put of the main oil pump only independently of the aux iliary pump Adjustments Settings This control should be adjusted depending upon com pressor size as follows For compressors manufactured after 1995 the AOP regulating valve should be adjusted ...

Page 30: ...sor stops due to a power failure the auxiliary pump can not start This should not damage the com pressor because the main oil pump will supply oil while the compressor slows down and residual oil will prevent bearing damage 2 As the compressor slows down the main oil pump pressure falls until the auxiliary oil pump starts au tomatically The control system may also automati cally start the pump on ...

Page 31: ...FORM 220 11 NM2 602 31 YORK INTERNATIONAL Operation 3 This page intentionally left blank ...

Page 32: ...tructions From Inspect as Compressor is Disassembled Once compressor parts have been disassembled and cleaned valuable indications of the compressor condi tion are lost For example Materials found in oil often indicate as to why a part or parts have failed Protect Parts and Surfaces Do not scatter removed parts indiscriminately Coat ma chined surfaces likely to rust with YORK Oil or a rust prevent...

Page 33: ...be performed more frequently if refrigerant losses exceed 10 of system charge 4 TABLE 8 MAINTENANCE REQUIREMENTS FOR YORK MULTISTAGE CENTRIFUGAL COMPRESSORS PROCEDURE DAILY WEEKLY MONTHLY QUARTERLY SEMI ANNUALLY YEARLY EVERY HOURS 24 HRS 160 HRS 1000 HRS 3000 HRS 3000 HRS 6000 HRS Check oil level record any additions removal X Check refrigerant charge X Check and repair leaks X Check vibration lev...

Page 34: ...the responsibility of the service technician and his her organization to be aware of current regulations and to comply with them Be careful that the system is not sub jected to a freeze condition during the transferring of refrigerant Be sure that rigging provided is rated for the Series M compressor components For example a 55 two stage top half weighs more than three tons Consult Table 2 and Tab...

Page 35: ...factors such as oil dilution sump pressure and exter nal seal gas pressure A 4 seal are found to be correct Scoring or wearing of the suction end inboard A 1 oil seal can result in oil loss into the compressor and you must pull the PRV sleeve to verify it Condition E can be caused by poor alignment extreme variations of oil pressure and temperature liquid refrig erant entering the compressor sucti...

Page 36: ...riven compressor disk fall to the floor 7 Remove the driven compressor disk and spacers Removing the Drive Coupling Disk 1 Be sure the clamp ring is in the driven disk 2 Install the wrenches Table 9 Item 1 with the 12 point wrench on the hex of the drive coupling half The wrench will not bear on the entire flat of the hex on the driver extension 3 Loosen the drive coupling disk and remove wrenches...

Page 37: ... FIG 10 COUPLING GUARD LD07322 LD07323 00622VIP 4 TABLE 9 COMPRESSOR TOOLS ITEM DESCRIPTION QTY TOOL KIT 1 1 WRENCHES 1 2 WRENCH SUPPORT 1 3 GUIDE PIN 4 4 SNAP RING PLIERS 1 5 SNAP RING PLIERS 1 6 MAIN SHAFT WRENCH 1 7 SNAP RING PLIERS 1 8 THREAD COMPOUND 1 9 HEX CAP SCREW 3 10 HEX CAP SCREW 4 11 OIL PUMP HAND 1 12 STUD GUIDE BEARING HOUSING 4 13 SLEEVES AND MANDRELS 1 ...

Page 38: ...YORK INTERNATIONAL 38 FORM 220 11 NM2 602 FIG 13 LOOSENING DRIVE SHAFT WITH WRENCHES FIG 12 LOOSENING THE DRIVE SHAFT WITH SPECIAL WRENCHES LD07324 LD07325 LD07326 Service ...

Page 39: ... COVER SHAFT SEAL 2 SPRING HELICAL 3 WASHER SPRING RETAINING 4 O RING 5 RING SHAFT SEAL 6 PIN INSERT 7 COLLAR SHAFT SEAL 8 RING RETAINING SEAL 9 SCREW MACH FLAT HD 10 GASKET 1 64 THK 11 GASKET 1 32 THK 12 GASKET 1 16 THK 13 SCREW CAP 12 PT HD 14 COUPLING GUARD BEARING HOUSING COVER PLATE X Installation Height Dimensions ...

Page 40: ...d proceed as follows Removing the Shaft Seal If sump is vented to atmosphere the shaft seal can be changed with oil in the main compressor sump The shaft seal reservoir will have to be drained Follow safety guidelines to isolate ma chine from operating 1 To facilitate shaft seal replacement with minimum loss of gas and oil the unit should be pumped down to remove refrigerant See Preparation for Se...

Page 41: ... shoulder on the inboard end of the drive shaft so that the two slots marked by a pencil slide over the insert pins the inside surface of the collar is against the rotor shaft and the rotor is on its active thrust face shaft out Measure Y per Fig 15 Remove shaft seal collar 7 from shaft and reas semble with O ring 4 installed in shaft seal collar 7 Measure Y per Fig 15 The Y measure ment should be...

Page 42: ...Check that an oil filter is in the housing Plastic flow indicates the bearing has experi enced extremely high temperature usually due to poor lubrication It may also show break down of bearing with particles circulated Remove one end bearing at a time re placing same before removing the other bearing REMOVING SUCTION END JOURNAL BEARING The actual bearing can be removed without removing the bearin...

Page 43: ...ed area Do not force the bearing into position It must slip in easily The bearing and housing should be at the same tem perature when assembling 3 Slip the bearing over the drive shaft and screw the bearing puller rods into the bearing Line up the bearing slot with the locating pin and push the bear ing into position Raise the shaft slightly to ease installation 4 Use the snap ring pliers to place...

Page 44: ...V sleeve housing and rotor shoulder for evidence of rubbing D Examine the seal ring flange and PRV housing mating surface for evidence of wear or scoring use bluing if necessary The inboard surface of the seal flange must sit flat within the PRV sleeve recess The oil seal is a stationary seal If it rotates you should see evidence of it Just a slight deviation from a flat seal can promote oil loss ...

Page 45: ...ness during reassembly 10 Install the shaft bearing and shaft seal as previ ously described REMOVING OIL PUMP ASSEMBLY THRUST BEAR ING AND DISCHARGE END JOURNAL BEARING The oil pump thrust bearings forward and reverse and the reservoir end journal bearing are accessible through the oil reservoir without removing the casing top half If it becomes necessary to replace any of these parts refer to Fig...

Page 46: ...er materials MAXIMUM OIL PUMP COMPRESSOR THRUST BEARING RUNOUT T I R OIL SEAL DIAMETRAL CLEARANCE SIZE AXIAL CLEARANCE FACE RIM DRIVE END RESERVOIR END 25 008 012 0005 0005 002 005 001 004 26 008 012 0007 0006 002 005 002 007 38 010 014 0010 0008 003 006 002 007 55 013 017 0013 001 004 008 002 007 TABLE 13 SCREW SIZES FOR PULLING DRIVE END JOURNAL BEARING COMPRESSOR COUPLING SCREW SIZE SIZE INCHES...

Page 47: ...ousing and is held in place with a roll pin to prevent rotation within the housing The discharge end journal bearings come in two styles taper bore and taper land See Removing Suction End Journal Bearing for explana tion The same restrictions on roll pin location apply if a bearing must be repositioned radially Refer to sec tion on Suction End Journal Bear ings for description 10 Screw puller rods...

Page 48: ...ese plugs remove the external oil piping and flush the oil galleries After cleaning replace the plugs using an oil or paste sealant Do not use teflon tape Some external oil lines are screwed di rectly into the sump with nipples and fittings When replacing the parts af ter flushing use only approved seal ants refer to piping prints Any leaks discovered after reassembly are diffi cult to correct Ins...

Page 49: ...A Set up a dial indicator capable of reading to 0 0005 on the rim of the large O D to check oil pump run out Use a magnetic base or screw an oil pump housing bolt into the sump Turn the pump and rotor by the clamping bolt using a long extension B Using a soft hammer or brass drift center the pump to within the following specifications 25 0005 26 0006 38 0008 55 001 The above values are max allowab...

Page 50: ... TABLE 14 If it becomes necessary to replace the discharge end seal ring or the balance piston seal ring the oil reser voir housing must be removed Proceed as follows 1 Refer to Removing Oil Pump Thrust Bearings and Oil Reservoir End Journal Bearing 2 Remove all oil tubing piping and electrical con nections attached to the reservoir 3 Remove cap screws from the flange holding the oil reservoir in ...

Page 51: ...ough the end of the compressor casing The seal ring 159 and spring washer 160 can now be pulled off the balance piston Fig 25 shows an ex ploded view of the balance piston seal assembly Observe the pin extending through the spring washer that prevents the seal from turning Early model compressors did not have this pin The addi tion of an anti rotation pin is recommended when service provides acces...

Page 52: ...o pull the sump evenly into compressor until the cap screws can be started Keep the sump as square as possible Do not force or damage to the piston ring may result 5 Relax the lifting rigging After the sump has been seated and all bolts torqued install the discharge end bearing If the suction end bearing is in place the rotor should turn easily Install the thrust bearing and oil pump assembly Repl...

Page 53: ...ssor The individual vanes seldom require service If foreign material has damaged the vanes or system dirt and corrosion have locked the vanes vane disassembly may be required Vanes are actuated by a rotating vane driving ring 202 through individual arms 228 To remove the vanes refer to Figs 26 27 and 28 proceed as follows 1 Remove the cap screw 205 securing the washer 229 vane arm 228 and washer 2...

Page 54: ... and the lever arm is bolted on Although some spares are still available for service it is recommended that the new style shaft and cover be installed whenever the compressor is being overhauled Some old style PRV covers control shaft covers were of solid construction but all machines now use a shaft cover that has seal return oil circulating through inter nal passages The circulating oil helps lu...

Page 55: ...as two fulcrum points upper andlower Dependingonhowtheactuatorismounted on the PRV housing either style may be supplied Some units are still supplied with the optional hand wheel and linkage for manual operation 5 Set the vane indicator pin to the C mark with the vanesfullyclosed Someapplicationsmayrequirethe actuator stroke to hold the pin about 3 32 open at minimum actuating air This will hold t...

Page 56: ...s 116 4 Screw the four guide studs shipped with the tools into four of the holes from which the casing cap LD07345 screws were removed one stud near each cor ner The purpose of guide studs is to insure that the casing is being lifted or lowered evenly to avoid damaging internal parts See Fig 29 5 Using four of the cap screws removed from the casing flange as jack screws turn the screws up into the...

Page 57: ...ressor models vary in construction details but each one essentially con REMOVING LABYRINTH SEALS AND COMPRESSOR ROTOR 1 Remove the oil reservoir and balance piston ring See Removing the Discharge End Seal Ring and Balance Piston Seal See Figs 23 24 2 Remove the piston ring housing 28 from the high stage diffuser and the exit vane plate 190 Fig 31 Compressors with 8 vane diffuser and more than two ...

Page 58: ...ing disk 74 from the lower half Use a pry bar or studs screwed into the tapped holes in the rim of the lower half of the diffuser to rotate it up on the impeller until you can screw an eye bolt into it and lift it off Be careful the diffuser has some sharp points on it and if it sinks back into the casing it will come up the other side and may cause injury or damage other parts If the compressor h...

Page 59: ... be necessary to remove the first stage diffuser disk If it becomes necessary to remove this plate the pre rotation vane assembly must first be removed as outlined under Removing the Pre rotation Vane Assembly Current production compressors lo cate the exit plates with roll pins Some older machines locate the exit diffus ers within a circle of machined hex head cap screws DISTURBING THESE SCREWS W...

Page 60: ...clearances 3 Inspect all new parts Be sure they are the correct items Physically try all bearings on the rotor and in the bearing housings before starting assembly Check clearances Fit labyrinth seals around the impellers and shaft Check clearances with a feeler gauge 4 Clean all casing parts thoroughly Pay special at tention to the diffuser grooves Minute particles can displace the diffusers enou...

Page 61: ...a reference point during assem bly Position the rotor full toward the suction and set the indicator to zero Refer to the diffuser dia gram Fig 31 Note the exit plate splitline relative to the insert pin 184 Units produced prior to 1995 had the roll pin at TDC Current production has the pin at the split line Viewing from the sump end rotate the first stage entrance plate diffuser approxi mately 45 ...

Page 62: ...ump gas kets Arotor that is not in center with diffusers may impact performance 6 Remove the oil pump Loosen the bolts holding the PRV housing and sump Slide each of them out ap proximately 1 4 Tie the gaskets back with thread Center the roll pins on top of the diffusers with a straight edge and level Make a reference mark on each diffuser at the casing gasket so you can see if the diffusers shift...

Page 63: ...ion and discharge flange connections are tightened Maxi mum allowable deflection is 002 total com bined Be sure to install correct flange gaskets Operation without a guard is not rec ommended Cordon off area if ma chine is operated without the guard Close supervision is required with un protected shafting 2 Install the drive coupling See YORK coupling in struction for details 3 Perform leak and va...

Page 64: ...ww york com P O Box 1592 York Pennsylvania USA 17405 1592 Subject to change without notice Printed in USA Copyright by York International Corporation 2002 ALL RIGHTS RESERVED Form 220 11 NM2 602 Supersedes 220 11 NM1 366 ...

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