manual de atlas copco

INSTRUCTION MANUALFOR

CENTRIFUGAL COMPRESSORS

Atlas Copco Comptec Inc.46 School RoadVoorheesville, New York 12186USAwww.atlascopco.com

Purchaser ................... Air Products and Chemicals

Purchaser P.O. No. .... OX27005

Customer.................... Southern Peru Copper Corp.

Model No. ................... SC-14

Sales Order No. ......... SC-23152

Machine Serial No. ..... ACC0423152

Built in ........................ 2004

LONGMJ

Text Box

0300384 SD 00-4-3265-K131 -27005 038R00

LONGMJ

Stamp

Air Products and Chemicals for Southern Peru CopperAtlas Copco Sales Order # SC-23152

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Copyright © 2005 Atlas Copco Comptec Inc. All rights reserved.

Text, data and drawings must not be made available to third parties. The owner ofthe compressor unit shall have the right to make copies of this instruction manualfor internal company use. However, Atlas Copco advises the owner to orderadditional copies from the Atlas Copco Comptec Inc. Parts and Service Centreagainst an invoice to ensure that the latest edition is available on the job.

The information in this instruction manual is correct at the date of issue. It is,however, subject to modifications prompted by alterations in design or to eliminatedeficiencies that have become obvious.

Users of this instruction manual are requested to advise Atlas Copco of each andevery insufficiency they detect, in particular those insufficiencies concerningproduct safety.

The binding copy of the compressor instruction manual shall be that electronicversion delivered by Atlas Copco Comptec Inc. as contractually stipulated.

preface-3Air Products and Chemicals for Southern Peru CopperAtlas Copco Sales Order # SC-23152

CONTENTS

PrefaceTopic Preface-Revisions to Instruction Manual ........................................................... 5Safety Precautions ................................................................................. 7Receiving and Storage .......................................................................... 9Warranty .............................................................................................. 11Limit of Liability ................................................................................. 12Standard Preventive Maintenance Agreements ................................... 13

1 General Compressor Description

2 Installation

3 Lubrication System

4 Seal System

5 Control System

6 Operation

7 Maintenance

8 Recommended Spare Parts

9 Bills of Material

10 Drawings

11 Component Literature


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This page intentionally left blank.


Revisions to Instruction ManualUpdates to this manual may be necessary throughout the life of thecompressor. This page is provided to track all revisions to this manual.

Revision # Date Description

0 April 2005 Initial release of manual


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Safety Precautions

WARNING

Centrifugal compressors have high-speed rotating components andcan cause fatal injury. Allow only qualified personnel to install,operate, and maintain this compressor and the associated equip-ment. To protect personnel from injury, follow the safety precau-tions contained in this manual.

Atlas Copco hereby notifies and forewarns the owner, lessor, oroperator of the compressor that failure to observe common safetyprecautions, whether specifically stated herein or not, may result ininjury to personnel or damage to equipment.

• Do not perform any maintenance on this unit unless it is fullypurged with nitrogen or clean, dry air and you have verified thatno process gas remains within the system.

• Use proper care and procedures in handling, lifting, installing,operating, and maintaining the equipment.

• Do not touch energized circuits or rotating parts.• Wear proper hearing protection when in close proximity to

machinery with high noise levels.• Do not bypass or render inoperative any safeguards or protective

devices.• Periodically check safety devices.• If process piping downstream of the compressor must remain

pressurized while you are performing maintenance on the com-pressor, be sure that a blind flange has been installed to preventinadvertent back-flow of air through the machine. Do not rely ona check valve.

• Do not remove any compressor parts, including guards, shields,screens, caps, or plugs before relieving pressure from the system.Oil or air under pressure can cause severe injury or death.

• Do not operate the compressor at pressures and speeds above itsrating (see General Information and Data in section 1).

• To avoid electrical shock, disconnect all power sources from themachine and accessories before maintenance. Safe maintenancepractices by qualified personnel are imperative.

• Ground electrical components and the machine in accordancewith the national electrical code and consistent with sound localpractice.

• Do not leave loose items (for example, tools, rags, or machineparts) on the compressor or gear assembly prior to start-up.

• Do not use flammable solvents for cleaning parts.


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Safety Precautions – continued• Keep dirt out of exposed openings by covering them with clean

cloth or kraft paper.• Do not use parts of the compressor or its piping as a ladder; use

temporary scaffolding.• Do not touch hot portions of the equipment; for example, the

intercoolers or compressor housing.• Supply material safety data sheets (MSDS) about the process gas

to all maintenance, service and operating crews to avoid unsafeconditions during operation and/or maintenance.

• Follow all applicable environmental laws and/or procedureswhen handling or disposing of materials.


Receiving and StorageThe compressor is shipped from the factory as a complete unit, readyfor installation and operation. Carefully inspect each piece of equip-ment upon receipt. File any damage claims immediately with thecarrier and then notify:

Parts and Service Centre ManagerAtlas Copco Comptec Inc.46 School RoadVoorheesville, New York 12186Phone: (518) 765-3344Fax: (518) 765-4889

During manufacturing, testing, and shipment preparations, AtlasCopco personnel observed basic procedures to protect the machineagainst rust and corrosion in general. If the machine has been ex-posed to low temperatures, unpack it only after it has reached thetemperature in which it is to be installed.

All machines have been operated at the factory. Although they areshipped without oil, a film of rust-inhibiting oil remains on the partsduring shipment. When the compressor is installed at the job site,Atlas Copco recommends that you fill all bearing and oil reservoirsto the proper level with the recommended oil as soon as possible.

In the event that the compressor will not be put into operation imme-diately or if the machine is to be stored for a period of time, certainprotective measures should be taken. This is extremely important ifstorage or idleness was not specified on the purchase order or antici-pated at the time of shipment preparation. Experience has shown thatadequate precautions during storage will avoid costly deterioration ofparts and lengthy maintenance procedures at time of installation andstart-up.

Unless otherwise specified, the compressor has been shipped withoutany special shipping preparation. If you will not be operating thecompressor for several months after installation, or if you will inacti-vate it after it has been in service, protect it from temperature ex-tremes and moisture by an enclosure and space heaters. To reducerusting during this time, operate the compressor once a month for aperiod of at least 10 minutes to thoroughly coat all parts with oil.

If you will be storing the compressor for a long period of time, AtlasCopco recommends that you store it in a dry, clean area, free fromtemperature extremes, in an approximately level position, withoutdistortion. If you store the machine outdoors, enclose it in a water-proof covering. Use space heaters or other temperature-control meth-ods to avoid temperature variations. Rotate the compressor shaft atleast once a month. Flush the bearings, journals and all bare metalparts with rust-inhibiting oil.


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Receiving and Storage – continuedProtect motors from moisture and temperature variations with spaceheaters or other temperature-control means. Inspect motor windingsperiodically by checking insulation resistance with a megohmmeter(also known as “meggering”). Immediately investigate significantchanges in meter readings. Insulation resistance, in megohms at500 VDC and at 104°F/40°C, should result in a value greater than orequal to:

motor voltage + 10001000

Rotate motor shafts at least 25 revolutions once a month.

Before reactivating the compressor, thoroughly clean it and inspect itfor rust and corrosion. Renew oil and grease. Refer to section 7,Maintenance.

Refer to section 11 Component Literature for further receiving andstorage procedures.


WarrantyAtlas Copco’s general product warranty is given below. Refer to thepurchase contract for additional and/or different warranty terms andconditions that may apply to your machine.

Atlas Copco warrants to the purchaser that the products manufac-tured by Atlas Copco and affiliates shall be free of defects in design,material and workmanship for 18 months from date of shipment topurchaser, or 12 months from date of initial start-up, whichever oc-curs first. Normal wear parts are sold AS IS and are not covered bywarranty.

Should any failure to conform with warranty appear prior to or aftershipment of the product to the purchaser during the specified periodsunder normal and proper use and provided the product has beenproperly stored, installed, handled, and maintained by the purchaser,Atlas Copco shall, if given prompt notice by purchaser, repair orreplace the nonconforming product or authorize repair or replace-ment by the purchaser and reimburse the purchaser for reasonableexpenses incurred.

When the nature of the defect is such that it is appropriate in thejudgement of Atlas Copco to do so, repairs will be made at the site ofthe product. Repair or replacement under the applicable warrantyshall be made at no charge for replacement parts, warranty labor, andservicemen transportation and living costs when work is performedduring normal working hours (8:00 a.m. to 4:30 p.m.). Labor per-formed at other times will be billed at the overtime rate then prevail-ing for services of Atlas Copco personnel.

Atlas Copco’s warranty does not extend to products not manufac-tured by Atlas Copco or affiliates. As to such products, the purchasershall be entitled to proceed only upon the terms of the particularmanufacturer’s warranty. Warranty does not apply to defects in mate-rial provided by purchaser or design stipulated by purchaser.

THE FOREGOING WARRANTIES ARE EXCLUSIVE AND INLIEU OF ALL OTHER WARRANTIES OF QUALITY, WRIT-TEN, ORAL OR IMPLIED, AND ALL OTHER WARRAN-TIES, INCLUDING WITHOUT LIMITATION ANY WAR-RANTY OF MERCHANTABILITY OR FITNESS AREHEREBY DISCLAIMED.

Correction of non-conformities as provided above shall bepurchaser’s exclusive remedy and shall constitute fulfillment of allliabilities of Atlas Copco (including any liability for direct, indirect,special, incidental or consequential damage) whether in warranty,strict liability, contract, tort, negligence, or otherwise with respect tothe quality of or any defect in products delivered hereunder.


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Limit of LiabilityAtlas Copco’s general statement of liability is given below. Refer tothe purchase contract for additional and/or different limitations ofliability that may apply to your machine.

IN NO EVENT SHALL ATLAS COPCO BE MADE LIABLEFOR SPECIAL, INDIRECT, INCIDENTAL OR CONSEQUEN-TIAL DAMAGES, however arising, whether in warranty, strictliability, contract, tort, negligence or otherwise, including but notlimited to loss of profits or revenue, loss of total or partial use of theproducts or facilities or services, downtime cost, or claims of pur-chaser for such or other damages whether on account of productsfurnished hereunder or delays in delivery thereof or services per-formed upon or with respect to such products.

Atlas Copco’s liability on any claim whether in warranty, strict li-ability, contract, tort, negligence or otherwise for any loss or damagearising out of, connected with, or resulting from this contract or theperformance or breach thereof, or from design, manufacture, sale,delivery, resale, repair, replacement, installation, technical directionof installation, inspection, servicing, operation or use of any productcovered by or furnished under this contract shall in no case (except asprovided in the General Terms and Conditions of Sale section en-titled “Patent Indemnity”) exceed the purchase price allocable to theproduct or part thereof which gives rise to the claim.

All causes of action against Atlas Copco arising out of or relating tothis contract or the performance hereof shall expire unless broughtwithin one year of time of occurrence thereof.


• Check oil reservoir level.• Check and record readings as recommended in compressor

operating manual.• Exercise inlet valve (IV) or inlet guide vanes (IGV) and

blow-off valve (BOV) to prevent binding.• Check discharge pressure and unit loading.

• Check condensate drain traps for proper drainage (ifapplicable).

• Check for oil, cooling water and instrument air leaks.• Check for abnormal noise, loose connections or cables,

loose bolts, etc.• Clean accumulated dirt on or around compressor.

Level A inspection by plant personnel — 4,000 running hours or annually• Perform daily inspection.• Check and record all temperatures and pressures.• Check and record vibration levels on each stage.• Check control panel display and all warning lights.• Check and record all interstage pressures.• Check and record gas temperatures.• Check and record cooling water temperatures.

• Check and record approach temperatures of coolers.• Check and record inlet filter differential pressure (if

applicable) or inlet pressure.• Check condensate drain traps.• Check instrument air supply lines and filter. Drain any

accumulated moisture and clean filter element if necessary.• Check and record oil filter differential pressure.

Level B — 8,000 running hours or annually• Perform daily and Level A inspections.• Inspect oil (send out for analysis). Change only if required.• Change oil filter elements.• Check gas cooler performance for fouling.• Inspect inlet filter housing surfaces for corrosion. Replace

all filter elements.• Visually inspect oil mist eliminator (if applicable). Replace

filter element.• Check IV/IGV calibration and inspect for leaks.• Check blow-off valve calibration and inspect for leaks.

• Inspect discharge check valve and inspect for leaks.• Visually inspect main drive coupling. Re-grease if

applicable.• Check motor alignment.• Grease motor bearings per vendor instructions (if

applicable).• Check all pressure transmitters.• Check all temperature elements.• Check all temperature and pressure readings.

Level C — 24,000 running hours or 3 years• Perform daily, Level A and Level B inspections.• Check all vibration proximitors.• Remove inlet shroud; inspect impellers/shrouds for rubs,

erosion, and corrosion.• Clean impellers and shrouds if necessary.• Check impeller-to-shroud clearances. Adjust if required.• Visually inspect diffuser vanes for erosion.• Remove gear cap; inspect gear mesh contact pattern and

measure backlash.• Inspect high-speed bearings for excessive wear.

• Inspect low-speed bearings for excessive wear.• Check high-/low-speed thrust bearing axial float clearances.

Adjust if required.• Inspect high-speed gas seals and oil seals.• Inspect low-speed oil seals.• Dismantle oil cooler; inspect coolant side for corrosion/

erosion.• Inspect process side of gas coolers for corrosion/erosion.• Inspect inlet throttle valve (or IGV) body.

Level D — 48,000+ running hours or 6 years

Daily inspection by plant personnel

Standard Preventive Maintenance AgreementsOur goal is to keep your compressor operating with the highest reli-ability. The following are recommended service intervals coveredunder our standard maintenance agreements. Call the Atlas CopcoComptec Service Department to set up a maintenance agreement foryour compressor.

• Perform daily, Level A, B and C inspections.• Inspect and clean oil reservoir.• Change oil.• Remove and replace high-speed labyrinth seals.• Remove and replace low-speed oil seals.

• Glass blast impellers and balance rotor assemblies (by others).• Blast clean shrouds and volutes, if required (cleaning by

others).• Overhaul main oil pump.• Overhaul auxiliary oil pump.


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1-1Air Products and Chemicals for Southern Peru CopperAtlas Copco Sales Order # SC-23152

Section 1General Compressor Description

IntroductionThis section provides data specific to your compressor(s) and a general description ofthe main compressor systems.

In this sectionThis section contains the following topics.

Topic Page 1-General information and data ............................................................... 3

Design conditions ............................................................................. 3Physical conditions ........................................................................... 4Connections ...................................................................................... 4

Compressor description ........................................................................ 4Main driver ....................................................................................... 4Gearing ............................................................................................. 4Base................................................................................................... 4Lubrication cooling ........................................................................... 4Control system .................................................................................. 5

Performance curves ............................................................................... 5


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General information and dataPurchaser Name ..................................... Air Products and ChemicalsPurchaser Address ......................................7201 Hamilton Boulevard

Allentown, PA 18195End User ...................................... Southern Peru Copper CorporationJob Site Location .......................................................................... PeruPurchaser P.O. No. ...............................................................OX27005Sales Order No. .................................................................... SC-23152Serial No. ....................................................................... ACC0423152Model No. .................................................................................. SC-14Type ................................................................................... CentrifugalNo. of Stages ...................................................................................... 1

Design conditionsType of Gas .................................................................................... AirFlow (Nm3/h) ................................................................... 44,636 max.Relative Humidity (%) ....................................................................... 0Mole Weight ............................................................................... 28.96Specific Heat Ratio (K) .............................................................. 1.395Comp. Factor (Z) ............................................................................ 1.0Inlet Pressure (bar a) .......................................... 5.01 min. / 5.25 max.Inlet Temperature (°C)................................................................ 13.80Discharge Pressure (bar a) .......................................................... 13.80Discharge Temperature (°C) .......................... 29.90 min. / 37.90 max.Coolant ....................................................................................... WaterCoolant Flow (m3/h) ..................................................................... 89.7Maximum Coolant Pressure (bar g) ............................................ 10.34Coolant Temperature (°C) ............................. 19.90 min. / 27.90 max.Required Power (kW) .................................................................. 1409Compressor Speed (RPM) .............. 3575 (Bull Gear), 17306 (Pinion)Driver Power (kW) ...................................................................... 1400Driver Speed (RPM) .................................................................... 3600Driver Voltage ............................................................................. 4000Driver Hertz ..................................................................................... 60Motor Service Factor ......................................................................... 1


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Physical conditionsOutline Drawing # .......................................................... SC23152085

Length (mm) ............................................................................. 6050.7

Width (mm) .............................................................................. 3653.3

Height (mm).............................................................................. 2806.7

Weight (kg) ............................................................................... 14,970

ConnectionsInlet Flange ............................................................. 14 in., 150 lb R.F.

Discharge Flange .................................................... 12 in., 300 lb R.F.

Oil Cooler ..........................................................................1.5 in. NPT

Cooling Water ............................................................ 6 in., 150 lb F.F.

Compressor descriptionThe compressor consists of overhung, open-type impellers and inletshrouds installed in nodular, cast iron housings. The impellers aremounted directly on high-speed pinion shafts that are supported bytwo tilting-pad bearings.

Main driverThe main motor drives the pinion through a flexible disc coupling andsingle-step, speed-increasing gear supported in two sleeve bearings.The drive motor bearings are sleeve-type with ring oil lubrication.

GearingThe gears are made of hardened steel and ground to AGMA Q-13standards. The gearbox is split horizontally in the pinion plane per-mitting easy inspection of the high-speed bearings and removal orinstallation of the complete rotor assembly.

BaseA unitized fabricated steel base supports the drive motor, gear casingand compressor housing. It also forms the oil sump and contains thelubrication system.

Lubrication coolingLube oil cooling is accomplished by a separate carbon steel shell andinhibited admiralty, oil-to-water heat exchanger.


Control systemThe compressor is supplied with an electric/pneumatic control sys-tem that monitors all critical parameters and provides permissivecircuits along with alarm and shutdown circuitry for safe operationof the equipment. See section 5, Control System for details.

Performance curvesThe following data sheets show the characteristic performancecurves for the design of your compressor(s).


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Section 2Installation

IntroductionThis section contains instructions and guidelines for the compressor installation.


Topic Page 2-Installation summary ............................................................................. 3

Keep a log ......................................................................................... 3Shipping and packing ............................................................................ 3Setting and leveling .............................................................................. 4Piping connections ................................................................................ 4

Drain valves ...................................................................................... 4Filters ................................................................................................ 5Instrument air .................................................................................... 5

Electrical connections ........................................................................... 5Lubrication system preparation ............................................................. 5Coupling alignment ............................................................................... 5

Coupling alignment data sheet .......................................................... 7Installation control check ...................................................................... 8Installation pre-start check .................................................................... 8


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Installation summaryThe compressor package has been fully shop tested and shippeddirectly to the job site. Following is a list of operations to be per-formed to install the compressor.

Step Action

1. Set and level the compressor on its foundation; bolt down.

2. Connect piping.

3. Service the lubrication system.

4. Align the coupling.

5. Connect electric power.

6. Check the control system.

7. Perform a pre-start check.

8. Perform initial start-up.

Atlas Copco recommends that you install the compressor as soon aspossible upon receipt. If the compressor will not be installed immedi-ately, refer to Receiving and Storage in the preface to this manual.

Keep a logAtlas Copco recommends that you establish an “installation log” torecord dates and time, and data such as oil reservoirs changing data,quantity of oil, type and make; base level setting; coupling alignment(see the Coupling Alignment Data Sheet, page 2-7); and machine andcontrol checks and inspections.

Shipping and packingUnless otherwise specified by the customer, Atlas Copco personnelhave not given the compressor package any special shipping prepara-tion. They followed basic procedures at the factory to protect the ma-chine against rust and corrosion in general.

All machines have been operated at the factory. Although they areshipped without oil, a film of rust-inhibiting oil remains on the partsduring shipment. Atlas Copco recommends that upon receiving thecompressor, you fill all bearing and oil reservoirs to the proper levelwith the recommended oil.

Atlas Copco has properly covered all connection openings to protectthe machine against dirt entry and damage. Do not remove thesecovers until just before connections are to be made. Check the driverfor packing spacers, shipping bolts, etc.


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Setting and levelingThe compressor has been designed and constructed such that thereare no unbalanced forces or couples at operating conditions. Thefoundation should be of adequate size and rigidity to support thecompressor. Installation guidelines follow.

• Place the compressor on sole plates or directly on a level con-crete slab.

• Use the gearbox mounting pad as a reference for leveling thebase and all other equipment.

• Measure the level of any point from the gearbox mounting pad(as shown on the outline drawing; see section 10, Drawings); itshould not exceed 16 mils/ft (1.3 mm/m).

• Bolt the compressor to the foundation to resist piping forces.

• Bolt the base pads in the two places that are provided underneaththe compressor gearbox. Allow the balance of the pads to floatfreely to allow thermal expansion. Grouting of these pads is notpermissible since it is important to allow the base to expand freely.

• Use shims to ensure a solid contact between the compressor baseand the foundation. Exercise caution when shimming and boltingso as not to distort the base.

• See the recommended bolting arrangement on the FoundationBolting drawing in section 10 of this manual.

Piping connectionsNOTE

All piping must be supported so that minimum weights and strainsare imposed on all pipe connections. The outline drawing (seesection 10 ) indicates the maximum allowable flange loadings.

Piping should be installed so that when a connection flange is brokenafter the machine has been operating and is still warm, no misalign-ment of the flanges can be seen.

Drain valvesAtlas Copco recommends that the customer install drain valves in alllow points of the piping system. Provisions (such as expansion joints,pipe hangers and supports) should be installed to compensate forthermal expansion of the piping and the compressor.

Also, automatic liquid drains must be installed on any vessel (up-stream of the compressor) that has the potential of producing conden-sate that could be ingested into the compressor.


FiltersIt is suggested that in-line screens or strainers be installed in inlet lines.

Instrument airInstrument air, supplied by the customer, is required for the inletguide vanes and the control valve. A coalescing air filter and an airpressure regulator must be provided to ensure clean, dry, controlledinstrument air for these devices. The required air pressure, unlessotherwise specified on the process and/or seal schematic drawings, isfrom a minimum 80 psig (5.62 kg/cm²) to a maximum 120 psig(8.44 kg/cm²).

Electrical connections

WARNING

Failure to properly ground this machine may cause serious injury topersonnel.

All components on the package have been pre-wired. Therefore, theonly customer wiring required is as shown on the Wiring Diagram(see section 10). Ensure that the compressor is properly electricallygrounded. Terminal box ground connections should be checked. Thefail-safe system should be checked to ensure all devices are function-ing properly. (See section 5, Control System.)

Lubrication system preparationNOTE

This compressor has been shipped without oil.

The lubrication system is an integral part of the compressor and hasbeen used during testing of the compressor. Therefore, all settingshave been made and checked. It is suggested these settings be re-checked before start-up. The oil sump must be filled to the level indi-cated on the sight gauge with the recommended oil (see section 3,Lubrication System). The sump is filled by removing the breather.

Coupling alignmentCheck the main drive coupling at installation and at maintenanceturnaround periods. The initial alignment should be done with bothmotor and compressor gearbox at equal temperature. At such time, thefollowing are the desired settings for angular and parallel alignment:


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Coupling alignment– continued• Angular face reading vertical and horizontal should be set

zero–zero ± 0.002 in. T.I.R. at the indicator stem.

• Vertical parallel offset should be such that the drive motor is0.006 in. T.I.R. ± 0.002 in. T.I.R. higher than the low-speedcompressor shaft.

• Horizontal parallel offset should be set zero–zero ± 0.002 in. T.I.R.

The above tolerances are to be considered the maximum allow-able for continuous safe operation between turnaround periods.

NOTE

All match marks and parts locations must be noted carefully, as partsmust be reassembled in the same manner they were disassembled tomaintain balance.

To check the coupling alignment, use the following steps.

Step Action

1. Remove the center member assembly.

2. Check the angular alignment.

• Mount a dial indicator securely to the driver coupling hub,with the extension arm toward the driven hub.

• Place the indicator stem to indicate the face of the drivenhub near the outside diameter as shown by indicator “A”on the Coupling Alignment Data Sheet.

• Set the indicator on “0” and rotate the drive hub 360°,recording indicator readings on the Coupling AlignmentData Sheet at each 90°. The horizontal and vertical varia-tion should not exceed the values stated above.

3. Check the parallel alignment.

• Place the indicator stem to indicate the outside diameter ofthe driven hub, as shown by Indicator “B” on the CouplingData Alignment Sheet.

• Rotate the driver hub 360°, recording the indicator read-ings on the Coupling Alignment Data Sheet at each 90°.The horizontal and vertical variation should not exceed thevalues stated above.

4. Adjust the alignment.

• Should either angular or parallel misalignment be greaterthan that allowed, make an adjustment to the location ofthe driver either by shims or relocation, as the case may be.

5. After final alignment and successful commissioning, dowelthe motor feet on opposite sides.


Coupling alignment data sheet

A

B

B

RL

T

D R I V E R

C O M P R E S S O R

+ -

+

-

INSPECTOR ______________________

DATE ___________________________

ANGULAR MISALIGNMENTRUNOUT INDICATOR "A"

VER HOR T R B L

PARALLEL MISALIGNMENTINDICATOR "B" RUNOUT

T R B L VER HOR


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Installation control checkMany potential problems associated with initial start-up and opera-tion of the compressor can be avoided by referring to the controldrawings and manually checking the control system. The procedurefor this check is given in section 5, Control System.

Installation pre-start checkNOTE

The compressor package has been given a full mechanical test atthe factory and, unless otherwise specified by the customer, has notreceived special packaging or shipping treatment.

After the above installation procedures have been followed, the com-pressor is ready for a pre-start check and initial start-up. Following isa list of items to be checked in preparation for start-up.

Step Action

1. Remove all loose material from the compressor, such astools, rags, loose parts, etc.

2. Check lubrication oil reservoir level. Oil should be at the fullmark on the reservoir sight gauge.

3. Fill the bearing lubrication oil reservoirs to the proper level.

4. Turn the main power switch to the OFF position.

5. Turn the auxiliary oil pump switch to the AUTO position.

6. Ensure that auxiliary power is available for the heater, auxil-iary oil pump and any other auxiliary equipment necessary.

7. Ensure that control power is available for the control circuit.

8. Rotate the compressor shaft by hand at the main drive cou-pling to ensure ease of rotation and that there is no rubbing.

9. Check the auxiliary oil pump motor rotation by turning theauxiliary oil pump switch to MANUAL.

10. Make main power available for the driver.

11. “Bump” the driver to check for proper rotation.

12. See driver instructions in the manufacturer’s information insection 11, Component Literature for further checks.

The compressor is now ready for the initial start-up. Follow the pro-cedure in section 6, Operation.


Section 3Lubrication System

IntroductionThis section contains information describing the lubrication oil system and thelubrication requirements of the compressor.


Topic Page 3-Lubrication system data ........................................................................ 3

Lubrication requirements .................................................................. 3Recommended oil ........................................................................ 3Recommended oil service interval ............................................... 3

Lubrication system description ............................................................. 4Overview........................................................................................... 4

Oil pumps..................................................................................... 4How it works ..................................................................................... 4Keeping the oil clean ........................................................................ 4Auxiliary oil pump oil leak collector ................................................ 5

How to replace the oil filter cartridge ................................................... 5Remove the used oil filter element ................................................... 5Install the new oil filter element ....................................................... 5

How to change the lubrication oil ......................................................... 6


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WARNING

Do not allow centrifugal compressors to rotate in reverse.Forces induced by gas flow into the compressor discharge cancause rotation opposite to the compressor’s intended rotationaldirection. Reverse rotation may result in severe damage.

Lubrication system dataSystem Capacity (l) ....................................................................... 358

Reservoir Capacity (l) ................................................................... 303

System Flow (l/s) ......................................................................... 1.93

Bearing Supply Pressure (bar g) ................................................... 2.07

Bearing Supply Temperature (°C) ................................................ 49.0

Bearing Drain Temperature (°C) .................................................. 65.5

Reservoir Temperature (°C) ......................................................... 60.0

Normal Filter Differential Pressure (bar) ........................................ 0.5

Filter Change Differential Pressure (bar) ...................................... 1.03

Filtration (microns) ....................................................................... 10.0

Coolant Flow (l/s) ........................................................................ 1.58

Coolant Supply Pressure (bar g) .......................................... 10.3 max.

Coolant Supply Temperature (°C) ..................... 19.9 min. / 27.9 max.

Lubrication requirements

Recommended oilDesigned specifically to meet the unique requirements of Atlas Copcocentrifugal compressors, Roto-H Plus* (part # 1420171909) is thelubricant recommended for optimum performance. To order Roto-HPlus or to ask about using lubricant other than Roto-H Plus, contactAtlas Copco Comptec customer support at 1-800-334-1237.

Recommended oil service intervalRoto-H Plus lubricant has an expected minimum service life of 16,000running hours or 24 months (whichever comes first). Service life is afunction of unit loading condition and operating environment. Con-duct an oil analysis at 6-month intervals, minimum. Of primary con-cern are loss of additive package, increases in TAN, and buildup ofoxidation by-products/contaminants with particle sizes smaller thanthe filtration system is capable of removing.

See section 11, Component Literature for driver and coupling lubri-cation requirements.xxxxxxxx* Detailed specifications and MSDS information are available on request.


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Lubrication system description

OverviewThe lubrication system is wholly contained on the compressor pack-age and supplies lubrication to the bearings and gears. The oil reser-voir is fabricated as part of the compressor base with baffling toprevent foaming and is of sufficient size for a minimum of 5 minutesretention time. The bottom is sloped toward the drain at the edge ofthe base. The tank is equipped with a breather fill pipe, cleanoutcover, and oil level sight glass with dial thermometer.

Oil pumpsThe main and auxiliary oil pumps are both positive displacementpumps. The main lubrication system oil pump is driven by the maindrive motor. The auxiliary lubrication system oil pump is driven by aseparate electric motor that assures full system lubrication oil pres-sure during initial start-up and maintains oil pressure until the mainoil pump is operable. If system oil pressure drops to a preset level,the auxiliary pump activates automatically and provides additionalpressure. A one-way check valve is provided to prevent flow reversalthrough the auxiliary oil pump.

How it worksThe lubrication system provides cooled and filtered light oil to thebearings and the gear mesh through a spray tube. Oil pressure to thebearings and gears is normally maintained by a piston-type pressurerelief valve that returns the surplus flow to the oil sump. The oilreturns by gravity to the main sump in the base. The pressurized oilfrom the oil pump discharge is circulated through a heat exchangerand oil filter before entering the supply manifold. A thermostaticmixing valve will mix the oil from the pump and the cooler to main-tain oil temperature. During cold operating conditions, this valverestricts oil flow through the oil cooler allowing for faster warm-upof the oil. As oil temperature rises, the valve will open and allow hotoil to circulate through the cooler.

Keeping the oil cleanOil filter cartridges are made of corrugated cellulose and are thethrow-away type. An oil strainer located on the suction side of theoil pump in the oil sump protects against entry of coarse material.Pressure indicators are provided to monitor pressure differentialacross the oil filter and help indicate when filter cartridges needreplacement.


Auxiliary oil pump oil leak collector As standard practice, Atlas Copco-supplied auxiliary oil pumps(those manufactured by Imo Industries only) are equipped with aspecial oil leak collector. The purpose of this collector is to catch oilleakage from the pump shaft seal. Under normal conditions when themain oil pump is in operation, the auxiliary oil pump is off. How-ever, the oil pressure at the auxiliary oil pump can be equal to themain pump discharge pressure if check valve FV204 is leaking back-ward. Under this condition, the auxiliary pump shaft seal may leak.This leakage will be collected by the oil leak collector to protect thebase from oil leakage.

Empty the oil leak collector periodically. Under normal use, thecollector may take a few weeks to fill up. However, if the pump shaftseal is worn or damaged, the oil collector will fill very quickly. Thisis an indication that the pump shaft oil seal needs to be replaced.Contact the Atlas Copco Service Centre for replacement of this seal.

How to replace the oil filter cartridgeRefer to the oil filter drawing(s) in section 10, Drawings for partidentification.

Remove the used oil filter cartridgeFollow this procedure to remove the oil filter cartridge.

Step Action

1. Remove the top retaining bolts. The filter housing and retain-ing ring will drop away from the filter head.

2. Remove the filter element.

3. Remove excess fluid and dirt from the interior of the housing,if necessary.

Install the new oil filter cartridgeFollow this procedure to install the oil filter cartridge.

Step Action

1. Lubricate the grommets in the filter cartridge.

2. Install the compression spring in the plate.

3. Install the spring and plate in the bottom of the elementbefore installing the element in the housing.

4. Attach the housing to the filter head. Tighten the bolts evenly.Avoid pinching the O-ring.

5. Pressurize the system. Check for leaks.


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How to change the lubrication oil

WARNING

Lock out electrical immersion heaters and all power to the com-pressor before proceeding.

Follow this procedure to change the oil.

Step Action1. Remove the drain plug from the base of the compressor.2. Remove the drain plug from the oil cooler, if so equipped.3. Drain the oil filter canisters.4. If the oil is severely contaminated, external oil lines should

be drained as well.5. Replace the drain plugs. Close the drain valves and reinstall

any piping that was removed.6. Remove the inspection cover from the base and inspect the

inside of the base. Clean, if necessary.7. Replace the strainer on the oil pickup.8. Replace the inspection cover. A new gasket may be necessary.9. Change the oil filters, using the previous instructions.10. Fill the base to the full mark on the sight glass with the

proper oil by removing the vent pipe. (Refer to page 3-3,Lubrication Requirements.)

11. Circulate the oil, check for leaks and recheck the oil level.

NOTE

The oil reservoir has electric immersion heaters. Ensure heaters areturned off when no oil is covering the elements. Severe overheating,element damage and/or fire may occur if heaters are left on.


Section 4Seal System

IntroductionThis section contains information describing the seal system of the compressor.


Topic Page 4-Seal system description ......................................................................... 3Telltale breather .................................................................................... 3Mist collector ........................................................................................ 3


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Seal system descriptionThe seal system supplied by Atlas Copco is a two-step unbuffereddesign consisting of high-quality stainless steel labyrinths (as rotat-ing components) running against aluminum stationary parts.

As shown on the seal schematic, port B of each compressor stage ismanifolded and then vented to atmosphere. This ensures positivepressure in all B ports at all times and prevents oil from drawing pastthe oil seal and into the compressor housing during throttled condi-tions. Port C of each stage is also manifolded and connected with adrain from the low-speed seal and returned to the gearbox.

Telltale breatherIn the event of seal failure, a telltale breather is provided for port C ofeach stage for oil seal failure indication. The seals incorporate a split-type design to facilitate easy removal and inspection. The gear capshould be removed and the seals inspected if seal failure is suspected.

Mist collectorA mist collector is supplied in the oil reservoir to develop between1-1/2 to 2 in. W.C. (38 to 50 mm of water column) vacuum in thegearbox. While the gearbox is maintained under vacuum, the oil ormist is always carried back to the reservoir, thus preventing carry-over of oil to the compressor side.


4-4



Section 5Control System

IntroductionThis section contains information describing certain control devices that Atlas Copcohas provided with the compressor. The customer is responsible for the control system.


Topic Page 5-Control system description ................................................................... 3

Devices for control, alarm and shutdown ......................................... 3Checkout of alarm and shutdown circuits ................................ 3Compressor start pushbutton ................................................... 3Automatic shutdown ................................................................ 3Alarm and shutdown indicators ............................................... 3

Auxiliary oil pump control (M204) .................................................. 4Pump start ................................................................................ 4Pump shutdown ....................................................................... 4Pump running time................................................................... 4

Oil reservoir heaters control (X201A/B) .......................................... 4Oil mist eliminator motor control (M202) ........................................ 4

Surge ..................................................................................................... 5


5-2



Control System DescriptionThis compressor does not have a control system supplied by AtlasCopco. Therefore, the customer is responsible for the control system.To properly protect the machine from damage, it is essential that thecustomer incorporate the control functions shown on the Process andInstrumentation Diagram (P&ID) in section 10, Drawings.

NOTE

Failure to monitor any of the alarm or shutdown conditions identi-fied on the P&ID could affect the machine warranty.

The control system should automatically control the lubricating oilsystem and should allow the compressor to start or continue operat-ing only when certain key machine parameters are within acceptablelimits. If any monitored parameter exceeds its setpoint, the controlsystem should indicate the exceeded parameter. If the exceeded pa-rameter is critical, the compressor should shut down automatically.

Devices for control, alarm and shutdownThe P&ID identifies all of the devices Atlas Copco has provided withthe compressor, including specific devices for control, alarm andshutdown. Included in the table are the setpoints for each device. Thesedevices must be connected to the customer-supplied control system.

Checkout of alarm and shutdown circuitsPrior to machine start-up, manually check the electrical control system.

WARNING

A qualified person familiar with this type of control equipment mustperform this checkout. Follow industry-standard safety procedures.

Compressor start pushbuttonPressing the Start button on the customer control system will start thecompressor only when all shutdown interlocks and start permissiveshave been satisfied.

Automatic shutdownThe customer-supplied control system must monitor compressor opera-tion and automatically shut down the compressor at preset conditions.Refer to the P&ID in section 10, Drawings for the shutdown condi-tions that the control system must monitor.

Alarm and shutdown indicatorsFor each parameter monitored, a separate display or indicator is to beused for each alarm and/or shutdown condition. Alarms and shut-downs must have first-out conditions.


5-4

Auxiliary oil pump control (M204)The following identifies the functions of the Atlas Copco-suppliedauxiliary oil pump control.

Pump startThe pump must start automatically when:

• The compressor is running and gearbox oil supply pressure(PT230) falls below 23 psig (1.59 barg), as indicated by a low-oil-pressure alarm.

• The compressor is coasting down after being stopped manuallyor after automatic shutdown and the supply pressure falls below15 psig (1.03 barg).

Pump shutdownThe pump must shut down automatically when gearbox oil supplypressure (PT230) reaches 34 psig (2.20 barg).

Pump running timeThe pump must run for a minimum of 60 minutes after compressorshutdown. It will stop automatically after running for 60 minutes whenthe auxiliary oil pump selector switch is in the Standby position.

NOTE

The auxiliary oil pump selector switch is located on the customermotor control center (MCC).

The pump must run and remain running during a compressor reverserotation condition. If the compressor discharge pressure does not fallbelow 15 psig (1.03 barg) after the compressor is shut down, the dis-charge check valve is leaking, and a reverse rotation condition is pos-sible. As long as this condition exists, the pump must not shut down.

CAUTION

Do not restart the compressor under the reverse rotation condition.

Oil reservoir heaters control (X201A/B)The oil heaters should be controlled in accordance with the setpointsshown on the P&ID in section 10.

To prevent energizing the heater without oil in the reservoir, theheater should be interlocked with the low-oil-level switch.

Oil mist eliminator motor control (M202)The compressor oil reservoir is equipped with a motor-driven oil mistseparator. The oil mist separator must be run whenever the auxiliaryor main oil pump is running.


SurgeSurge is an unstable operating condition that can cause structuraldamage to compressor rotor blades. Surge is characterized by rhyth-mic fluctuations of discharge pressure; typically, a pulse time ofbetween 0.25 and 5 seconds.

Several conditions can cause surge: for example, a momentary dis-charge spike beyond the response time of the valves or poorly ad-justed controls. Surge can be sensed by a rapid drop in dischargepressure or motor current, followed by a rise. If the control systemdetects a surge, the compressor should unload automatically andremain unloaded until the cause of surge is determined.

WARNING

Do not operate this machine under surge conditions.


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Section 6Operation

IntroductionThis section contains information describing compressor operation, including start-up, shutdown, physical inspection and troubleshooting.


Topic Page 6-Initial compressor start-up instructions ................................................. 3

Check list for initial compressor start-up .......................................... 3Process cooler start-up ...................................................................... 4

Thermal shock danger .................................................................. 4Heat exchanger shutdown ............................................................ 4Performance ................................................................................. 4

Normal compressor start-up/shutdown ................................................. 5Preparation for start-up ..................................................................... 5Start-up ............................................................................................. 6Shutdown .......................................................................................... 6

Automatic compressor shutdown .......................................................... 7Operation record ................................................................................... 7Compressor care .................................................................................... 7

Parts replacement .............................................................................. 7Spare parts ........................................................................................ 7Routine maintenance ......................................................................... 8Testing devices ................................................................................. 8Condensate removal .......................................................................... 8Alignment and balance checks.......................................................... 8

Maintenance minimum inspection requirements .................................. 9Compressor trouble analysis ................................................................ 13


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Initial compressor start-up instructionsThe following sequence is the recommended operation procedure tobe followed to avoid possible damage to the compressor during ini-tial start-up.

• Install a cone-type strainer upstream of the compressor. Thepurpose of the strainer is to protect the compressor from anyforeign objects that may be in the pipeline. Before initial start-up,blow out the piping with air to prevent the strainer from pluggingduring start-up.

• Check compressor controls as described in section 5. Followingcheckout, the compressor may be started using the normal start-up procedure.

• Supply dry, clean, regulated air as specified on the processschematic drawing for the inlet guide vanes and for all thecontrol valves. Also, the seal gas (nitrogen and/or other gases) mustbe clean, dry and filtered for units with seal gas requirements.

NOTE

Customers must supply air line filters on all instrument air lines,ensuring clean and dry air to the instruments.

Check list for initial compressor start-upBefore start-up, check that:

• All loose materials are removed from the unit; for example, tools,rags, and loose parts.

• All inlet and discharge piping is fully clean and that expansionjoints and the piping arrangement meet the requirements shownon the process schematic.

• Lubricating oil in the oil reservoir is at the full mark on thereservoir sight gauge.

• Motor bearing lubricating oil, if used, is at the proper level in itsreservoir(s).

• All power circuits for the main driver, oil heater, auxiliary oilpump and other auxiliary equipment, as necessary, are connectedand available to the compressor control panels.

• The main drive shaft at the coupling does not rub and rotateseasily (use strap wrench to rotate the shaft by hand, counter-clockwise).

• Main driver rotation is in the proper direction. This is achievedby uncoupling the driver, “bumping” the driver to check rotation,and then re-coupling the driver.

• Dry, clean instrument air is available and regulators are set attheir proper settings.


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• Purge air (if applicable) is available at the control panel and thatpurge pressure is set at the specified requirements shown on theprocess schematic.

• All instrument block valve positions are set as per process, sealand lube oil schematics (open or closed as shown).

• All piping, compressor casings and intercoolers (gas sides) aredry and free of all liquid. Refer to the Process cooler start-upsection below.

• Cooling water is available to the oil cooler, intercoolers andaftercooler, as applicable.

• The auxiliary oil pump motor rotates in the proper direction.

Process cooler start-upFollow these instructions to prepare for a compressor start-up.

Step Action

1. Check the system for cleanliness. Protective screens orstrainers in piping are recommended.

2. Open vent valves before admitting fluid to heat exchanger.

3. Check all flange bolting for tightness.

4. Start the flow of fluids gradually, introducing colder fluidfirst. When the system is completely filled and all air isvented, close the vent valves.

5. When operating temperatures are reached, bolting and packedjoints should be retightened to prevent leaks and gasket failures.

6. The heat exchanger should never be operated at pressures,temperatures or flows greater than those specified on thenameplate and design specification sheet.

Thermal shock dangerTake extreme caution to avoid subjecting the heat exchanger to ther-mal shock, excessive pressures, and temperatures. These conditionscan impose stresses resulting in premature failure of heat exchangerparts and other components in the system.

Heat exchanger shutdownHeat exchangers with removable tube bundles may be shut down bygradually reducing the flow of the hot medium and then the coldmedium. Should it be necessary to stop the cold fluid, first stop thehot medium completely.

PerformanceWhen performance does not meet specified requirements, investigatethe following:


• Fouled tube surfaces resulting from sludge or scale.

• Incorrect piping connections; refer to process schematic.

• Trapped air because of improper venting or lack of vents.

• Operation at conditions other than design; check performancedata sheets.

• Bypassing or short circuiting of either medium; check passpartition gaskets, seal strips and baffle clearance.

Refer to section 11, Component Literature for detailed maintenanceinformation.

Normal compressor start-up/shutdownNOTE

Prior to starting the compressor, the oil temperature must be 90°F(32°C) or higher. If the oil temperature is below 90°F, the compres-sor will not start, and there will be a low oil temperature indicationon the compressor panel. It is recommended that the heater powerbe kept on and the auxiliary oil pump operating when the compres-sor is not in use. The electric oil heater is thermostatically con-trolled by the control system, which maintains the oil temperaturenear 100°F (37°C).

Preparation for start-up

Step Action

1. Drain the inlet piping and compressor housing of any liquidthat may have built up while the compressor was not operating.

2. Check the buffer gas supply, if applicable.

3. Power must be available to the main drive motor, auxiliaryoil pump, control panel and the compressors. Coolant to theintercoolers and the oil cooler must be available and allisolation valves to the coolant should be open.

4. Depress the Reset button to clear any alarms. If any alarmsstill exist, check the cause and clear the alarm prior to start-up.

5. Open the manual block valves on the inlet and dischargepipes of the compressor, if so equipped. Ensure that theblow-off valve or recycle valve is completely open and theinlet valve or inlet guide vanes are physically closed to theminimum position set at the factory (this can be adjusted inthe field by qualified personnel or an Atlas Copco servicetechnician).

6. Ensure that all permissives are met and that the oil reservoirtemperature is above 90°F (32°C).


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Start-up

Step Action

1. Depress the Start button to start. The auxiliary oil pumpshould turn off automatically after the compressor reachesfull operating speed.

2. After the compressor reaches full speed, verify that allmechanical conditions are within the specified limits stated insection 1, General Compressor Description.

3. Proceed to load the compressor per the description insection 5, Control System. (If the control system is suppliedby the customer, this will be noted in section 5. In this case,operation and the control system are the sole responsibilityof the customer.)

Shutdown

Step Action

1. Prior to compressor shutdown, unload the compressor inaccordance with the control system description given insection 5.

2. To shut down, press the Stop button. The auxiliary oil pumpwill come on automatically when the oil pressure dropsbelow 20 psi (1.41 kg/cm²).

3. The cooling water supply valve should be closed 30 minutesafter the compressor is shut down to provide uniform coolingof the oil system with the oil pump still running. If the cool-ing water system is equipped with return valves only, thenthese valves should be closed 30 minutes after the compres-sor is shut down.

CAUTION

At job sites where the ambient temperature can fall below thefreezing point of water (32°F/0°C), it is the responsibility ofthe customer to provide adequate freeze protection for thecoolers, cooling water lines and sensing lines for pressuretransmitters located on the compressor interstage piping. As aminimum, the coolers should be drained after the compressoris shut down during periods of ambient freezing temperatures.


Automatic compressor shutdownThe fail-safe system monitors the operation of the compressor andwill shut down the compressor at preset conditions. Refer to sec-tion 5, Control System for shutdowns monitored by the fail-safesystem. (Atlas Copco-supplied control systems will automaticallyunload the compressor at shutdown.)

NOTE

The parameters that have a high–high alarm or low–low alarm arecritical to compressor operation. If the compressor is allowed tocontinue to operate during these types of alarm, compressor dam-age is possible and compressor warranty is jeopardized. For propercompressor protection, it is recommended that the compressor beshut down immediately if any high–high or low–low alarms occur.

Operation recordIt is recommended that an operation log be established and operatingconditions recorded periodically. It is suggested that the readingsinclude inlet and discharge pressure and temperature, oil pressure andtemperature, oil filter pressure, vibration level, etc.

Record and plot the operating and mechanical data and observe anytrends. If significant deviation from original performance or me-chanical data is noticed, the deviation must be evaluated for the spe-cific cause and corrected before premature failure.

Compressor careAll disassembly, cleaning, inspection, repair and replacement can beaccomplished using standard tools and standard shop procedures,with the exception of the impeller-to-pinion attachment. This re-quires tie bolt stretch tooling, which can be purchased as an optionwith the compressor.

Parts replacementWhen a worn or damaged part needs to be replaced, refer to section 9,Bills of Material for the part number, description and quantity re-quired. Contact the Atlas Copco Parts and Service Centre and pro-vide this information along with the machine serial number andmodel number (listed on the manual cover page).

Spare partsAtlas Copco recommends that the customer stock a standard mini-mum quantity of spare parts at the compressor site to avoid extendedshutdown periods resulting from delays in obtaining parts.


6-8

Section 8, Recommended Spare Parts identifies parts that : 1) arereplaced as part of normal inspection and preventative maintenanceprocedures, or 2) are subject to deterioration or wear. These parts arealso listed on the bills of material to indicate next-higher assemblyrelationship.

When ordering spare parts, refer to section 8 for the part number,description, and quantity required. Contact the Atlas Copco Parts andService Centre and provide this information along with the machineserial number and model number (listed on the manual cover page).

Routine maintenanceAfter the compressor is placed into operation, a routine inspectionand preventative maintenance plan must be developed. The chart onthe pages that follow presents minimum inspection and preventativemaintenance standards and, as such, should be integrated with theoverall system schedule. (Unusual or unanticipated operating condi-tions may require more frequent intervals of inspection than areindicated in the chart.)

Contents of the maintenance chart are subject to change or modifica-tion without notice.

Testing devicesIn addition to the normal inspection and preventative maintenanceprocedures, it is recommended that all gauges, meters and otherindicating devices be tested periodically for accuracy.

Condensate removalProvision should be made for the periodic removal of condensatefrom the instrument air supply. In cold climates, freeze protection ora dryer should be provided to prevent possible interruption of instru-ment air lines.

Alignment and balance checksIt is recommended that the following be checked periodically.

• Shaft Misalignment—Angular (face-to-face) misalignment ofthe drive coupling (with spacer removed) should not exceed0.002 in. (0.05 mm) TIR. Parallel or rim misalignment shouldnot exceed 0.002 in. (0.05 mm) TIR. Refer to section 2, Installa-tion and the coupling manufacturer’s instructions.

• Impeller Unbalance—If the system gas (or air) is dirty, abuildup of minute particles of foreign matter on the impellers cancause unbalance, which can lead to impeller rub.

• Piping Loads—If piping loads are above the specified limits dueto expansion or contraction, the compressor or driver can bepushed out of alignment.


Maintenance Minimum Inspection Requirements

Daily

Gearbox

Check for…• Vibration or unusual noise• High bearing temperature• Low oil pressure• Oil leaks• Frayed or worn electrical cables• Damaged pressure and temperature gauges• Loose mounting bolts• Air eductor or mist eliminator system failure

Clean…• All accumulated dirt

Compressor housing, piping and impellers

Check for…• Vibration or unusual noise• System gas (or air) leakage• Damaged gauges and switches• Loose Victaulic joints


Intercoolers and aftercooler

Check for…• System gas (or air) leakage• Cooling water leakage• High cooling water temperature or fouled cooler• Damaged cooling water temperature gauges• Loose Victaulic bolts• Faulty operation of condensate traps• Plugged strainer or constant bleed valve


6-10

Daily – continued

Lube oil system

Check for…• Low oil level in reservoir• Low oil pressure• High oil temperature or fouled oil cooler• Oil leakage• Damaged gauges, switches and transmitters• Frayed or worn electrical cables• Cooling water leakage• Loose mounting bolts• Auxiliary pump operation/vibration/noise

Main drive motor or turbine

Record…• Bearing/stator temperature and vibration data if so equipped

Check for…• Erratic or noisy operation• Frayed or worn electrical cables• Overspeed or trip switches (if turbine drive)• Loose mounting bolts


Inspect…• Driver in accordance with manufacturer’s recommendations

Operating and mechanical data

Record…• Operating and mechanical data• Interstage compressor performance data• Vibration data• Oil data• Intercooler data.


Monthly

Lube Oil System

Check for…• Water or acid in oil• Dirty or clogged oil filter

Test…• Auxiliary pump motor or turbine start-up

YearlyNOTE

If performance and/or mechanical data trends indicate significantdeviation as compared to initial start-up data, conduct the yearlymaintenance procedure.

Gearbox

Inspect…• Thrust bearings and journal bearings for signs of wear if vibra-

tion trend dictates• Bull gear and pinion teeth for signs of wear and cracked or

broken teeth• Pinion shaft thrust collar for signs of wear• All seals for signs of rubbing

Check…• Rotor float

Compressor shroud housing, piping and impellers

Inspect…• Impellers and scrolls for signs of wear, corrosion, rubbing and

cracking• All housings and piping drains for foreign debris

Check…• Clearance between impellers and shroud• Impeller tie bolt nut

Clean…• Impellers with brass brush and steel wool to remove deposits of

foreign material, which may cause impeller unbalance


6-12

Yearly – continued

Intercoolers and aftercooler

Inspect and clean...• Intercooler tubes: clean tubes chemically or with rotary brush• Clean fins on air (or gas) side with air or steam as required to

remove deposits of foreign material

Test...• Cooling water for excessive concentration of treating chemicals

Lube oil system

Change...• Oil: drain, flush and refill with new oil

Inspect...• Oil cooler tube bundle

Clean...• Both oil and water sides of oil cooler

Compressor drive motor or turbine

Inspect...• Driver in accordance with manufacturer’s recommendations• Main drive coupling for signs of wear, corrosion and pitting

Check…• Main drive coupling alignment. Remove coupling spacer and

check alignment with dial indicator (see section 2, Installation)

Coupling

Repack…• Grease

Inspect…• Flexible elements and replace any worn hardware

Oil pressure gauges, transmitters, switches

Test…• All devices and calibrate as necessary

Oil temperature gauge temperature elements

Calibrate...• Remove the device from the oil system piping and calibrate as

necessary


Yearly – continued

Air pressure and temperature gauges

Calibrate...• Remove devices from compressor inlet and discharge piping

and calibrate.

Instrumentation: pressure, temperature, monitors, etc.

Calibrate...• Every six months or earlier as needed.

Compressor trouble analysisThe table on the following pages represents the recommended proce-dures for determining the cause of a malfunction in the compressorand its operating systems.

When a malfunction occurs, scan the “Trouble” column within theapplicable group (preliminary setup or operating cycle) to locate thecorrect trouble analysis step. One or more probable causes are listedtogether with the suggested remedial procedures for each step.

When problems are encountered that require repair and/or replace-ment of compressor internal parts and/or the problem is beyond theexperience of operating personnel, request assistance from the AtlasCopco Parts and Service Centre, Voorheesville, New York, or adesignated Atlas Copco service facility near your plant.

Contents of the trouble analysis table are subject to change or modifi-cation without notice.


6-14

Step Trouble Probable Cause Remedy

Defective primary power source Repair or replace primary power source as necessary

Defective circuit breaker in primary power source

Check circuit breakers in primary power source; repair or replace

Defective interconnecting cabling, or loose or broken connection

Check all connections; perform continuity check on cabling; repair or replace as necessary

Defective instrument air compressor

Repair or replace air compressor as necessary

Instrument air supply valve closed Open air supply valve

Ruptured or pinched air line Replace air line

Leaks around fittings; defective or plugged regulator

Tighten or replace fittings as necessary

Defective main lube oil pump Repair or replace pump as necessary

Clogged or leaking oil filter Clean or replace filter as necessary

Leaks around fittings Tighten or replace fittings as necessary

Broken pump coupling Replace or repair coupling as necessary

Damaged pump gear train Inspect drive, idler, pump gears

Improperly adjusted or defective regulator

Adjust or replace regulator as necessary

Compressor and driver shafts misaligned

Refer to alignment procedures in Installation Section

Worn or defective shaft coupling Replace shaft coupling

Build up on impeller Clean impeller

Unit is in or near surge Decrease discharge pressure; increase inlet pressure

Worn or defective compressor journal bearing Replace journal bearing

Damaged bull gear or pinion Replace bull gear or pinion

Defective driver Repair or replace driver as necessary

Impeller build up or erosion Inspect impeller; rebalance if necessary

4

3

2

1 Preliminary set upNo primary voltage

No instrument air pressure (or low air pressure)

Shut down due to no lube oil pressure (or low oil pressure)

Operating cycle vibration

Note: Real time analyzer to be used for frequency analysis in order to determine the actual cause of vibration. An Atlas Copco service representative can provide this assistance.



Water system not balancedBalance all coolers to design condition using intercooler return valves

Water flow to oil cooler interrupted Check cooling water system

Temperature control (Amot) valve malfunction.

Repair or replace temperature control valve

Fouled oil cooler Clean oil cooler water sideDefective auxiliary pump motor or electric starter

Repair or replace motor as necessary

Defective auxiliary lube oil pump Repair or replace motor as necessary

Grounded RTD or defective instrument Replace or repair as necessary

Lube oil system malfunctioning Same as step 6

Defective bearing Replace bearingOil cooler problem See step 5

Faulty temperature valve Perform oil cooler heat load analysis

Abnormal process conditionsCorrect excessive mole weight, high inlet pressure, intercooler fouling

Water flow to intercoolers interrupted

Check cooling water system and open necessary cooling water valve

Recirculation occurring Repair or replace eroded shroud and/or impeller

Diffuser guide vane (DGV) failure (closed)

Open DGV, check actuator, instrument air

Process Correct inlet temperature, MW and/or fouled cooler

Fouled intercooler Clean coolersInlet valve or inlet guide vanes (IGV) open too far

Throttle IGV or inlet valve to design

Motor voltage low. Check source voltage supply & correct as possible

Inlet pressure above design and IGV or inlet valve too far open.

Throttle IGV or inlet valve as necessary

Defective motor Consult your Atlas Copco service representative

Inlet temperature colder than design and IGV or inlet valve open too far

Close IGV or inlet valve

Gas mole weight higher than design

Close IGV or inlet valve or reduce mole weight

High lube oil temperature

9

Loss of lube oil pressure (or low pressure) - auxiliary pump NOT operating

High bearing temperature

High discharge air or gas temperature

High main drive current

5

6

7

8


6-16


Discharge pressure above design

Open blow off or recycle valve to reduce discharge pressure and increase flow

Inlet pressure below design Open inlet valve to increase inlet pressure

Inlet temperature too highSee cooler trouble shooting — adjust cooler to design condition

O-ring hard and brittle and will no longer seal Install minor pump repair kit

Carbon face seal scratchedInstall minor pump repair kit and check reservoir for dirt contamination

Tuning valves too fast; process varies too much

Re-tune valves for current conditions; install process stabilizer such as surge tanks if necessary

Failed positioner Repair or replace

Low instrument air pressure Provide correct air supply pressure.

Sticky valve Repair or replace

Excessive venting causing an ejector effect. Check & clear all vents.

Seal drain line plugged Check & clear drain lines, inspect seals

Excessive seal leakage Replace seals

Defective device for input or output wired to PLC

Check LED on input or output cards to see if energized; check and repair device if necessary

Bad channel on input or output module

Check LED after verifying signal; replace module if necessary

10

11

12

13

14

Surge

Note: Prolonged surging will cause catastrophic failure of compressor

Oil pump leaks from small weep hole

Control valves hunt excessively or unstable

Oil leaks from vent breather

Input or output to PLC not working properly (see section 5 of the instruction manual for PLC troubleshooting)


Section 7Maintenance

IntroductionThis section contains information describing the compressor maintenance and inspec-tion procedures.


Topic Page 7-Maintenance technician notes ............................................................... 3Device adjustments ............................................................................... 3

Vibration and rotor position monitoring ........................................... 3Probe, cable and proximitor calibration check ................................. 3Monitor gain adjustment (Bently Nevada systems only) .................. 4Alternate system calibration check (Bently Nevada systems only) .... 5

Major maintenance procedures ............................................................. 6How to remove the shroud ................................................................ 7How to remove the gear cap ............................................................. 8How to remove the high-speed bearing, seal and rotor .................... 9How to remove the low-speed bearing and gear .............................. 11

Inspection ............................................................................................. 12Impeller ............................................................................................ 12Shafts ............................................................................................... 12Gear .................................................................................................. 12Bearings ........................................................................................... 12Seals ................................................................................................. 12

Reassembly .......................................................................................... 13How to reassemble the low-speed bearing and gear ........................ 13How to reassemble the high-speed bearing and rotor ...................... 14How to reassemble the high-speed seal assembly ........................... 14How to reassemble the shroud assembly ......................................... 15How to verify rotor float and set wheel-to-shroud clearances ......... 15How to check gear mesh .................................................................. 16How to re-install the gear cap .......................................................... 17


7-2



Maintenance technician notesNOTE

Persons who will operate and/or open the unit must read the follow-ing instructions and familiarize themselves with drawings, literatureand handling techniques before operating or performing mainte-nance on an Atlas Copco centrifugal compressor. If major repairsare required, contact Atlas Copco Comptec Inc. Parts and ServiceCentre (see Preface, Receiving and Storage for address, telephoneand fax numbers).

Device adjustmentsThe switches and regulators that are provided with the compressorare preset at the factory. However, their calibration should be re-checked prior to start-up.

Vibration and rotor position monitoringThis compressor has been supplied with at least one radial displace-ment probe per high-speed shaft. These probes detect excessive vi-bration and shut down at prescribed levels to prevent extensive dam-age to the bearings and, more importantly, the gears.

As an option, axial position monitoring of the rotor(s) may also beprovided. In both cases, the same type of instruments are used.

Typically, two types of systems are provided, depending on theapplication.

• Where a separate monitor is specified, the system consists of aproximity probe, cable, proximitor (with 200 mV/mil output) anda monitor displaying either radial vibration or axial position.

• Where the vibration system is integrated into a PLC-basedcontroller, a proximity probe, cable and vibration transmitter(with a 4–20 mA output) are provided.

Probe, cable and proximitor calibration check

Step Action

1. Using the micrometer fixture on the Bently Nevada TK3wobulator, set the probe with zero gap.

2. Measure the proximitor output voltage (DC).

3. Starting at zero gap, record the gap and voltage at 0.010-in.(0.25-mm) increments until no increase in voltage occurs.


7-4

Step Action – continued

4. Plot the voltage (Y-axis) vs. probe gap (X-axis) and measurethe slope (change in Y / change in X). This gives the correctprobe/proximitor gain, which should be 200 mV/mil peak-to-peak for Bently Nevada proximitor systems, and 100 mV/milfor Metrix-based systems. (See Figure 7-1 below.)

Monitor gain adjustment (Bently Nevada systems only)

Step Action1. Using the TK3 wobulator, set the probe gap for approximately

40 mils (or approximately midway in the linear range asdetermined above). While reading the proximitor output volt-age on an oscilloscope, set the sliding mechanism so that theequivalent of 3 mils is observed (3X gain - mV/mil).

2. Adjust the gain potentiometer in the monitor so that themeter reads 3 mils.

3. Move the sliding mechanism so that a 1-mil vibration exists(repeating step 1, above).

4. Verify that the meter reads 1 mil. If not, adjust meter to zeroand repeat step 1. Repeat steps 1 and 3 until proper calibra-tion is obtained.

5. Check to see if the monitor will trip when setpoint levels areexceeded (normally 0.7 alarm and 1.0 for shutdown).

ProximitorGap (in.) output voltage0.0 -0.750.009 -0.750.030 -5.00.040 -7.00.054 -9.40.070 -13.00.084 -15.10.104 -19.50.120 -22.10.136 -22.1

Figure 7-1. Typical transducer curve


Alternate system calibration check (Bently Nevada systems only) NOTE

The procedure that follows may also apply to other monitoring sys-tems. However, discrepancies on the gain adjustment will be evident.

Should an oscilloscope not be available, the following procedure maybe used to perform a rough calibration.

Step Action1. Check settings.

• Place the dial indicator (included in the TK3) into theadjustable mount located over the vibration generator ofthe TK3. (Avoid tightening the clamping screw more thannecessary to hold the indicator.)

• Check the operation of the indicator carefully to ensurethat the clamp is not causing the indicator to bind.

• When setting the indicator, make sure it maintains constantcontact with the vibration generator disc while maintain-ing sufficient movement so that it will not “bottom out.”

2. With the power turned off, turn the vibration generator disclightly by hand and adjust the location of the dial indicatoruntil a pre-chosen peak-to-peak vibration is indicated (nor-mally, 3.0 and 1.0 mils). A pencil line may be made acrossthe cross slide to indicate these positions.

3. Remove the dial indicator and replace with the probe to becalibrated, being sure to use the same proximitor and leadlength that will be used in service. (A substitute probe, whichcan be matched to the probe in the compressor, can be usedwhen the mounted probe cannot be removed conveniently.)

4. Set the probe gap using a feeler gauge to match the probegap to be used in the compressor.

Using the TK3 wobulator, set the probe gap for approximately40 mils (or approximately midway in the linear range as de-termined in Probe, cable and proximitor calibration check ).

5. Connect 110–120 VAC power to the monitor console on theterminal strip provided.

6. Connect the proximitor cable to the monitor on the terminalstrip provided and to the proximitor terminals.

7. Connect the probe lead to the proximitor with the connectorprovided.


7-6

Alternate system calibration check (Bently Nevada systems only) – continued

Step Action

8. Note if the “OK” circuit check light on the monitor is on,indicating that the probe gap is proper and that all connec-tions are correct and voltage is being supplied to the system.If the “OK” circuitry light is not on, recheck all connectionsand adjust as required.

9. Turn on the wobulator (vibration motion generator) toapproximately the compressor speed range to be protected(or maximum).

• Observe the reading of the meter on the monitor. Themeter should read as the input vibration signal. If anyother reading exists, adjust the gain potentiometer for thatchannel to set that reading. Stop the wobulator to see thatthe meter reading returns to zero.

• Vary the speed on the wobulator for minimum (about 60rpm) to maximum (more than 10,000 rpm), observing themeter reading. The reading should remain constant, allow-ing for minor changes in either direction due to mechani-cal resonances of the wobulator structure.

• Recheck at least these two points any time that the gainsetting is changed. Lock the gain potentiometer securelyin position with the locking nut.

NOTE

Probes of different face diameters are not interchangeablewithout re-calibration of the proximitor.

Major Maintenance ProceduresPrior to attempting to perform any major maintenance on your AtlasCopco compressor, it is strongly recommended that the people whoare going to perform this work are familiar with equipment of this typeand have read these instructions and reviewed the related drawings.

The following operations are explained:• Removal procedures for:

— Shroud— Gear cap— High-speed bearing, seal and rotor— Low-speed bearing and drive gear

• Inspection• Reassembly.


WARNING

If process piping downstream of the compressor must remain pressur-ized while you are performing maintenance on the compressor, be surethat a blind flange has been installed to prevent inadvertent back-flowof process gas through the machine. Do not rely on a check valve.

Do not remove any compressor parts, including guards, shields,screens, caps, or plugs before relieving pressure from the system.Oil or gas under pressure can cause severe injury or death.

How to remove the shroud

Step Action

1. Remove inlet piping to the compressor. Remove the inletguide vane assembly, if applicable.

2. Leaving the top and bottom bolts (two total) that hold theshroud to the compressor housing in place, remove all otherbolts and lock washers. Install a sling, lifting eye or fixture tothe shroud and take up slack with a crane or hoist.

3. Place two guide pins, a minimum of 12 in. (304.8 mm) long,180° apart on the horizontal in two of the bolt holes fromwhich the bolts were removed in step 2.

4. Remove the two remaining bolts (the top and bottom bolts)that hold the shroud to the compressor housing.

5. Use the three jacking bolts in the jacking bolt holes in theshroud to separate the shroud from the compressor housing.

• Tighten the jacking bolts evenly to prevent the shroudfrom cocking in the compressor housing.

• Should a fixture not be available, install another slingbehind the flange to balance the assembly.

• Remove the shroud the rest of the way from the compres-sor housing.

• Use care to keep the shroud from tipping when it isremoved from the compressor housing. Make sure theshroud does not hit and damage the compressor impeller.

6. Place the shroud on a wood pallet or wood blocks once it hasbeen removed from the compressor. The shroud should notbe placed directly on a concrete floor, as damage can occur.

7. Do not attempt to remove the impeller from the shaft. This isan assembly; it cannot be disassembled while it is in the com-pressor. Rotor assembly removal is covered underHow to remove the high-speed bearing, seal and rotor.


7-8

How to remove the gear cap

Step Action

1. Remove the vibration probe(s) and radial probe(s):

• Unscrew the top of the screw-cover head.

• Disconnect the probe cable from the extension cable.

• Loosen the lock nut and unscrew the vibration probeassembly from the compressor.

Once the probe has been removed, protect the probe tip (itdamages easily) by wrapping it in a soft material (clean rags,soft rubber, etc.). Store the probe in a safe place.

2. Remove the end caps from the gearbox, if supplied. Theseare usually plates that are bolted across the gearbox split lineat the end of each rotor.

• Remove the bolts and lock washers that attach the caps tothe gearbox.

3. Remove any seal piping from the compressor housing thatmight interfere with gear cap removal.

• Clearly mark alignment lines so parts can be reinstalled inthe proper location during reassembly.

• Cover all openings to prevent contamination.

4. Remove the bolts and two dowel pins holding the gear cap tothe gearbox.

• Place two guide pins (usually threaded rod) at least 12 in.(304.8 mm) long in two corner bolt holes opposite eachother to prevent the gear cap from swinging until it isclear of the drive gear.

5. Rig the holes supplied in the top of the gear cap to an over-head hoist to allow a straight vertical pull.

• Use two gear cap bolts in the tapped holes in the gear capto jack the gear cap off of the bearings. When the entirebearing can be seen through the space, then the gear capcan be lifted by an overhead crane.

• Carefully remove the gear cap. Make sure it is liftedstraight up so it does not swing and damage the drive gear.

6. Place the gear cap on a wood pallet or wood blocks. Do notplace it directly on the ground or floor as the split-line sur-face may become damaged and cause future oil leaks.


How to remove the high-speed bearing, seal and rotor NOTE

The high-speed bearings are the tilting-pad type . Use cautionduring removal and replacement as pads can fall out of the bearingshell, either damaging the pads or falling into the oil sump.

If bearings are instrumented with RTDs, extreme care is required, asthe lead wires damage easily. Prior to any maintenance activities onthe bearings, disconnect and label the lead wires.

Step Action

1. Remove the upper half of the high-speed journal bearing: it isthe high-speed bearing nearest the compressor housing. Thetwo bearing halves are held together with two small screws.

• To gain access to these screws, rotate the bearing slightly,if necessary, to align the bearing and gearbox split lines.

• After removing the screws, carefully remove the upperhalf of the bearing.

— If the bearing upper half will not come off by hand, itmay be pried off using small Allen wrenches placedin the oil feed holes on the bearing outer diameter.

• Store upper half of the bearing in a safe place.

• Leave bottom half of the bearing in place.

NOTE

Do not attempt to split the bearing by using a screwdriver ora chisel as a wedge on the bearing split line. The split line isa sealing surface.

2. Remove the high-speed oil seal.

• Lift the top half off.

• Rotate the bottom half to remove it from around the shaft.

— If you must tap the lower half of the oil seal to removeit, use a soft material such as wood or plastic. Using ahard material will damage the split line of the oil seal.

3. Remove the buffer seal.

• Using the four tapped holes provided, pull the top half ofthe buffer seal towards the motor. The fit will probably bevery tight and may require making a special puller.

• For the seal to come out, the seal split line must match thegearbox split line.


7-10

How to remove the high-speed bearing, seal and rotor – continued

Step Action

3. Remove the buffer seal – continued

• Once the top half of the buffer seal has been removed,rotate the bottom half to remove it from around the rotor.

— You may need to tap the bottom half of the seal torotate it around the shaft. Use a soft material such asplastic or wood to prevent damage to the split line ofthe buffer seal.

Repeat this procedure to remove the second section of thebuffer seal.

4. Remove the high-speed journal/thrust bearing and position-ing shim.

• Remove the two small Allen-head screws holding the twohalves of the bearing together.

• Remove the top half of the bearing. The positioning shimwill remain attached to the bearing. The rotor assemblyshould now be supported only by the lower portions ofthe high-speed journal bearings.

• Use care as the rotor may tip toward the inlet due to theweight of the impeller. (If it is still installed on the pinion.)

5. Remove the rotor assembly.

• On large machines, this task is at least a two-personoperation.

— One person should support the compressor impellerfrom the inlet.

— The other person should lift the pinion from the oppo-site end and roll the lower half of the high-speed jour-nal bearing out from under the shaft.

— Then remove the rotor assembly from the inlet of thecompressor.

• Use extreme care so that seal teeth, bearing and probe areasor gears are not damaged. Scratches in these areas, espe-cially on probe surfaces, could result in expensive repairs.

6. Once the rotor assembly has been removed, store parts in asafe, dry area to prevent damage from moisture, mishandlingor process gas.


How to remove the low-speed bearing and gearIf the low-speed bearings are only to be inspected or changed, it isnot necessary to remove the drive gear.

Step Action

1. Remove the two small socket head screws holding the twohalves of the low-speed bearings together.

• Rotate the bearing so that the split line of the bearingsmatches the split line of the gearbox.

• Remove the top half of each bearing.

• Make sure each half of the bearing is marked for locationas the halves are not interchangeable.

• Remove the lower halves of the low-speed bearings bylifting the drive gear slightly. It is not necessary to lift thegear far, but just enough to take the weight off the low-speed bearings. The bottom half of the low-speed bear-ings can now be rolled out.

2. Remove the drive gear using these steps.

• Remove the upper halves of the low-speed bearings asdescribed above.

• Remove the center spacer section of the main drivecoupling.

• Put a steel rod through one of the holes drilled through thedrive gear (approximately 3/4 in. (19.1 mm) in diameter)and rig to an overhead lift. The gear can be removed withthis steel rod.

• Carefully remove the gear from the gearbox. Do not setthe gear directly on the floor. It is recommended that thegear be placed on a stand so that it is supported on thebearing journal surfaces. Protect the journal surfacesfrom damage.

3. Protect parts from dirt and moisture if the compressor willnot be reassembled immediately. Cover the parts and takeappropriate measures to protect them from damage.


7-12

InspectionDuring or after disassembly, carefully examine the parts listed belowto determine whether they can be reused or replaced.

Conduct a general inspection of all stationary parts, gearbox, com-pressor housing, shroud and diffuser prior to reassembly. Check forcracks or unusual wear.

ImpellerExamine the impeller for rubs, corrosion, erosion, water damage, orcracks.

• If there is a buildup on the impeller, clean it prior to inspection.A solvent and a wire brush are suitable to clean the impeller.

• If any metal has been removed from the impeller, rotor balancewill be affected and can lead to vibration problems. If this condi-tion occurs, return the impeller/rotor to Atlas Copco for balancing.

ShaftsInspect shafts for wear and scratches in the bearing areas.

• Carefully inspect any buildup or discoloration in the bearing areas.

• Never use an abrasive on the bearing areas to clean off buildups.

Inspect the probe areas of the high-speed shaft for scratches or dents.Any marks in these portions of the shaft will show up as vibration onthe vibration monitor, giving a false vibration reading.

GearExamine gears for unusual wear, chips, cracks or broken teeth.

BearingsCheck bearings for wear, cracks, scratches, discoloration and buildupdue to overheating.

Pay special attention to the high-speed bearings, as a high-speedbearing failure can cause severe damage to the rotating elements inthe compressor.

SealsInspect seals for rubs, split-line damage and bent labyrinth teeth.

The teeth on the buffer seal (high-speed gas seal) are on the shaft, noton the seal itself. Minor rubbing on these seals is common.

If the labyrinth teeth on the shaft are not damaged, the seal can prob-ably be reused, even if it has rubbed slightly.


ReassemblyAll clearances and other assembly specifics are shown on the gear-box/compressor housing assembly drawing.

Prior to reassembly, thoroughly clean all parts. Remove all old seal-ant from the gearbox split line using solvent, rags and a scraper.

How to reassemble the low-speed bearing and gear

Step Action

1. Place the lower half of the low-speed bearings in the bearingbores. Place oil on both the journals and thrust faces.

2. Carefully place the low-speed gear in the bearings.

3. Oil the top halves of the bearings, then install them andconnect the top and bottom halves with two small screws.

NOTE

Not all of the low-speed bearings are equipped with thesetwo screws. Bearing halves are not interchangeable.

4. Rotate bearings until the anti-rotation pin enters the slot inthe gearbox split line.

5. Make sure the bearings are pushed tightly against the gearboxby pushing the gear against one bearing, holding that bearingin place and pushing the gear against the other bearing.

6. Check the thrust clearance of the low-speed bearings bycarefully inserting feeler gauges between the thrust face ofthe bearing and the thrust face of the gear.

7. Install the low-speed oil seal using silicone grease on itsinner and outer diameters.


7-14

How to reassemble the high-speed bearing and rotor

Step Action

1. Place the lower halves of the high-speed bearings in theirbores in the compressor housing. Oil the bearings.

2. Before the rotor is put into the compressor, place the O-ringthat goes around the high-speed oil seal over the shaft. (Oncethe shaft has been installed, getting this O-ring past the drivegear is difficult.)

3. Place the rotor into the compressor through the inlet.

4. Place the rotor into the lower halves of the high-speedjournal bearings.

5. Do not install the top half of the high-speed journal bearingat this time, as space is needed to install the high-speed seals.The top halves are to be installed after the rotor clearanceshave been set and the seals have been installed, and beforethe gear cap is installed

How to reassemble the high-speed seal assembly

Step Action

1. Push the lower half of the high-speed buffer seal into theupper half of the seal area. It may be necessary to tap the sealinto place. Do not use a hard material to tap the seal; plasticor wood is recommended.

• Once the seal is in place, rotate it so that it is in the lowerportion of the seal area. Again, it may be necessary to tapit into position.

• If rotating the seal into place is difficult, lift the compres-sor end of the rotor up and down while rotating the seal.

2. To install the high-speed oil seal, place the previously in-stalled O-ring around the lower portion of the oil seal.

3. Rotate the bottom half of the seal around the shaft to locate itunder the shaft.

4. Apply a small amount of silicone sealant to the split line ofthe bottom half of the seal.

5. Install the upper portion of the oil seal, stretching the O-ringslightly. Align the upper half of the seal to the bottom half.Wipe off excess sealant at the split line.

6. Rotate seal until drain slot is at bottom dead center or, if drainslot is not present, rotate seal until the gearbox and seal splitlines are 10°–15° apart. Make sure the seal’s anti-rotation pinis in the groove machined for it in the gearbox, if so equipped.


How to reassemble the shroud assembly

Step Action

1. Make sure the shroud and diffuser have been cleaned.

2. Place the O-ring around the shroud and coat it with siliconegrease.

3. Install the shroud using the same rigging and guide pins usedearlier in this procedure.

• It may be necessary to pull the shroud in with four boltsfor the last inch of engagement.

• Tighten these bolts evenly to avoid binding.

4. Once the shroud is in place, finish installing it to the com-pressor using the remaining housing bolts.

• It is recommended that all of these bolts be coated with ananti-seize compound when they are installed to preventfuture difficulties when the shroud is removed.

How to verify rotor float and set wheel-to-shroud clearancesIf the rotor, thrust bearing or shroud have been changed, or the com-pressor housing has been removed, the wheel-to-shroud clearancewill need to be adjusted.

Step Action

1. With the shroud installed tightly and the high-speed thrustbearing positioning shim packs not installed, put a dial indica-tor on the end (nearest the motor) of the high-speed pinion.

2. Push the rotor assembly toward the shroud until the compres-sor wheel contacts the shroud. Zero the indicator. Rotate therotor in 90° intervals and record readings. Verify that thedifference among the four readings is 0 to 0.003 in. (0 to0.076 mm). If the difference is greater, contact the AtlasCopco Parts and Service Centre.

3. Pull the rotor assembly back toward the motor to the desiredshroud clearance value.

4. Move the journal thrust bearing axially until the main thrustbearing contacts the thrust surface on the rotor.

5. Measure the width of the slot in the gearbox that holds thebearing shims. Measure the thickness of the thrust flange onthe bearing. The difference between these two measurementsis the total shim pack thickness.


7-16

How to verify rotor float and set wheel-to-shroud clearances – continued

Step Action

6. Measure the gap between the flange on the thrust bearingtoward the impeller and the gearbox. Install the proper-thickness shims in this location.

7. Install shims from the high-speed positioning shim packbetween the bearing flange and the gearbox.

8. Push the rotor towards the shroud as far as it will go. Thebearing should hit the shim before the wheel hits the shroud.

9. The reading on the indicator will be the wheel-to-shroudclearance. Record this reading.

10. Once the proper clearance has been obtained, install shimson the opposite side of the bearing flange to hold the bearingin place. (The thickness of these shims should be the differ-ence between the total shim pack thickness and those alreadyinstalled in step 6.)

11. Remove the shim and push the rotor forward toward theshroud to make sure the indicator returns to zero. If the indi-cator does not return to zero, repeat steps 1–11 until it does.

12. Reinstall shims.

13. Check the high-speed thrust bearing clearance with shimsinstalled.

How to check gear mesh

Step Action

1. After both the pinion and drive gear have been installed, visu-ally check to make sure the two gears are aligned properly

• The teeth of the two gears should have a minimum of90% contact between them. For example, if the gears are3 in. (76.2 mm) wide, at least 2.7 in. (68.6 mm) of thegears must be in contact.

Incorrect contact is usually caused by foreign matter thatis trapped between the bearings and bearing bores.

2. If one or both gears have been changed, check the backlashof the gears in four places.

The backlash will normally be 0.010 to 0.025 in. (0.25 to0.64 mm). If it is not, contact the Atlas Copco Parts andService Centre for advice.


How to re-install the gear cap NOTE

Prior to installing the gear cap, make sure:

• All bearings and seals have been positioned properly so thattheir anti-rotation pins are in the slots machined for them in thelower half of the gearbox

• Both gearbox split-line surfaces have been cleaned properly .

• The O-ring seal is fully in place wherever an O-ring groove existson the split line (the area where the gear cap and compressorhousing join).

— To prevent leakage at the corner where the gear cap andcompressor housing intersect with the gearbox, a thin beadof silicone sealant may be applied.

CAUTION

Do not apply any silicone sealant in the vicinity of the bear-ings where it can potentially be squeezed out into the bearingfeed grooves.

• The gear cap will not damage or pinch any instrumentationwiring (as required).

Step Action

1. Carefully lower the gear cap with the same rigging that wasused to remove the cap so that it remains level and does notswing and damage the drive gear.

2. Replace the two dowel pins and the bolts holding the gearcap to the compressor housing.

3. Tighten the bolts. Start from the center of the gear cap andwork toward the outside.

4. Using a dial indicator, check the drive gear end float toensure the low-speed thrust bearings are seated properly.

• This value should agree with the previously checkedvalues, but should never be less than 0.008 in. (0.20 mm).

• Should this value be less than 0.008 in. (0.20 mm), loosenthe gear cap bolts and push the drive gear all the waytoward the compressor end. Tighten the two bolts over thecompressor-end bearings and then pull the drive geartoward the driver. Complete the bolt tightening sequenceand recheck the float. If it is still below specification,remove the gear cap and investigate.


7-18

How to re-install the gear cap – continued

Step Action

5. Replace the end cap after sealing it with gasket cement(Permatex® #3, aviation grade).

6. Replace the vibration probes that were removed earlier.When replacing these probes, be careful not to damage theprobe tips. Set the gap to the specified voltage.

7. Replace any seal piping that was removed earlier.

8. Replace process piping.


Section 8Recommended Spare Parts

IntroductionThis section provides information about parts that need replacement during normalinspection and maintenance procedures or that are subject to deterioration or wear.Each row in the parts list shows:

• drawing and/or bill of material number associated with the part• item number as it appears on the bill of material• quantity required• unit of measure• brief description• part number• usage code (E = emergency, M = maintenance, S = start-up).

OrderingTo order spare parts, contact the following with your purchase order:

Atlas Copco Comptec Inc.Parts and Service Centre46 School RoadVoorheesville, NY 12186USAPhone: (518) 765-3344Fax: (518) 765-4889

Parts listDwg/BM# Item Qty Description Part # Usage

SC23152032 005 1 ea PROXIMETERS 1420115082 E

SC23152032 006 1 ea PROX CABLE 1420112623 E

SC23152032 007 1 ea PROXIMETERS 1420115081 E

0806253024 001 93 in. GASKET MATERIALS 0806252000 E/M

1420090152 XXX 2 ea AERCOLOGY ELEMENT PRIMARY 1420090645 /M

1420090152 XXX 2 ea AERCOLOGY ELEMENT SECONDARY 1420090644 /M

1420116394 002 1 ea O-RINGS 1420050264 E/M

1420120188 XXX 2 ea OIL PUMP MINOR REPAIR KIT 1420120176 E/M

1420152231 001 2 ea O-RINGS 0800004336 E/M

1420152239 001 2 ea O-RINGS 0800004336 E/M

23152BASE 007 1 ea O-RINGS 0663937001 E/M

9455000313 027 1 ea PIPE COUPLING VICTAULIC 0634100008 E/M



8-2

Parts list – continuedDwg/BM# Item Qty Description Part # Usage



9455002256 001 2 ea GASKET STANDARD PIPE FLANGE 0420302112 E/M






9455100363 003 2 ea BEARING MODIFIED 9455105256 E/M

9455100363 012 1 ea ROTOR ASSEMBLIES 9455120242 E/M

9455100363 013 1 ea JOURNAL BEARINGS 1420010735 E/M

9455100363 014 1 ea JOURNAL BEARINGS 1420010736 E/M

9455100363 015 2 ea SHIMS, BEARINGS 0807911003 E/M

9455100363 038 1 ea O-RING FABRICATED 0806253024 E/M

9455100363 043 1 ea O-RINGS 0800001760 E/M

9455100363 045 10 ea O-RINGS 1420050332 E/M

9455100363 046 100 in. GASKET MATERIALS 0800001238 E/M

9455100364 002 1 ea SEAL BUFFER GAS MFG 9455102332 E/M

9455100364 004 1 ea SEAL BUFFER GAS MFG 9455106155 E/M

9455100364 005 1 ea SEAL OIL MFG 9455105857 E/M

9455100364 007 1 ea O-RINGS 0800001313 E/M

9455105747 002 2 ea BEARING ROLLING ELEMENT 0502109032 E/M

9455105747 008 1 ea O-RINGS 0800001761 E/M

9455106047 003 2 ea O-RINGS 0800000499 E/M

9455106055 001 1 ea PROBES AND PICK-UPS 1420112622 E/M

9455106142 001 1 ea SEAL OIL MFG 9455105383 E/M

9455106142 002 1 ea SEAL OIL PURCHASED 0808253002 E/M

9455106151 003 1 ea O-RINGS 1420051012 E/M

9455106152 001 1 ea PROBES AND PICK-UPS 1420112622 E/M

9455200200 007 1 ea RTDs 1420115758 E

9455200200 022 1 ea TRANSDUCER, TRANSMITTER 1420116698 E



9455221195 006 2 ea BEARING ROLLING ELEMENT 0502109032 E/M

9455221218 009 2 ea COUPLING PARTS 15HP LESS PUMP COUP 1320708225 E/M

9455222015 XXX 6 ea OIL FILTER ELEMENT 1320707710 E/M/S

9455225375 001 1 ea SWITCH LEVEL 1420115595 E


Section 9Bills of Material

IntroductionThis section provides the bills of material for each main assembly of the compressor.Each bill shows the assembly parts with a complete part number, description andquantity. If the corresponding drawing number is different, it is displayed in paren-theses following the description.

Bills of material listB/M # Description

ACC0423152 Top Level Bill of Material

SC23152030 Enclosure Assembly, 24 Volt

SC23152031 Enclosure Assembly, Analog

SC23152032 Enclosure Assembly, Vibration/RTD


SC23152089 Spare Parts Bill of Material

SC23152090 Ship Loose Bill of Material

SC23152093 Ship Loose Dismounted Parts Bill of Material

9455000313 Process Piping and Valving Assembly

9455007748 Aercology Mounting Assembly

9455007773 Cooling Water Manifold Assembly

9455022482 Lube Oil Assembly

9455100363 Core Unit Assembly

9455120242 Rotor Assembly

9455190208 Tool Assembly, Wheel Puller

9455200200 Control Assembly

9455221195 Pump Package Assembly, Main (dwg 9455221188)

9455221218 Pump Package Assembly, Auxiliary (dwg 9455221187)


9-2


ACCSLB ATLAS COPCO COMPRESSORS INC. SINGLE LEVEL BILL OF MATERIAL DATE 20050419 PAGE 1

COMPONENT - ACC0423152 BOM. REV. BOM. ECN. BOM. DATE 00000000 STATUS DRAWING # - DRW. REV. DRW. ECN. DRW. DATE

DESCRIPTION BM T/L SC-14 60 HZ AIR PRODUCTS

ITEM SUB-COMPONENT DESCRIPTION QUANTITY UM PSM TEXT 001 SC23152090 BM S/L SC14 SALES ORDER # 1.00 EA M N 002 SC23152087DRW REFERENCE DRAWINGS .00 EA P N 003 SC23152089 BM SPARES SC14 SALES ORDER # 1.00 EA M N 004 SC23152093 BM S/L SC14 SALES ORDER # .00 EA M N 999 23152PREP MISC. ASSEMBLIES 1.00 EA M N


COMPONENT - SC23152030 BOM. REV. 0 BOM. ECN. BOM. DATE 00000000 STATUS DRAWING # - SC23152030 DRW. REV. 0 DRW. ECN. DRW. DATE 00000000

DESCRIPTION ENCL ASSY 24 VOLT

ITEM SUB-COMPONENT DESCRIPTION QUANTITY UM PSM TEXT 001 9711165605 ELECT ENCLOSURE NEMA4 1.00 EA P N 002 9711165606 PANEL ELECT ENCLOSURE 1.00 EA P N 003 1311003986 ELECT TERMINAL BOARD ACCESSORI 2.00 FT S N 004 1420111452 ELECT MOUNTING HARDWARE 2.00 EA S N 005 1311003984 ELECT TERMINAL BLOCK 25.00 EA S N 006 1420110373 FUSE AND CIRCUIT BREAKER ACCES 1.00 EA S N 007 1420114773 ELECT TIES 2.60 FT S N 008 1420112696 ELECT TIES 2.60 FT S N



DESCRIPTION ENCL ASSY ANALOG

ITEM SUB-COMPONENT DESCRIPTION QUANTITY UM PSM TEXT 001 9711165605 ELECT ENCLOSURE NEMA4 1.00 EA P N 002 9711165606 PANEL ELECT ENCLOSURE 1.00 EA P N 003 1311003986 ELECT TERMINAL BOARD ACCESSORI 2.00 FT S N 004 1420111452 ELECT MOUNTING HARDWARE 2.00 EA S N 005 1311003984 ELECT TERMINAL BLOCK 25.00 EA S N 006 1420110373 FUSE AND CIRCUIT BREAKER ACCES 1.00 EA S N 007 1420114773 ELECT TIES 2.60 FT S N 008 1420112696 ELECT TIES 2.60 FT S N


COMPONENT - SC23152032 BOM. REV. 2 BOM. ECN. 36219 BOM. DATE 20050315 STATUS DRAWING # - SC23152032 DRW. REV. 1 DRW. ECN. 36063 DRW. DATE 20050210

DESCRIPTION ENCL ASSY VIBRATION/RTD

ITEM SUB-COMPONENT DESCRIPTION QUANTITY UM PSM TEXT 001 1420111887 ELECT ENCLOSURE NEMA4 1.00 EA P N 002 1420111888 PANEL ELECT ENCLOSURE 1.00 EA P N 003 1420113545 ELECT TIES 2.00 FT S N 004 1420112698 ELECT TIES 2.00 FT S N 005 1420115082 PROXIMETERS 1.00 EA S N 006 1420112623 PROX CABLE 2.00 EA S N 007 1420115081 PROXIMETERS 1.00 EA P N 008 0801464000 ELECT ACCESSORIES (HOLE SEALS, 4.00 EA S N 009 1420114773 ELECT TIES 6.00 FT S N 010 1420112696 ELECT TIES 6.00 FT S N 011 1311003986 ELECT TERMINAL BOARD ACCESSORI 3.00 FT S N 012 1420111452 ELECT MOUNTING HARDWARE 4.00 EA S N 013 1311003984 ELECT TERMINAL BLOCK 36.00 EA S N 014 1420110373 FUSE AND CIRCUIT BREAKER ACCES 1.00 EA S N 015 1420116784 TRANSDUCER,TRANSMITTER 1.00 EA P N 016 1420116786 TRANSDUCER,TRANSMITTER 1.00 EA P N 017 1420116785 TRANSDUCER,TRANSMITTER 1.00 EA P N 018 1420116787 TRANSDUCER,TRANSMITTER 1.00 EA P N 019 1420116788 TRANSDUCER,TRANSMITTER 1.00 EA P N 020 1420110369 ELECT TERMINAL BLOCK 5.00 EA S N



DESCRIPTION ENCL ASSY 120V

ITEM SUB-COMPONENT DESCRIPTION QUANTITY UM PSM TEXT 001 0800065000 ELECT ENCLOSURE NEMA4 1.00 EA P N 002 1420111091 PANEL ELECT ENCLOSURE 1.00 EA P N 003 1311003986 ELECT TERMINAL BOARD ACCESSORI .50 FT S N 004 1311003984 ELECT TERMINAL BLOCK 5.00 EA S N 005 1420110373 FUSE AND CIRCUIT BREAKER ACCES 1.00 EA S N 006 1420111452 ELECT MOUNTING HARDWARE 2.00 EA S N


COMPONENT - SC23152089 BOM. REV. 0 BOM. ECN. BOM. DATE 00000000 STATUS DRAWING # - DRW. REV. 0 DRW. ECN. DRW. DATE 00000000

DESCRIPTION BM SPARE PARTS SC-23152

ITEM SUB-COMPONENT DESCRIPTION QUANTITY UM PSM TEXT 001 0420302016 GSKT STANDARD PIPE FLANGE 2.00 EA S N 002 0420302114 GSKT STANDARD PIPE FLANGE 2.00 EA S N 003 1320707710 FILTER PARTS (ELEMENTS, ORINGS 2.00 EA S N 004 0806253024 O-RING FABRICATED 1.00 EA M N


COMPONENT - SC23152090 BOM. REV. 0 BOM. ECN. BOM. DATE 00000000 STATUS DRAWING # - DRW. REV. 0 DRW. ECN. DRW. DATE 00000000

DESCRIPTION BM S/L SC-14 SC-23152 AIR PRODUCTS

ITEM SUB-COMPONENT DESCRIPTION QUANTITY UM PSM TEXT 001 SC23152001DRW REFERENCE DRAWINGS .00 EA P N 002 SC23152015DRW REFERENCE DRAWINGS .00 EA P N 003 SC23152062DRW REFERENCE DRAWINGS .00 EA P N 004 SC23152085DRW REFERENCE DRAWINGS .00 EA P N 005 SC23152086DRW REFERENCE DRAWINGS .00 EA P N 006 1420030052 SCREW HEX HEAD 12.00 EA S N


COMPONENT - SC23152093 BOM. REV. 0 BOM. ECN. BOM. DATE 00000000 STATUS DRAWING # - DRW. REV. DRW. ECN. DRW. DATE

DESCRIPTION BM S/L DISMOUNTED PARTS SC-14 SC-23152 AIR PRODUCT

ITEM SUB-COMPONENT DESCRIPTION QUANTITY UM PSM TEXT 001 9455007773 MISC. ASSEMBLIES 1.00 EA M N


COMPONENT - 9455000313 BOM. REV. 3 BOM. ECN. 36202 BOM. DATE 20050308 STATUS DRAWING # - 9455000313 DRW. REV. 3 DRW. ECN. 36202 DRW. DATE 20050308

DESCRIPTION PROCESS PIPING & VALVE ASSY- SC-23152 AIR PRODUCTS

ITEM SUB-COMPONENT DESCRIPTION QUANTITY UM PSM TEXT 001 1420153057 VALVE ASSEMBLY 1.00 EA P N 002 1420153058 VALVE ASSEMBLY 1.00 EA P N 003 1420153059 VALVE ASSEMBLY 1.00 EA P N 004 1420153060 VALVE CHECK 1.00 EA P N 005 1420151226 VALVE BALL 2.00 EA P N 006 1420150529 VALVE BALL 2.00 EA P N 007 1420152700 VALVE MISCELLANEOUS 1.00 EA P N 008 1420081603 HEAT EXCH TEMA C FLANGES 1.00 EA P N 009 1420091420 STRAINERS ALL 1.00 EA P N 010 9455007760 PIPE AND TUBE ASSEMBLY 1.00 EA P N 011 9455007761 PIPE AND TUBE ASSEMBLY 1.00 EA P N 012 9455007762 PIPE AND TUBE ASSEMBLY 1.00 EA P N 013 9455007763 PIPE AND TUBE ASSEMBLY 1.00 EA P N 014 9455007764 PIPE AND TUBE ASSEMBLY 1.00 EA P N 015 9455007765 PIPE AND TUBE ASSEMBLY 1.00 EA P N 016 9455007766 PIPE AND TUBE ASSEMBLY 1.00 EA P N 017 9455007767 PIPE AND TUBE ASSEMBLY 1.00 EA P N 018 9455007768 PIPE AND TUBE ASSEMBLY 1.00 EA P N 019 9455007769 PIPE AND TUBE ASSEMBLY 1.00 EA P N 020 9455007770 PIPE AND TUBE ASSEMBLY 1.00 EA P N 025 1320709723 PIPE CPLG VICTAULIC 1.00 EA P N 026 1420046093 PIPE CPLG VICTAULIC 1.00 EA P N 027 0634100008 PIPE CPLG VICTAULIC 1.00 EA S N 028 1420043026 PIPE CPLG VICTAULIC 1.00 EA S N 029 0634100006 PIPE CPLG VICTAULIC 1.00 EA S N 030 1420041582 PIPE CPLG VICTAULIC 1.00 EA S N 031 0634100005 PIPE CPLG VICTAULIC 1.00 EA S N 032 1420041581 PIPE CPLG VICTAULIC 1.00 EA P N 033 9455007755 FLANGE BOLTING ASSEMBLIES 2.00 EA M N 034 9455007754 FLANGE BOLTING ASSEMBLIES 2.00 EA M N 035 9455007756 FLANGE BOLTING ASSEMBLIES 1.00 EA M N 036 0420302116 GSKT STANDARD PIPE FLANGE 1.00 EA P N 037 9455007367 FLANGE BOLTING ASSEMBLIES 1.00 EA M N 038 9455002258 FLANGE BOLTING ASSEMBLIES 1.00 EA M N 039 9455002259 FLANGE BOLTING ASSEMBLIES 2.00 EA M N 040 9455007757 FLANGE BOLTING ASSEMBLIES 2.00 EA M N 041 9455007758 FLANGE BOLTING ASSEMBLIES 1.00 EA M N 042 9455002256 FLANGE BOLTING ASSEMBLIES 2.00 EA M N 043 1420040272 PIPE WELD FLANGE 1.00 EA P N 044 1420041590 PIPE WELD FLANGE 1.00 EA P N 045 1420044903 TUBE FIT CONNECTOR MALE 1.00 EA P N 046 1420044556 TUBE FIT MALE TUBE ADAPTER 1.00 EA S N 047 1420044336 TUBE FIT ELBOW UNION 1.00 EA S N 048 1420170588 TUBING, ROUND 10.00 FT S N 049 0800690000 PIPE NIPPLES 2.00 EA S N



DESCRIPTION PROCESS PIPING & VALVE ASSY- SC-23152 AIR PRODUCTS

ITEM SUB-COMPONENT DESCRIPTION QUANTITY UM PSM TEXT 050 3455040006 PIPE PLUGS 2.00 EA S N 051 1420040923 PIPE NIPPLES 2.00 EA S N 052 0420095104 PIPE PLUGS 2.00 EA S N 055 0144349403 SCREW HEX HEAD 4.00 EA S N 056 0800003080 NUT HEX 4.00 EA S N 057 0801935000 WASHER LOCK SPLIT 4.00 EA S N 058 1420031166 WASHER FLAT 4.00 EA S N 059 9455007759 SUPPORTS, PIPING 2.00 EA P N 060 1420180608 HANGER, STANCHION, SADDLE 2.00 EA P N 061 0800003029 THREADED ROD 36.00 IN S N 062 1420031204 NUT LOCK 6.00 EA P N 063 0801283000 SCREW HEX HEAD 6.00 EA S N 064 1420030144 NUT HEX 6.00 EA S N 065 1420030118 WASHER LOCK SPLIT 6.00 EA S N 066 9455001319 SUPPORTS, PIPING 2.00 EA P N 067 9455001320 SUPPORTS, PIPING 2.00 EA P N 068 0801275000 SCREW HEX HEAD 8.00 EA S N 069 1420030118 WASHER LOCK SPLIT 8.00 EA S N 070 1420170092 STRUCTURAL TUBING SQ,RECT 36.00 IN S N 071 0800000423 STRUCTURAL ANGLES 16.00 IN S N 072 0804679000 STRUCTURAL TUBING SQ,RECT 24.00 IN S N 073 1311003222 PIPE WELD FLANGE 1.00 EA S N 074 9455002239 FLANGE BOLTING ASSEMBLIES 1.00 EA M N 075 0800000894 PIPE NIPPLES 1.00 EA S N 076 1420042237 PIPE FIT ELBOW 90 DEG 1.00 EA S N 077 0420095109 PIPE PLUGS 1.00 EA S N 078 1420041436 PIPE FIT UNION 1.00 EA S N 079 1420170967 PIPE NIPPLES 2.00 EA S N 080 0800002383 VALVE GATE 1.00 EA P N


COMPONENT - 9455007748 BOM. REV. 0 BOM. ECN. BOM. DATE 00000000 STATUS DRAWING # - 9455007748 DRW. REV. 0 DRW. ECN. DRW. DATE 00000000

DESCRIPTION AERCOLOGY MTG ASSY W/SEP DRAINS SC-23152

ITEM SUB-COMPONENT DESCRIPTION QUANTITY UM PSM TEXT 001 1420090152 BREATHERS ALL 1.00 EA P N 002 1420040642 PIPE FIT REDUCERS 1.00 EA S N 003 1420042237 PIPE FIT ELBOW 90 DEG 4.00 EA S N 004 1420170244 PIPE 108.00 IN S N 005 0606311528 PIPE NIPPLES 1.00 EA P N 006 0800738000 PIPE NIPPLES 1.00 EA S N 007 1420042381 PIPE NIPPLES 3.00 EA M N 008 1420170724 STRUCTURAL ANGLES 18.00 IN S N 010 1420041091 HOSE 8.00 IN S N 011 0800005110 CLAMPS, CLIPS 4.00 EA P N 016 0144329000 SCREW HEX HEAD 4.00 EA S N 017 1420030116 NUT HEX 4.00 EA S N 018 1420030117 WASHER LOCK SPLIT 4.00 EA S N 019 1420030065 WASHER FLAT 4.00 EA S N 020 0420064105 TUBE FIT CONNECTOR FEMALE 1.00 EA S N 021 1420170593 TUBING, ROUND 120.00 IN S N 022 1420044913 TUBE FIT CONNECTOR O-RING SEAL 1.00 EA S N 023 1420043973 TUBE FIT CONNECTOR FEMALE 1.00 EA P N 024 1420046615 SERVICE PARTS 1.00 EA P N 025 1420044947 TUBE FIT REDUCER 1.00 EA P N 026 1420170588 TUBING, ROUND 10.00 FT S N



DESCRIPTION COOLING WATER MANIFOLD ASSY SC-23152 AIR PRODUCTS

ITEM SUB-COMPONENT DESCRIPTION QUANTITY UM PSM TEXT 001 1420150588 VALVE GATE 1.00 EA M N 002 1420150965 VALVE GATE 2.00 EA S N 003 9455007774 LUBE OIL PANEL ASSEMBLY AND OP 2.00 EA P N 004 9455002241 FLANGE BOLTING ASSEMBLIES 3.00 EA M N 005 9455002234 FLANGE BOLTING ASSEMBLIES 2.00 EA M N 006 1420130102 SIGHT AND LEVEL GAUGES 2.00 EA S N 007 1420130673 GAUGE TEMP AND THERMOMETERS 3.00 EA S N 008 1420150517 VALVE BALL 2.00 EA P N 009 1420041510 PIPE NIPPLES 2.00 EA S N 010 3455040005 PIPE PLUGS 2.00 EA S N 011 1420040853 PIPE FIT REDUCING HEX 1.00 EA S N 012 0420095109 PIPE PLUGS 1.00 EA S N 013 1420170967 PIPE NIPPLES 1.00 EA S N 014 1420042237 PIPE FIT ELBOW 90 DEG 3.00 EA S N 015 1420170244 PIPE 240.00 IN S N 016 0564000027 PIPE FIT STANDARD TEE 2.00 EA S N 017 9711160403 PIPE FIT REDUCING HEX 3.00 EA S N 018 3035009543 PIPE FIT REDUCING HEX 1.00 EA S N 019 1420170245 PIPE 120.00 IN S N 020 0800443000 PIPE FLG THREADED 2.00 EA S N 021 1420041010 PIPE FIT ELBOW 90 DEG 1.00 EA S N 022 1420042216 PIPE FIT CROSS 1.00 EA S N 023 0605830030 PIPE FIT REDUCING HEX 3.00 EA S N 024 1420041009 PIPE FIT STANDARD TEE 1.00 EA S N 025 1420170247 PIPE 48.00 IN S N 026 1420040207 PIPE FIT ELBOW 90 DEG 2.00 EA S N 027 0801807000 PIPE FIT UNION 2.00 EA P N 028 1420042669 PIPE FIT UNION 4.00 EA S N 029 1420041436 PIPE FIT UNION 4.00 EA S N



DESCRIPTION LUBE OIL ASSY SC-23152 AIR PRODUCTS

ITEM SUB-COMPONENT DESCRIPTION QUANTITY UM PSM TEXT 001 9455222016 FILTERS OIL,LIQUIDS 1.00 EA M N 002 1420152604 VALVE TEMPERATURE (THERMOSTAT) 1.00 EA P N 003 1320704145 STRAINERS ALL 1.00 EA S N 004 1420081606 HEAT EXCH TUBE AND SHELL TYPES 1.00 EA P N 005 1420152259 VALVE RELIEF (SAFETY) 1.00 EA P N 006 1420152783 VALVE RELIEF (SAFETY) 1.00 EA P N 007 1420152231 VALVE CHECK 1.00 EA P N 008 1420152239 VALVE CHECK 1.00 EA P N 009 1420130163 SIGHT AND LEVEL GAUGES 1.00 EA S N 010 1320712797 NAME PLATES 1.00 EA M N 011 1420151226 VALVE BALL 1.00 EA P N 012 0800689000 PIPE NIPPLES 1.00 EA P N 013 3455040006 PIPE PLUGS 1.00 EA S N 014 1420120244 PUMP ACCESSORIES 2.00 EA P N 015 1420120030 PUMP ACCESSORIES 1.00 EA S N 016 1420044914 TUBE FIT CONNECTOR O-RING SEAL 4.00 EA P N 017 1420120240 PUMP ACCESSORIES 2.00 EA P N 018 1420044160 TUBE FIT ELBOW UNION 1.00 EA P N 019 1420044708 TUBE FIT CONNECTOR O-RING SEAL 8.00 EA S N 020 1420046405 TUBE FIT MALE TUBE ADAPTER 6.00 EA P N 021 1420044368 TUBE FIT TEE UNION 4.00 EA S N 022 1420047812 TUBE FIT TEE UNION 1.00 EA P N 023 1420044841 TUBE FIT CONNECTOR MALE 2.00 EA S N 024 1420044559 TUBE FIT MALE TUBE ADAPTER 1.00 EA S N 025 1420041009 PIPE FIT STANDARD TEE 4.00 EA S N 026 1420040213 PIPE FIT REDUCING HEX 3.00 EA S N 027 0420096024 PIPE FIT REDUCING HEX 2.00 EA S N 028 0605830030 PIPE FIT REDUCING HEX 2.00 EA S N 029 0800720000 PIPE NIPPLES 2.00 EA S N 030 1420041459 PIPE NIPPLES 2.00 EA P N 031 1420170586 TUBING, ROUND 10.00 FT S N 032 1420170588 TUBING, ROUND 50.00 FT S N 033 1420031733 SCREW SOCKET HEAD CAP 8.00 EA S N 034 1420030358 SCREW HEX HEAD 4.00 EA S N 035 1420030116 NUT HEX 4.00 EA S N 036 1420030117 WASHER LOCK SPLIT 4.00 EA S N 037 0801283000 SCREW HEX HEAD 4.00 EA S N 038 1420030144 NUT HEX 4.00 EA S N 039 1420030118 WASHER LOCK SPLIT 4.00 EA S N 040 1420170323 BARS FLAT OR RECTANGLE 36.00 IN S N



DESCRIPTION CORE UNIT ASSY SC-14 (44/213) SC-23152

ITEM SUB-COMPONENT DESCRIPTION QUANTITY UM PSM TEXT 001 9455111403 GEARBOX FINISHED MACHINED, MOD 1.00 EA M N 002 0807722G03 GEAR DRIVE ASSEMBLIES 1.00 EA M N 003 9455105256 BEARING MODIFIED 2.00 EA M N 004 0808359001 CAPS SHAFTS 1.00 EA S N 006 9455106142 MISC. ASSEMBLIES 1.00 EA M N 009 9455221195 PUMP PACKAGE ASSEMBLY (MAIN PU 1.00 EA M N 010 9455105747 PUMP PACKAGE ASSEMBLY (MAIN PU 1.00 EA M N 012 9455120242 ROTOR ASSEMBLIES 1.00 EA M N 013 1420010735 JOURNAL BRGS 1.00 EA P N 014 1420010736 JOURNAL BRGS 1.00 EA P N 015 0807911003 SHIMS, BEARINGS 2.00 EA S N 016 0802330000 SCREW FLAT HEAD 8.00 EA S N 017 9455100364 GEARBOX AND COMPRESSOR HOUSING 1.00 EA M N 019 9455102331 SHROUD, VOLUTE FINISHED, MOD 1.00 EA M N 020 9455106151 END CAP, PROBE HOLDER FAB 1.00 EA M N 022 9455102377 DIFFUSER PLATE 1.00 EA P N 029 9455106088 MISC. ASSEMBLIES 1.00 EA M N 031 9455106047 MISC. ASSEMBLIES 1.00 EA M N 038 0806253024 O-RING FABRICATED 1.00 EA M N 043 0800001760 O-RINGS 1.00 EA S N 045 1420050332 O-RINGS 10.00 EA S N 046 0800001238 GASKET MATERIALS 100.00 IN S N 047 0144349403 SCREW HEX HEAD 18.00 EA S N 048 1420030363 SCREW HEX HEAD 2.00 EA S N 052 0804022000 SCREW DRIVE ALL 4.00 EA S N 053 1420031315 SCREW HEX HEAD 2.00 EA S N 056 1420030146 WASHER BELLEVILLE 20.00 EA S N 057 0801909000 WASHER LOCK SPLIT 2.00 EA S N 064 9455106055 MISC. ASSEMBLIES 1.00 EA M N 068 0805608000 CONDUIT OUTLET BODIES, BOXES A 1.00 EA S N 069 9455106143 MISC. ASSEMBLIES 1.00 EA M N 070 9455106147 PIPE AND TUBE ASSEMBLY 1.00 EA M N 071 1420040893 TUBE FIT CONNECTOR O-RING SEAL 1.00 EA P N 072 1420043571 TUBE FIT CONNECTOR MALE 3.00 EA S N 073 1420044346 TUBE FIT TEE UNION 1.00 EA S N 074 1320708053 TUBING, ROUND 6.00 FT S N 076 0686610401 PIPE PLUGS 3.00 EA S N 077 3455058906 PIPE PLUGS 1.00 EA S N



DESCRIPTION ROTOR ASSY SC-14 SC-23152

ITEM SUB-COMPONENT DESCRIPTION QUANTITY UM PSM TEXT 001 9455121350 IMPELLER FINISHED 1.00 EA P N 002 9455104487 PINION 1.00 EA P N 003 9455123206 TIE BOLT 1.00 EA P N 006 9455123134 NUT-ROTOR ASSEMBLY MANUFACTURE 1.00 EA M N 011 9455123332 SEAL LABYRINTH MFG 1.00 EA M N 012 0802241000 PIN DOWEL 1.00 EA S N 020 1420180096 OIL, MANUFACTURES DESIGNATION 1.00 OZ S N 030 9455190368 MISC. DRAWINGS 1.00 EA M N 040 9455190208 TOOLS ROTOR ASSY 1.00 EA M N 050 9455190095DRW REFERENCE DRAWINGS 1.00 EA P N


COMPONENT - 9455190208 BOM. REV. 1 BOM. ECN. 33795 BOM. DATE 20030812 STATUS DRAWING # - 9455190208 DRW. REV. 0 DRW. ECN. DRW. DATE 00000000

DESCRIPTION WHEEL PULLER ASSY TOOL 2.000 BC

ITEM SUB-COMPONENT DESCRIPTION QUANTITY UM PSM TEXT 001 9455190212 TOOLS ROTOR ASSY 1.00 EA M N 002 1320709712 TOOLS ROTOR ASSY 1.00 EA S N 003 0800803000 NUT HEX 3.00 EA S N 004 0806454001 THREADED ROD 2.00 FT S N



DESCRIPTION CONT ASSY SC-23152 AIR PRODUCTS

ITEM SUB-COMPONENT DESCRIPTION QUANTITY UM PSM TEXT 001 SC23152030 ELECT ENCLOSURES ASSEMBLIES 1.00 EA M N 002 SC23152031 ELECT ENCLOSURE ASSEMBLY 1.00 EA M N 003 SC23152032 ELECT ENCLOSURE ASSEMBLY 1.00 EA M N 004 SC23152033 ELECT ENCLOSURE ASSEMBLY 1.00 EA M N 005 9455002282 MISC. ASSEMBLIES 1.00 EA M N 006 9455225375 OIL LEVEL CONTROL ASSEMBLY 1.00 EA M N 007 1420115758 RTD'S 1.00 EA P N 008 1420113980 ELECT ACCESSORIES (CAP, WELLS, 1.00 EA S N 009 1420116394 MISC. ASSEMBLIES 1.00 EA M N 010 1420115759 RTD'S 1.00 EA P N 011 1420113982 ELECT ACCESSORIES (CAP, WELLS, 1.00 EA S N 012 1420130673 GAUGE TEMP AND THERMOMETERS 3.00 EA S N 013 1420130680 GAUGE TEMP AND THERMOMETERS 1.00 EA P N 014 1420130684 GAUGE TEMP AND THERMOMETERS 1.00 EA P N 015 1420130672 GAUGE PRESSURE AND DIFFERENTIA 1.00 EA P N 016 1420130808 GAUGE PRESSURE AND DIFFERENTIA 1.00 EA P N 017 1420130624 GAUGE PRESSURE AND DIFFERENTIA 2.00 EA P N 018 1420151971 VALVE SHUT-OFF 4.00 EA P N 019 1420130232 GAUGE PRESSURE AND DIFFERENTIA 1.00 EA P N 020 1420150529 VALVE BALL 2.00 EA P N 021 1420047680 VALVE BALL 4.00 EA P N 022 1420116698 TRANSDUCER,TRANSMITTER 1.00 EA P N 023 1420116696 TRANSDUCER,TRANSMITTER 1.00 EA P N 024 1420116697 TRANSDUCER,TRANSMITTER 1.00 EA P N 025 0420096033 PIPE FIT REDUCING HEX 1.00 EA S N 026 1420047930 PIPE NIPPLES 2.00 EA P N 027 1420043582 TUBE FIT CONNECTOR MALE 2.00 EA S N 028 1320708125 PIPE FIT REDUCING HEX 1.00 EA S N 029 1420040884 TUBE FIT CONNECTOR O-RING SEAL 1.00 EA S N 030 1320708053 TUBING, ROUND 50.00 FT S N 031 1420044605 TUBE FIT FEMALE TUBING ADAPTER 1.00 EA S N 032 1420043582 TUBE FIT CONNECTOR MALE 2.00 EA S N 033 1420043576 TUBE FIT CONNECTOR MALE 4.00 EA S N 034 1420043602 TUBE FIT CONNECTOR MALE 2.00 EA S N 035 0800002511 TUBING, ROUND 20.00 FT S N 036 1420044510 TUBE FIT MALE TUBE ADAPTER 2.00 EA S N 037 1420150517 VALVE BALL 4.00 EA P N 038 1420040157 PIPE NIPPLES 4.00 EA S N 039 3455040005 PIPE PLUGS 4.00 EA S N 040 1420045481 TUBE FIT MALE TUBE ADAPTER 1.00 EA S N 041 1420151637 VALVE BALL 2.00 EA P N 042 1420044669 TUBE FIT CONNECTOR O-RING SEAL 1.00 EA S N 043 1420044525 TUBE FIT MALE TUBE ADAPTER 1.00 EA P N 044 0144329000 SCREW HEX HEAD 16.00 EA S N 045 1420030116 NUT HEX 16.00 EA S N



DESCRIPTION CONT ASSY SC-23152 AIR PRODUCTS

ITEM SUB-COMPONENT DESCRIPTION QUANTITY UM PSM TEXT 046 1420030117 WASHER LOCK SPLIT 16.00 EA S N 047 1420042198 PIPE FIT HALF COUPLING 2.00 EA P N 048 1420040637 PIPE CAP BW 2.00 EA S N 049 1420170244 PIPE 10.00 IN S N 050 9455007772 SUPPORTS, MISCELLANEOUS 1.00 EA P N 051 0801280000 SCREW HEX HEAD 6.00 EA S N 052 1420030144 NUT HEX 6.00 EA S N 053 1420030118 WASHER LOCK SPLIT 6.00 EA S N 054 1420131012 GAUGE PRESSURE AND DIFFERENTIA 1.00 EA P N 055 1420114063 GAUGE PRESSURE AND DIFFERENTIA 1.00 EA P N 056 3176786807 PIPE PLUGS 1.00 EA S N


COMPONENT - 9455221195 BOM. REV. 0 BOM. ECN. BOM. DATE 00000000 STATUS DRAWING # - 9455221188 DRW. REV. 1 DRW. ECN. 35538 DRW. DATE 20041006

DESCRIPTION PUMP PKG ASSY MAIN 143SE/3G CI 1:1 W/SAE EXT OIL

ITEM SUB-COMPONENT DESCRIPTION QUANTITY UM PSM TEXT 001 1420120188 PUMPS 1.00 EA S N 002 9455105864 MOUNTING BRACKET, PUMPS FABRIC 1.00 EA S N 003 1320701573 SPCR, MISC, SHROUD, BACKPLATE, 1.00 EA S N 004 1320706452 GEAR PUMP DRIVE 1.00 EA S N 005 0808559400 CPLG FLEXIBLE TYPE 15HP & LESS 1.00 EA M N 006 0502109032 BEARING ROLLING ELEMENT 2.00 EA S N 007 9455105222 MISC CORE MFG PARTS 1.00 EA S N 008 0144336503 SCREW HEX HEAD 4.00 EA S N 009 1420030229 KEY - WOODRUFF 1.00 EA S N 010 0686311601 PIPE PLUGS 1.00 EA S N 011 0420095206 PIPE PLUGS 1.00 EA S N 012 0800002836 NUT LOCK 1.00 EA S N 013 0800000504 SNAP RING 1.00 EA S N 014 0802315000 KEYSTOCK 3.00 IN S N 015 0801280000 SCREW HEX HEAD 6.00 EA S N 016 1420030118 WASHER LOCK SPLIT 10.00 EA S N 017 1420030068 WASHER FLAT 6.00 EA S N 018 1420046018 TUBE FIT ELBOW MALE 1.00 EA S N 019 9455002390 MISCELLANEOUS MAIN ASSY MACH P 1.00 EA S N



DESCRIPTION PUMP PKG ASSY AUX 143 CI 5HP 460/3/60

ITEM SUB-COMPONENT DESCRIPTION QUANTITY UM PSM TEXT 001 1420100978 MOTOR UNDER 15HP 1.00 EA P N 002 1420120188 PUMPS 1.00 EA S N 003 1420030115 SCREW SOCKET HEAD CAP 8.00 EA S N 004 1420030120 WASHER BELLEVILLE 8.00 EA S N 005 1320709907 PUMP ACCESSORIES 1.00 EA S N 006 1320708216 CPLG PARTS 15HP LESS PUMP COUP 1.00 EA S N 007 1320708240 CPLG PARTS 15HP LESS PUMP COUP 1.00 EA S N 008 1320708231 CPLG PARTS 15HP LESS PUMP COUP 1.00 EA S N 009 1320708225 CPLG PARTS 15HP LESS PUMP COUP 1.00 EA S N 010 0800003553 SCREW SOCKET HEAD SET ALL TYPE 1.00 EA S N 011 0420096001 PIPE FIT REDUCING HEX 1.00 EA S N 012 1420040925 PIPE FIT ELBOW STREET 1.00 EA S N 013 1420040924 PIPE NIPPLES 1.00 EA S N 014 1420090114 FILTERS AIR, GAS 1.00 EA S N


Section 10Drawings

IntroductionThis section provides the drawings for each main assembly of the compressor and forschematic diagrams. In the list below, if the bill of material number or part numberdiffers from the drawing number, it is shown in parentheses following the drawingdescription. Drawings of assemblies show the assembly parts that cross reference tothe associated bill of material included in section 9. Schematic diagrams show suchitems as tag numbers, wire numbers, alarm and shutdown setpoints.

Drawings listDrawing # Description

SC23152001 Process and Instrumentation Diagram (P&ID)

SC23152015 Wiring Diagram, Compressor


SC23152031 Enclosure Assembly, Analog

SC23152032 Enclosure Assembly, Vibration/RTD


SC23152085 Outline Diagram

SC23152086 Foundation Bolting Diagram

1420071088 Coupling, Main Drive

1420081603 Intercooler

1420081606 Cooler, Oil

1420100978 Motor, Pump

1420111347 Heater, Immersion

1420115595 Switch, Level

9455000313 Process Piping and Valving Assembly

9455007748 Aercology Mounting Assembly

9455007773 Cooling Water Manifold Assembly

9455022482 Lube Oil Assembly

9455100363 Core Unit Assembly

9455120242 Rotor Assembly

9455190095 Procedure, Rotor Assembly


10-2

Drawings listDrawing # Description

9455190208 Tool Assembly, Wheel Puller

9455200200 Control Assembly

9455221187 Pump Package Assembly, Auxiliary (BOM 9455221218)

9455221188 Pump Package Assembly, Main (BOM 9455221195)

9455222014 Filter Assembly, Oil, With Drain Valve


Section 11Component Literature

IntroductionThis section provides information about various sub-vendor parts used in the com-pressor. Generally, operation and maintenance instructions are provided. The compo-nent list below is presented in alphabetical order by sub-vendor name, followed by adescription and the Atlas Copco part number.

Component ListVendor Description ACC #

Basco Intercooler 1420081603

Basco Cooler, Oil 1420081606

Heatrex Heater, Immersion 1420111347

Imo Pump, Flanged 1420120188

Innovative Switch, Level 1420115595

Teco Westinghouse Motor, Pump 1420100978

Thomas Rexnord Coupling, Main Drive 1420071088


11-2


INSTALLATION

Except when the hot fluid is dirty or is prone to fouling, it is preferable to pass the cooling medium through thetubes and the hot medium through the shell. Since the tubes can be mechanically cleaned it is sometimesadvantageous to pass the hot dirty fluid through the tubes. When installing a single pass unit the shell inlet mustbe at the same end of the exchanger as the tubeside outlet (counter current flow).

When the BASCO Type �500� is used with steam as the heating medium, the steam must be in the shell. Either orboth shell connections may be used as steam inlets. Water to be flowing prior to injection of steam to avoiddifferential expansion.

OPERATIONS

At start up or after maintenance inspection, both shell and tubeside should be carefully vented and full of liquid.Improper venting and fouling are the most common causes of heat exchanger malfunction.

To obtain maximum performance the following precautions should be taken:

1. Make sure all other equipment in the fluid ciruits are functioning properly.2. Maintain rated flow of both fluids but be sure flow rates are not excessive. Frequently, tube failures can be

directly traced to excessive fluid flow, causing tube erosion and corrosion. In the case of heavy oils highflow rates can reduce cooler efficiency.

3. A periodic venting program should be followed if air or vapor tends to accumulate in the system.4. Observe a regular maintenance program.

INSPECTION

A periodic inspection and maintenance program should be followed with any heat exchanger. To ensurecontinuous satisfactory performance of your Type �500� exchanger the following steps should be taken.

1. Inspect filters in system and replace or clean as required.2. Remove bonnets from heat exchanger and inspect the zinc pencils for erosion or oxide deposits. Scrape to

bright surface and replace if more than half corroded away.3. Carefully examine tubes for scale and clean if necessary. After cleaning, examine for erosion or corrosion.

CLEANING

The interior surfaces of the tubes can be cleaned in several ways. Many deposits can be removed by flushing ahigh velocity stream of water through them. For more stubborn deposits, wire brushes or rods can be used. If thespecial air or water gun is available rubber plugs can be forced through the tubes.

Both shell and tubeside can be cleaned chemically by circulating cleaning solutions through the exchanger. Formost deposits a mild oakite solution is satisfactory. Circulate the cleaning solution until exchanger is clean. Be sureto wash out all chemicals thoroughly with clean water before returning the exchanger to service.

OPERATING INSTRUCTIONSBASCO TYPE �500� EXCHANGERS

API Basco2777 Walden AvenueBuffalo, New York 14225Toll Free - 877-API-HEATFax (716)[email protected]

...world leaders in heat transfer technology

tbicmms

rec'd: 2/3/04

Horizontal Mount Liquid Level Switches

Installation & Maintenance Series L007 L070 L090

General Information:

Switches should be installed securely and clear of obstructions so the float is free to move with liquid level changes. Switches should be mounted in an area of the tank free of turbulence or direct streams Operate only within listed electrical ratings

Maintenance

Periodically inspect the float to be sure it is not coated or contaminated by any ma-terial or substance that would significantly change its weight or volume

Important Points

• Always operate within specified temperature and pressure ratings. Possible surges in temperature and pressure should also be observed, (see table below)

• Only use with liquids compatible with the material of construction. (Consult factory for information)

• Changes in fluid temperature can affect switch set-points since density/specific gravity may vary with temperature.

General Temperature & Pressure Limits Float Material Temperature Pressure Polypropylene (L007) 120ºF 100 PSIG Buna-N (L090) 180ºF 150 PSIG Stainless (L070) 300ºF 1500 PSIG Stainless (L007) 300ºF 300 PSIG Stainless (L090) 300ºF 100 PSIG

Electrical Ratings and Wiring Diagrams Reed switches in Innovative Solutions level switches are hermetically sealed and a mag-netically actuated SPST or SPDT rated as maximum power limits in Volt-Amps, (VA) CAUTION: DO NOT EXCEED MAXIMUM LOAD RATINGS Contact protection such as a diode,(DC), or resistor, (AC), should be used to suppress high transient voltages or in rush currents that may cause burning or welding of the switch contacts.

Innovative Solutions, LLC 60 Great Hill Road Naugatuck, CT 06770 Ph: (203) 729-6434 Fax: (203) 729-6696 5/03

Switch Ratings—Maximum Loads (Resistive)

VA Volts Amps (AC) Amps (DC)

50 (SPST) 0-50 0.5 0.5

120 0.4 0.4

120 0.8 0.8

240 0.2 0.2

30 (SPDT) 120 0.25 0.25

100 (SPST)

RED

RED

RED

RED

ORANGE

RED

BLACK

COM. N.0.

N.C.

SPST, NORMALLY OPEN -DRY

SPST, NORMALLY CLOSED -DRY

SPDT, NORMALLY CLOSED -DRY

L070 Hazardous Location 2”NPT External Mount

Typical Wiring Diagram

N .O .

N.C.

L090 Bent Stem Internal Mount 1/8”NPT or 3/8”-24

L007 Internal Mount 3/8”-24 with retaining nut

L007 External Mount 1/2” NPT

Typical Installations

INSTALLATION ANDMAINTENANCE INSTRUCTIONSFOR THREE PHASEINDUCTION MOTORS

Frames 143T - 449TZ

5100 North IH 35 Round Rock, Texas 78681Phone: 800-451-8798 512-255-4141 Fax: 512-244-5512

RECEIVING1. Check nameplate data.2. Check whether any damage has occurred during transportation.3. After removal of shaft clamp, turn shaft by hand to check that it turns freely.4. If motor is to be reshipped (alone or installed to another piece of equipment) the shaft must

again be clamped to prevent axial movement.Note: Remove the bearing clamp before turning the shaft on 284T-449TZ frame motors.

WARNINGTHE FOLLOWING SAFETY PRECAUTIONS MUST BE OBSERVED:1. Electric rotating machinery and high voltage can cause serious or fatal injury if improperly

installed, operated or maintained. Responsible personnel should be familiarized withNEMA MG2; Safety Standards for Construction and Guide Selection. Installation and Useof Electric Motors and Generators; National Electric Code and all local safety requirements.

2. When servicing, all power sources to the motor and to the accessory devices should be de-energized and disconnected and all rotating parts should be at standstill.

3. Lifting means, when supplied, are intended for lifting the motor only. When two liftingdevices are supplied with the motor a dual chain must be used.

4. Suitable protection must be used when working near machinery with high noise levels.5. Safeguard or protective devices must not be by-passed or rendered inoperative.6. The frame of this machine must be grounded in accordance with the National Electric Code

and applicable local codes.7. A suitable enclosure should be provided to prevent access to the motor by other than

authorized personnel. Extra caution should be observed around motors that areautomatically or have automatic re-setting relays as they may restart unexpectedly.

8. Shaft key must be fully captive or removed before motor is started.9. Provide proper safeguards for personnel against possible failure of motor-mounted brake,

particularly on applications involving overhauling loads.10. Explosion proof motors are constructed to comply with the label service procedure manual,

repair of these motors must be made by TECO-Westinghouse Motor Company or U/L listedservice center in order to maintain U/L listing.

LOCATION1. Drip-proof motors are intended for use where atmosphere is relatively clean, dry, well

ventilated and non-corrosive.2. Totally enclosed motors may be installed where dirt, moisture, or dust are present and in

outdoor locations.3. Explosion-proof motors are built for use in hazardous locations as indicated by

Underwriters’ label on the motor.4. Chemical duty enclosed motors are designed for installation in high corrosion or excessive

moisture locations.Note: in all cases, no surrounding structure should obstruct normal flow orventilating air through or over the motor.

MOUNTING1. Mount motor securely on a firm, flat base. All ball bearing normal thrust motors up to and

including 256T frame size may be side-wall or ceiling mounted; all others check nearestTECO-Westinghouse office for mounting recommendations.

2. Align motor accurately, using a flexible coupling if possible. For drive recommendations,consult with drive or equipment manufacturer, or TECO-Westinghouse.

3. Mounting bolts must be carefully tightened to prevent changes in alignment and possibledamage to the equipment. The recommended tightening torque’s for medium carbon steelbolts, identified by three radial lines at 120 degrees on the head, are:

Recommended Torque (Ft-lb.)Bolt SizeMinimum Maximum

2/8 25 371/2 60 905/8 120 1803/4 210 320

4. V-belts Sheave Pitch Diameters should not be less than those shown in Table 1 (NEMArecommended values)

5. Tighten belts only enough to prevent slippage. Belt speed should not exceed 5000 ft. permin.

TABLE 1. V-Belt Sheave Pitch Diameters (MG1-14.42)V-Belt Sheave

Conventional NarrowA, B, C, D AND E 3V, 5V, AND 8V

Horsepower atSynchronous Speed, RPMFrame

Number 3600 1800 1200 900

MinimumPitch

DiameterInches

*MaximumWidthInches

MinimumOutside

DiameterInches

**MaximumWidthInches

143T 1.5 1 .75 .5 2.2 4.25 2.2 2.25145T 2-3 1.5-2 1 .75 2.4 4.25 2.4 2.25182T 3 3 1.5 1 2.4 5.25 2.4 2.75182T 5 … … … 2.6 5.25 2.4 2.75184T … … 2 1.5 2.4 5.25 2.4 2.75184T 5 … … … 2.6 5.25 2.4 2.75184T 7.5 5 … … 3.0 5.25 3.0 2.75213T 7.5-10 7.5 3 2 3.0 6.5 3.0 3.375215T 10 … 5 3 3.0 6.5 3.0 3.375215T 15 10 … … 3.8 6.5 3.8 3.375254T 15 … 7.5 5 3.8 7.75 3.8 4254T 20 15 … … 4.4 7.75 4.4 4256T 20-25 … 10 7.5 4.4 7.75 4.4 4256T … 20 … … 4.6 7.75 4.4 4284T … … 15 10 4.6 9 4.4 4.625284T … 25 … … 5.0 9 4.4 4.625286T … 30 20 15 5.4 9 5.2 4.625

TABLE 1. V-Belt Sheave Pitch Diameters (MG1-14.42)V-Belt Sheave

Conventional NarrowA, B, C, D AND E 3V, 5V, AND 8V

Horsepower atSynchronous Speed, RPMFrame

Number 3600 1800 1200 900

MinimumPitch

DiameterInches

*MaximumWidthInches

MinimumOutside

DiameterInches

**MaximumWidthInches

324T … 40 25 20 6.0 10.25 6.0 5.25326T … 50 30 25 6.8 10.25 6.8 5.25364T … … 40 30 6.8 11.5 6.8 5364T … 60 … … 7.4 11.5 7.4 5.785365T … … 50 40 8.2 11.5 8.2 5.785365T … 75 … … 9.0 11.5 8.6 5.785404T … … 60 … 9.0 14.25 8.0 7.25404T … … … 50 9.0 14.25 8.4 7.25404T … 100 … … 10.0 14.25 8.6 7.25405T … … 75 60 10.0 14.25 10.0 7.25405T … 100 … … 10.0 14.25 8.6 7.25405T … 125 … … 11.5 14.25 10.5 7.25444T … … 100 … 11.0 16.75 10.0 8.5444T … … … 75 10.5 16.75 9.5 8.5444T … 125 … … 11.0 16.75 9.5 8.5444T … 150 … … … 16.75 10.5 8.5445T … … 125 … 12.5 16.75 12.0 8.5445T … … … 100 12.5 16.75 12.0 8.5445T … 150 … … … 16.75 10.5 8.5

*Max. Sheave width = 2(N-W) - .25**Max Sheave width = N-W***Sheave ratios grater than 5:1 and center-to-center distance less than the diameter of the large sheave should be referred to TECO-Westinghouse.

POWER SUPPLY & CONNECTIONS1. Wiring of motor and control, overload protection and grounding should be in accordance

with National Electrical Code and all local safety requirements.2. Nameplate voltage and frequency should agree with power supply. Motor will operate

satisfactorily on line voltage within ±10% of nameplate voltage; or frequency with ±5% andwith a combined variation not to exceed ±10%. 230-volt motors can be used on 208-voltnetwork systems, but with slightly modified performance characteristics as shown on thenameplate.

3. Dual voltage and single voltage motors can be connected for the desired voltage byfollowing connection diagram shown on the nameplate or inside of the conduit box.

4. All Explosion Proof motors have Temperature Limiting Devices in the motor enclosure toprevent excessive external surface temperature of the motor in accordance with U/Lstandards. Terminals of thermal protectors (P1 & P2) should be connected to the motorcontrol equipment, according to the connection diagram inside of the conduit box.

5. Standard connection diagram for three phase, not thermally protected, dual rotation motorsare shown in diagrams A through E.(Note: To change rotation, Interchange any two line leads)

A. 3 Lead, Single Voltage

B. 6 Lead, Dual Voltage & Voltage Ration 1 to 3

B-1 Across the Line Start & Run B-2 Wye Start & Delta Run(Low Voltage only)

C. 9 Leads; Dual Voltage & Voltage Ratio 1 to 2, Wye Connected

C-1 Across the Line Start & Run C-2 Part Winding Start(Low Voltage only)

D. 9 Leads; Dual Voltage & Voltage Ration 1 to 2, Delta Connected

D-1 Across the Line Start & Run D-2 Part Winding Start(Low Voltage only)

E. 12 Leads, Dual Voltage

E-1 Across the Line Start & Run

E-2-1 Wye Start & Delta Run (Low Voltage only)

E-2-2 Wye Start & Delta Run (High Voltage only)

E-3 Part Winding Start (Low Voltage only)

*Important: For Part Winding Start, M2 contactor should be closed within two (2) secondsafter M1 contactor is closed.Only 4 pole and above (e.g., 6P, 8P…) motors are satisfactory for Part WindingStart at low voltage.

START UP1. Disconnect load and start motor. Check direction of rotation. If rotation must be changed,

ALLOW THE MOTOR TO STOP COMPLETLEY. Interchange any two leads of a three-phase motor.

2. Connect load. The motor should start quickly and run smoothly. If no, shut power off atonce. Recheck the assembly including all connections before restarting.

3. If excessive vibration is noted, check for loose mounting bolts too flexible motor supportstructure or transmitted vibration from adjacent machinery. Periodic vibration checksshould be made; foundations often settle.

4. Operate under load for short period of time and check operating current against nameplate.

TESTINGIf the motor has been in storage for an extensive period or has been subjected to adversemoisture conditions, it is best to check the insulation resistance of the stator winding with amegometer. Depending on the length and conditions of storage it may be necessary toregrease or change rusted bearings.If the resistance is lower than one megohm the windings should be dried in one of the followingtwo ways:1. Bake in oven at temperatures not exceeding 194°F until insulation resistance becomes

constant.2. With rotor locked, apply low voltage and gradually increase the current through windings

until temperature measured with a thermometer reaches 194°F. Do not exceed thistemperature.

MAINTENANCE

INSPECTIONInspect motor at regular intervals. Keep motor clean and ventilation openings clear.

LUBRICATION1. Frame 143T-256T: Double shielded and pre-lubricated ball-bearing motors without grease

fittings and don’t need relubrication, except on MAX-E1® and MAX-E2® products whichhave regreasable features.

2. Frames 280TS, 320-449TZ(TS): Motors having grease fittings and grease dischargedevices at brackets. Motors are shipped with grease for initial running. It is necessary torelubricate anti-friction bearing motors periodically, depending on size and type of service.See Table 2 to provide maximum bearing life. Excessive or too frequent lubrication maydamage the motor.

TABLE 2

Horsepower StandardConditions

SevereConditions

ExtremeConditions

1 Thru 30 Hp, 1800 rpm and below 7 years 3 years 180 days40 Thru 75 Hp, 1800 rpm and below 210 days 70 days 30 days100 Thru 150 Hp, 1800 rpm and below 90 days 30 days 15 days1 Thru 20 Hp, 3600 rpm 5 years 2 years 90 days25 Thru 75 Hp, 3600 rpm 180 days 60 days 30 days100 Thru 150 Hp, 3600 rpm 90 days 30 days 15 days

Note:A. Standard conditions: 8 hours operation per day, normal or light loading, clear and 40°C

ambient conditions.B. Severe conditions: 24-hour operation per day or light shock loading, vibration or in dirty

or dusty conditions.C. Extreme conditions: With heavy shock loading or vibration or dusty conditions.D. For double shielded bearings, above data (lubrication frequency) means that the

bearing must be replaced.

3. Be sure fittings are clean and free from dirt. Using a low-pressure grease gun, pump in therecommended grease until new grease appears at grease discharge hole.

4. Use the ALVANIA R3 grease or equivalent lithium based grease unless special grease isspecified on the nameplate.

5. If relubrication is to be performed with the motor running, stay clear of rotating parts. Afterregreasing, allow the motor to run for ten to thirty minutes.

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