SUNDYNE LMC/BMC-311F Compressors

Instruction and Operation Manual

December 2007

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COPYRIGHT All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise without the prior permission of Sundyne Corporation. © 2007 Sundyne Corporation

WARRANTY Sundyne Corporation warrants to Buyer for a period of twelve (12) months from the date of being placed in service (but not to exceed eighteen (18) months after the date of shipment) that the equipment at the time of shipment will be free from defects of design, material and workmanship. If any defects or malperformance occur during the warranty period, Sundyne’s sole obligation shall be limited to alteration, repair or replacement at Sundyne’s expense, F.O.B. Factory, of parts or equipment, which upon return to Sundyne and upon Sundyne’s examination prove to be defective. Equipment and accessories not manufactured by Sundyne are warranted only to the extent of and by the original manufacturers’ warranty. Sundyne shall not be liable for damage or wear to equipment caused by abnormal conditions, vibration, failure to properly prime or to operate equipment without flow or caused by corrosives, abrasives or foreign objects. THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER EXPRESSED OR IMPLIED INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. In no event shall Sundyne be liable for consequential or incidental damages.

TABLE OF CONTENTS Text Symbols..................................................................................................................1 Equipment and Safety Precautions..............................................................................1 Explosion / Fire Hazard .................................................................................................2 Using this Manual ..........................................................................................................3 1. Installation ..................................................................................................................5 Introduction to the Sundyne Compressor.........................................................................5 Inspection ........................................................................................................................5 Short Term and Long Term Storage ................................................................................6 Installing the Suction and Discharge Piping - Guidelines .................................................7 Seal Environment Control System ...................................................................................7 Baseplate Grouting ..........................................................................................................8 Horizontal Unit Gearbox Support Bracket ........................................................................9 Driver and Coupling .........................................................................................................9 2. Lubricating Oil System ..............................................................................................9 3. Start-up .....................................................................................................................13 Compressor Control During Start-Up .............................................................................14 Run-In of the Compressor..............................................................................................14 4. Servicing...................................................................................................................15 Regular Maintenance .....................................................................................................15 5. Maintenance .............................................................................................................16 Gearbox Disassembly ................................................................................................16 Diffuser Gap Set-up Impeller/Diffuser Cover Alignment.............................................21 Impeller/Diffuser Clearance Calculation.....................................................................24 6. Gearbox Disassembly .............................................................................................26 7. Gearbox Reassembly ..............................................................................................34 8. Troubleshooting ......................................................................................................47 9. Operation .................................................................................................................50 10. Spare Parts .............................................................................................................51 11. Sundyne Compressor Warranty ...........................................................................53 Reference A Critical Start-up Checklist ...........................................................................................49 Reference B Lock-out/Tag-out Guidelines ......................................................................................54

Reference C Seal Arrangement Drawings for Single, Double, and Tandem Configuraiton ........55

Reference D Compressor Drawings.................................................................................................59

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INTRODUCTION & SAFETY

Text Symbols The following symbols may be found in the text of this manual. They have the following meanings:

WARNING: Text accompanied by this symbol indicates that failure to follow directions could result in bodily harm or death.

ELECTRICAL HAZARD: Text accompanied by this symbol indicates that failure to follow directions could result in electrical damage to equipment or electrical shock.

RECOMMENDED: Text accompanied by this symbol indicates recommended usage.

REMINDER: Text accompanied by this symbol indicates a reminder to perform an action.

EQUIPMENT USE ALERT: Text accompanied by this symbol indicates that failure to follow directions could result in damage to equipment.

Equipment and Safety Precautions

Sundyne Corporation manufactures compressors to exacting International Quality Management System Standards (ISO 9001) as certified and audited by Lloyd’s Register Quality Assurance Limited. Genuine parts and accessories are specifically designed and tested for use with these products to ensure continued product quality and performance. Sundyne cannot test all parts and accessories sourced from other vendors; incorrect design and/or fabrication of such parts and accessories may adversely affect the performance and safety features of these products. Failure to properly select, install or use authorized Sundyne compressor parts and accessories is considered misuse and damage or failure caused by misuse is not covered by Sundyne’s warranty. Additionally, modification of Sundyne products or removal of original components may impair the safety of these products and their effective operation.

CAUTION Sundyne compressors may handle hazardous, flammable, and/or toxic fluids. Proper personal protective equipment should be worn. Precautions must be taken to prevent physical injury. Residual fluid must be handled and disposed of in accordance with applicable environmental regulations. Note: Safety procedures must be applied

prior to any installation, maintenance, or repair of a Sundyne compressor. Failure to follow safety precautions may lead to injury!

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Wearing Personal Protective Equipment To ensure safety, protective equipment must be worn at all times when installing, performing maintenance, or repairing equipment. The following safety recommendations must be adhered to for optimum safety:

• Safety glasses, with the minimum requirement of side shields, must be worn at all times.

• Steel-toed shoes must be worn when lifting equipment greater than 15 pounds (7 kg) or if pallet jacks or forklifts are operated.

• Hearing protection is strongly recommended at all times when noise levels exceed 85 dB during an eight (8.0) hour period.

Note: Chemical resistant gloves must be used if

chemicals are utilized (refer to Using Chemicals for additional information).

Note: A dust mask respirator must be worn if

chemicals have warning labels regarding fumes, dust, or mists.

When using more than one piece of protective equipment, consider their compatibility. For example, safety glasses will not interfere with hearing protection equipment. Be sure to clean all pieces of personal protective equipment immediately after each use. Using Forklifts Any persons operating a forklift must have an active recognized operator license. Note: Before initializing forklift operation, verify

that the lift is in a safe operating position.

Ensuring Electrical Safety All electrical sources must be powered-off before installation, service, or repair of equipment occurs. Note: Sundyne recommends that a Lock-

out/Tag-out program be followed prior to altering the equipment. Locks or tags must be provided to warn employees that equipment is temporarily unavailable.

Once all work has been completed, the person installing the lock or tag must remove it according to company procedure.

Testing Equipment Prior to performing a test on newly installed, maintained, or repaired equipment; all personnel in the immediate area must be warned. Note: Follow company procedures prior to

equipment testing at all times.

Using Chemicals Any chemicals to be used must be accompanied by a relevant material safety data sheet (MSDS), in accordance with government legislation. If applicable, use chemical proof gloves. Note: An eye wash station (or equivalent)

should be available in the event of injury. If any hazardous or flammable chemicals pass through the equipment, a complete decontamination of the equipment is required.

Protection from Falling Fall protection and associated preventative measures are required when working on equipment located six feet or higher from the ground. Note: Follow company fall prevention

procedures prior to working on equipment.

Preventative Machine Guards Preventative guards must remain in place on all equipment. Note: Only remove the guards while performing

maintenance or repair.

Replace the guards immediately after working on the equipment and prior to start up.

EXPLOSION/FIRE HAZARD Note: Never use an acetylene torch, open flame,

or heat to attempt to remove parts that have seized together in Sundyne equipment. Any residual process gas or liquid that is flammable can result in an explosion or fire with potential for serious injury or death.

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Using This Manual: Organization This manual is part of the final data package for the Sundyne LMC/BMC-311F compressor. In addition to this manual, the final data package includes such information as the following: Drawings, Sundyne specification sheet with test performance curves, test data, inspection data, material certificates if required; and auxiliary equipment information. When using the specification sheet, section 1 of the final data package, and drawings, last section of final data package, in this manual compare the release date with those in the maintained final data package to ensure that you are using the most current information. This manual explains procedures for the Sundyne compressor, including how to: install it, maintain it, service it, troubleshoot problems; and order parts. Whenever you talk or write to your Sundyne representative, provide your compressor’s unique serial number. This manual contains the following sections: 1. Installation Describes how to install the compressor and how to store it until you install it. 2. Lubricating Oil System Provides the following information: how to prepare the gearbox for start-up; how the lubricating oil

system works; and specifications for gearbox lubricants. 3. Start-up Provides a procedure for starting and controlling the compressor. A critical start-up checklist is

included as Reference A. 4. Servicing Provides procedures for servicing the compressor. 5. Maintenance Provides procedures for disassembling the LMC/BMC compressor and its seal housings. 6. Gearbox Disassembly Provides procedures for disassembling & reassembling the gearbox of the compressor. 7. Reassembly

Procedure for Checking High-Speed Shaft End Play 8. Troubleshooting

Provides tables for the following: a) Looking up a problem. b) Identifying the possible cause. c) Selecting the corrective action.

9. Operation

Provides general guidelines for controlling a compressor such as surge control, suction throttling, discharge throttling, and speed control.

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10. Spare Parts

Contact and reference information. 11. Sundyne Compressor Warranty

Provides a warranty statement for the compressor/gearbox unit. Reference A Critical Start-up Checklist Reference B Lock-out/Tag-out Guidelines Reference C Seal Arrangement Drawings for single, double, and tandem configuration Reference D Compressor/Gearbox Drawings

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1. Installation This section provides an introduction to the compressor, procedures for inspecting and installing it, and procedures for storing it if you are not installing it immediately. It contains a subsection on each of the following: Introduction: This provides a brief description about the compressor and how it is used. Inspection: As soon as you receive the compressor, inspect it thoroughly. Short-term Storage: If the unit will be installed within 6 months follow these procedures. Long-term Storage: If the unit will not be installed within 6 months follow these procedures. Suction and Discharge Piping: Follow these procedures to set up the piping for suction and discharge. Seal Environment Control System: Follow these procedures to set up the seal environment controls, even if you use the standard system supplied by the factory. Baseplate Grouting: Use this information for applying grouting to the baseplate. Horizontal Unit Gearbox Support Bracket: Follow these procedures to drill and pin the gearbox support bracket on a horizontal unit. Driver and Coupling: Follow these procedures to align the driver and the compressor. Do this after grouting, and before you connect the piping for suction and discharge. Introduction to the Sundyne Compressor Sundyne LMC/BMC compressors have a single stage with an integral gearbox. It increases the pressure of a continuous flow gas by applying centrifugal action. Sundyne LMC/BMC compressors are most commonly used in chemical process plants to increase the pressure in a recycle loop. They are also used in refineries, petrochemical plants, and power generation plants. Within these facilities, Sundyne Compressors are used in booster, regeneration, vapor recovery, boil-off, and other gas process applications. Sundyne LMC/BMC compressors offer industrial quality in a compact unit that is simple to assemble. It provides high-energy performance and competitive efficiencies. For detailed specifications for Sundyne LMC/BMC compressors, see the specification sheet and bill of materials or consult Sundyne Compressors. For the primary components, see Reference D, compressor /gearbox module drawings. Inspection 1. When you receive the Sundyne LMC/BMC compressor, check for any damage. If you find any, inform

the carrier and Sundyne promptly. 2. Use Outline drawings in the final data package to ensure that all auxiliary items are properly included. 3. Check the gearshaft carefully. Seal drag may cause it not to turn freely at first. This is normal. But if

the gearshaft binds, it may be damaged, or it may need adjusting.

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Short-term Storage - 1 day to 6 months 1. If the compressor is to be stored near strong chemicals or salt water, protect it immediately. To do

this, follow steps 5 through 11 from the long-term storage procedures below. 2. Protect the unit from moisture and dust. 3. Make sure that the factory’s shipping covers for the housing flanges and the seal ports are securely

in place. 4. Carefully follow the instructions provided by the manufacturer of the motor or turbine driver.

Long-term Storage - 6 months or more If you store the LMC/BMC compressor for a long period of time, the methods you use are very important. Please contact Sundyne at (303)-425-0800 USA and ask for the Field Service Department for further instructions. 1. Be sure the storage area has: Humidity below 65%; and temperature range from 45° to 85°F (7°C to 29°C). 2. Do not allow contact of airborne chemicals with the internal components of the unit. 3. If the unit is being stored near strong chemicals or salt water, protect it immediately. 4. Protect the unit from moisture and dust. 5. Make sure that the factory’s shipping covers for housing flanges and seal ports are securely in

place. 6. Prevent corrosion to the components of the gearbox and the fluid-end. 7. Store the unit indoors. 8. Keep the room temperature and humidity constant. 9. Use desiccant bags to absorb moisture. Either of the following: 10. Purge the internal components with an inert gas. or 11. Oil flooding of component internals Review Long Term Storage Instructions supplied with Final Data Package. Should you have any

questions, contact the factory in Arvada, Colorado. After long-term storage, have an authorized Sundyne service engineer inspect all components and

supervise any necessary repair to be sure that they work properly. Any components not made by Sundyne (except mechanical seals) must be inspected or replaced as determined by the manufacturer’s authorized personnel, at the purchaser’s expense. Any Field Service work must be clearly stated at the time of purchase to validate an Extended Warranty.

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Because storage location and unknown factors at the site of storage are beyond our control,

Sundyne does not accept any liability for damage to the equipment during storage, nor do we guarantee the quality of the equipment during and after the storage period. An Extended Warranty will be null and void if the proper equipment preparation is not maintained.

Installing the Suction and Discharge Piping - Guidelines Step 1: Clean the suction line. Step 2: Install a strainer to protect the impeller from damage by mill scale, welding slag, or other

foreign particles. Step 3: Make sure that the piping is aligned with the compressor flanges. Step 4: Support all piping independently of the compressor. Step 5: When you move the piping into place, never use excessive force at the flanged suction and

discharge connections. This could strain the unit. Step 6: Use suction pipe that has a diameter at least as large as the diameter of the suction inlet of

the compressor. Step 7: Make sure that the suction and discharge piping have no unnecessary elbows, bends, and

fittings. These increase the losses caused by friction. Also, be sure that all piping and fittings are large enough to minimize losses caused by friction.

Step 8: Before you connect the piping to the compressor, tighten the hold-down bolts on the

compressor. Step 9: Do not use elbow parts near the suction flange. A straight pipe run of at least 3 times the pipe

diameter is desirable between an elbow and the suction flange. Step 10: Use block valves on both suction and discharge pipes to isolate the compressor

during shutdown, minimize process leakage, and reduce the likelihood of backflow through the compressor, which can cause reverse rotation.

Seal Environment Control System For the seal used with the compressor, always maintain the environment shown on the specification sheet for your unit. For some arrangements and applications, you may need a system to control the seal environment. For many applications, you can obtain a standard system from the factory. Make sure that the system is installed properly and that the ports are open or plugged, as applicable. See Outline drawing in the Final Data Package. Always be sure to leave port 1 free to drain leakage from the gearbox oil seal and vent the gas seal. You must vent case drain port 1 to atmospheric pressure and allow it to gravity drain properly. Otherwise oil could contaminate the outboard gas seal. This port can be attached to a flare line, but should not have back-pressure in excess of 5 psi.

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A. GAS BUFFER SYSTEM – A gas buffer system must be used with double gas seals to prevent

process gas leakage out of the compressor. The buffer must be a cooled, dry, filtered gas, which is compatible with the process gas and the compressor metallurgy. The buffer is introduced into seal port 7 at a pressure range of 40 to 80 psi (2.8 to 5.6 kg/cm2) greater than compressor suction pressure (max. of 160 psig – 11.2 kg/cm2) and at an average temperature no higher than 250°F (121°C). Part of the buffer flows across the lower seal into the process gas and part flows across the upper seal and is vented from port 1. A buffer flow of 1.0 to 2.0 scfm (0.028 to 0.056 Nm3/min) must be maintained through the seal cavity, and should be regulated by a valve or orifice on port 2. It is also acceptable to provide a buffer into port 2 and regulate by a valve or orifice out of port 7. The buffer system must be in operation prior to starting the compressor. Refer to compressor specification sheet for specific buffer requirements.

A buffer gas may also be used between tandem seals to reduce process leakage when buffer contamination of the process gas is not permissible. Contact the factory for buffer pressure and flow requirements.

B. LIQUID BUFFER SYSTEM – A liquid buffer system is used with double liquid seals and is functionally

identical to a gas buffer. The buffer liquid is introduced into port 7 or 2, allowed to flow through the seal cavity, and out the opposing port.

Buffer flow should be 0.5 to 3 gpm (2 to 12 liters/min) with an inlet temperature of 60° to 120°F (16° to 49°C), and inlet pressure a minimum of 20 psi (1.4 kg/cm2) above process suction pressure.

If a closed loop buffer system is used, the buffer must be cooled prior to returning to port 7. Otherwise, heat generated by seal friction will build up in the buffer, resulting in shorter seal life. If an open loop system is used, an orifice or valve on port 2 should be used to regulate flow to proper value.

NOTE: The compressor casing of units with double liquid seals must be drained prior to starting.

C. SEAL FLUSH – An optional seal flush system is available for use with single or tandem gas seal

arrangements when the process gas is contaminated with dust, dirt, or any other types of solid particles. A clean, cool gas, either from external sources or cooled, filtered gas throttled from the discharge is introduced into port 5 or 6 at a pressure slightly higher than suction pressure. Thus, only clean gas will contact the seal face minimizing erosion and seal deterioration.

A flush is not required with a double gas seal due to the flushing action of the buffer leakage across the lower seal.

D. PORT 1 PIPING – Units equipped with gas seals must vent case drain port 1 to atmospheric

pressure and allow it to gravity drain properly. Otherwise oil could contaminate the outboard gas seal. This port can be attached to a flare line, but should not have back-pressure in excess of 5 psi.

Baseplate Grouting A rigid concrete mounting base is recommended for all installations. Use a non-shrink grouting to fill the baseplate grout-fill holes. The concrete foundation should have minimum deflections and freedom from resonant frequencies in the operating range of the equipment being supported. The stand shall be secured in position by one inch diameter bolts. The bolts shall be installed in the foundation with sufficient length to protrude one quarter inch above the nut. The customer shall provide a 4” x 4” x 1/4” steel plate under each leveling screw.

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BMC UNITS WITH HORIZONTAL STANDS: The base plate should be leveled prior to grouting. Grout shall set for the time limit as determined by the grout manufacturer. LMC UNITS WITH VERTICAL STANDS: The top of the stand (driver mounting surface) should be leveled by shimming under the base prior to grouting. The channels are to be filled with grout through the access holes. The nuts on the foundation bolts should not be tightened until the grout has set as determined by the grout manufacturer. Horizontal Unit Gearbox Support Bracket A gearbox support bracket (BK01AW04) is attached to the gearbox bearing plate and provides support to the gearbox in the horizontally mounted configuration. The bracket is a two-piece slotted hole design attaching the two pieces to provide adjustability in the field during field installation alignment. A shim (1/4” thickness preferred) should be placed under the bracket and alignment completed. The bracket should then be drilled and pinned (3/8” minimum pin diameter) in two locations to prevent possible shifting of the bracket during operation of the unit. Driver and Coupling

Lock out starting switch on driver prior to working on coupling, following lock-out/tag-out procedure. UNITS WITH VERTICAL OR HORIZONTAL STANDS - ALIGNMENT-- If other than Sundyne supplied couplings are used, they must be flexible disc or gear type couplings capable of tolerating parallel and angular misalignment of .005 inch maximum as well axial end play of .060 inch maximum. Always refer to the coupling manufacturers recommendations for installation and maintenance. The motor and compressor coupling hubs are normally installed at the factory. For alignment specifications, see Coupling Manufacturers Bulletin in the Final Data Package. Align the driver and compressor after grouting and before you connect the suction and discharge piping. After you install the piping, inspect the alignment again. 2. Lubricating Oil System Oil Specification

The oil used in Sundyne gearboxes must meet the specifications presented in Field Engineering Bulletin 40.2.04. In general, an ISO viscosity grade 32 oil will meet these specifications. Before using any oil, you should verify its properties by consulting its manufacturer. Failure to use the proper gearbox lubricant will void the warranty.

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Field Engineering Bulletin

Sundyne & Sunflo & HMP Gearbox Lubricant Recommendations

EFFECTIVE : MAY 2006 Rev: E

For years the preferred gearbox lubricant for Sundyne pumps and compressors has been automotive automatic transmission fluid (ATF). However, over time the additives in automatic transmission fluid have changed to coincide with the technical improvements in automobile transmissions. The additives in the new formulations of ATF, such as Dexron III, have been found to have negative effects on Sundyne gearboxes and could compromise mechanical integrity and reliability of the equipment. ISO Viscosity Grade 32 or 46 general purpose or synthetic oils are the recommended lubricants for Sundyne gearboxes as shown in Table 1 below. ISO VG 46 lubricants are now recommended for high horsepower gearbox models 33X and 34X with spherical roller bearings and high ambient temperature installations. Gearbox lube oil should be changed twice yearly or more frequently in severe environments which may be detrimental to the lubricant. Oxidized oil is frequently characterized by a darkening and/or thickening of the oil. Operating of gearboxes with oxidized lubricant should be avoided. Synthetic oils possess different characteristics than conventional mineral oils which make them desirable for various extreme conditions such as high and low temperature operation. Synthetic oils offer very low pour points, high temperature oxidation stability and a higher viscosity index. The operation of Sundyne equipment in high or low ambient conditions may require special consideration of gearbox lubricant and/or supplemental protective equipment such as heat exchangers or gearbox heaters. The lubricant chosen must be compatible with gearbox elastomers, Viton and Buna N. Any oil that contains an inert additive such as PTFE, molybdenum disulfide or silicon should not be used in Sundyne gearboxes. Use of lubricants containing inert additives will void the product warranty. Use ISO Viscosity Grade 32 Lubricant ** Use ISO Viscosity Grade 46 Lubricant

Models: LMV/BMP-311 LMC/BMC-311F

LMC-BMC-311 LMV/BMP-313 LMC/BMC-313 LMV-322 All Sunflo Gearboxes HMP-3000 HMP-5000

Models: LMV/BMP-331 LMV/BMP-341 LMC/BMC-331F LMC/BMC-341F LMC/BMC-331P LMC/BMC-341P LMV/BMP-333 LMV/BMP-343 LMC/BMC-333 LMC/BMC-343 LMC/BMC-337 LMV-346 BMP-338 LMC/BMC-347 BMP-348

** Use ISO VG 46 lubricant for high ambient temperatures above 40 °C (100 °F).

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Recommended ISO VG 32 gearbox lube oil specifications: Gravity, API 28 - 37 Pour Point, °C (°F) -7 (20) max. Flash Point, °C (°F) 204 (400) min. Viscosity, cSt at 40°C cSt at 100°C SUS at 100°F SUS at 210°F

28.8 to 35.2 5.2 min. 150 to 180 44 min.

Viscosity Index 95 min. ISO Viscosity Grade 32 Color, ASTM D 1500 1.5 Neutralization Number, Maximum 0.20 Rust Protection, ASTM D 665, A & B Pass Demulsibility, ASTM D 1401 Time to 0 ml emulsion at 54°C (130°F) after 30 min. at 82°C (180°F) after 60 min.

Pass Pass

Foam Limits, ASTM D 892 Sequence 1 Sequence 2 Sequence 3

25/0 max. 50/0 max. 25/0 max.

Note: No other additives are recommended.

Recommended ISO VG 46 gearbox lube oil specifications: Gravity, API 28 - 37 Pour Point, °C (°F) -7 (20) max. Flash Point, °C (°F) 204 (400) min. Viscosity, cSt at 40°C cSt at 100°C SUS at 100°F SUS at 210°F

41.4 to 50.6 6.5 min. 217 to 260 48.8 min.

Viscosity Index 95 min. ISO Viscosity Grade 46 Color, ASTM D 1500 2.0 Neutralization Number, Maximum 0.25 Rust Protection, ASTM D 665, A & B Pass Demulsibility, ASTM D 1401 Time to 0 ml emulsion at 54°C (130°F) after 30 min. at 82°C (180°F) after 60 min.

Pass Pass

Foam Limits, ASTM D 892 Sequence 1 Sequence 2 Sequence 3

25/0 max. 50/0 max. 25/0 max.

Note: No other additives are recommended.

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Lube Oil System The integral Sundyne lube oil system consists of the following major components: gearbox sump, main lube pump, oil heat exchanger (if necessary), and oil filter. Oil is taken from the sump by the lube pump, then passed through internal passages to an external integrally mounted manifold, through the heat exchanger, then through the filter and back into the gearbox to the bearings. After passing through the bearings, the oil drains back to the sump.

The gearbox sump holds approximately seven U.S. quarts (7.4 liters) of oil not including auxiliary piping and heat exchanger. For wet sump gearboxes, fill gearbox within ¼” from top of oil level sight glass. DO NOT overfill gearbox, as this will cause excessive foaming and overheating of the oil.

The main lube pump is a constant displacement gear type pump directly driven by the input shaft.

The standard heat exchanger is a shell and tube water cooled type mounted on the gearbox manifold. Some low speed or low temperature units do not require a heat exchanger. For units having a heat exchanger, cooling water should be provided at 150 psig (11 kg/cm2) maximum pressure. See the specification sheet for cooling water requirements. Coolant flow should be controlled by a hand valve installed in the cooling fluid discharge line to maintain a gearbox sump temperature between 140°F to 200°F (60°C to 93°C). Approximately one hour may be required to stabilize temperature.

The oil filter is a disposable pleated paper element type. Gearbox oil and filter should be changed every six months. Optional Lube Oil System Auxiliaries A. LUBE OIL PRIMING KIT – A pre-lube system is required on units operating at high speed, high

pressure, or high horsepower conditions. It is also mandatory with the use of certain auxiliary equipment. The kit consists of a motor driven positive displacement pump, check valve, gages, and necessary piping. To start compressor, operate the pre-lube pump at least 30 seconds with a minimum of 7 psig (0.492 kg/cm2) indication prior to starting the main driver.

The pre-lube pump is to shut down only after main driver is at full operating speed. B. REMOTE HEAT EXCHANGER – Some large water-cooled and all air-cooled heat exchangers are

mounted off the gearbox. Except for packaged units, the interconnecting piping is the purchaser’s responsibility. The heat exchanger MUST be mounted lower than the oil filter; otherwise, air pockets may be present in the lube oil lines at start-up, causing oil starvation at the bearings. Equivalent length of piping and fitting must not exceed 20 feet (6m), using minimum of 3/4” (19mm) I.D. tubing or pipe. If greater pipe lengths are required, pipe diameter must be increased accordingly.

C. GEARBOX SUMP HEATER – A sump heater is required when ambient temperatures may fall below

the temperature at which the gearbox oil becomes too viscous for proper lube pump operation. Both steam and electric sump heaters are available. The lube oil priming pump must be operated anytime the sump heater is in operation.

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3. Start-up If a Sundyne supplied control panel is to be used with the Sundyne LMC/BMC compressor, use the control panel recommended start-up procedure in addition to the steps below. Before starting the LMC/BMC compressor, complete the following procedure in the order in which the steps are provided: Step 1: Make sure that the driver has been serviced as per manufacturer recommendations. Check

motor rotation before installing coupling. Step 2: For the auxiliaries: Check the connections of the utilities; verify that the auxiliary piping

meets the requirements shown in the Outline Drawing. Step 3: Install flushing screens in all field-assembled piping connections. Clean these screens prior

to commissioning. Check frequently for cleanliness and clean as.needed. Step 4: Drain any liquids (blow-down) from the compressor and inlet pipe. Step 5: Prime the lubricating system, as follows:

• Fill the oil reservoir with lubricating oil in accordance with the Field Engineering Bulletin Gearbox Lubricant Recommendations.

• Add oil as necessary through the fill opening. • With wet sump compressors, add oil as necessary until the oil level stabilizes at the top

of the bull’s eye in the sight glass. With dry sump, check oil level at reservoir sight glass. • Start the auxiliary lubricating pump, and run it until the oil reaches the correct pressure

and temperature. Add oil as necessary until the oil level stabilizes 3/4 of the way from the bottom of the sight glass.

• Allow lube pump to operate for at least 30 seconds with a minimum of 7 psig (0.492 kg/cm2) indication prior to starting the main driver.

Step 6: Turn on the cooling water to lubrication systems heat exchanger (if applicable), or turn on air

cooled heat exchanger. Verify high points (e.g. heat exchanger and filters) have been vented.

Step 7: For double seal configurations, the buffer system must be pressurized to the pressure

specified on the spec sheet and on outline drawings prior to pressurizing the unit. Step 8: Charge the compressor with process gas. Step 9: Start compressor, following process control startup procedures. Step 10: Once the gearbox oil temperature has stabilized, adjust cooling water supply until the oil

temperature to the bearings is 120º - 160ºF on units equipped with water cooled heat exchangers. Maximum recommended temperature is 180ºF.

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Compressor Control During Start-Up Single Units:

A. Suction throttling (preferred method). Start compressor with the discharge valve open while throttling the suction valve to bring the compressor to the design operating point.

B. Discharge throttling. Start the compressor with the suction valve completely open while

throttling the discharge valve to bring the compressor to the design operating point. C. Other Methods – Insure that the compressor does not go into surge (flow too low) or that the

design horsepower is not exceeded (flow too high) while starting or operating the compressor. Check unit specification sheet for flow limits.

Series Operation:

In series operation, it is necessary to have a bypass from the discharge of the second stage back to the suction of the first stage. A check valve should be placed in the discharge line downstream of the bypass. Typical start-up procedure is as follows: A. Open the suction and discharge block valves and the bypass valve. B. Start the second stage unit and maintain stable operation. C. Start the first stage unit and maintain design flow to both units. D. When sufficient pressure is being produced to overcome system back-pressure, the check

valve will open and the units will be on stream. E. Close the bypass valve, being sure that the flow to the compressor is above the surge point.

Parallel Operation:

Check valves must be placed in the discharge piping of each compressor to prevent back-flow when one unit is started prior to the others. It is advantageous to install separate bypass loops around each compressor for additional operational flexibility.

The first unit may be started as described above for single units. However, prior to starting the second unit, it is preferable that the on-stream unit not be operating near its peak head capability. This will lessen the chance of surging when the second unit is started.

Run-In of the Compressor

If the compressor is to be run-in or mechanically tested under conditions which are considerably different from those that the unit is designed for (such as gas molecular weight, suction pressure, flow rate, etc.) Sundyne should be consulted to insure that the run-in conditions are compatible with the compressor.

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4. Servicing General Requirements To increase the operating life of your compressor and keep it in good operating condition, you should inspect and service it regularly. Measure all of the operating parameters documented in the specific maintenance procedures and log your measurements. Make sure that all major equipment, such as lubricating pumps, heat exchangers, and instrumentation, perform according to the manufacturer’s recommendations. Whenever you find a deviation from specifications, identify its source immediately, and take any corrective steps that are required to bring the unit into manufacturer’s specifications. Regular Maintenance Gearbox Oil Check the level of the oil in the gearbox immediately before and after initial start-up, and regularly while the compressor is running. Be sure to keep the level of the oil within the gearbox design limit. The oil level must be maintained within the MIN/MAX range on the sight glass. You can add oil to the wet sump gearbox while the compressor is running. See tagging information on gearbox for where to add oil during operation. This location is different from the initial fill location. Each must be used for its tagged purpose. Overfilling the gearbox will cause excess foaming and overheating and should be avoided at all times. Oil may be added to the external reservoir of the dry sump gearbox at the fill port. Oil Pressure The correct oil pressure from the main pump of the gearbox depends on the configuration of the bearings and the characteristics of the lubricating oil used. In the normal operation, the oil pressure supplied to the gearbox should be between 18-60 psig (1.2 - 4.2 Kg/cm2 ) (15 psi alarm, 10 psi shutdown). Changing the gearbox oil and filter Change the oil in the reservoir and the oil filter elements every 6 months. Sundyne recommends synthetics may go for a longer period of time before an oil change out is required. For dual oil filter units with a transfer valve, vent and fill the idle oil filter before operating the transfer valve. Seal Leakage Seal leakage out of port 1 should be checked periodically. Seals should be replaced if leakage increases to an unacceptable level. With double seals, buffer pressure and usage should be monitored to insure that seals are functioning properly. Driver Inspect the driver to make sure that it performs according to the manufacturer’s specifications. Coupling Inspect the coupling according to the manufacturer’s specifications. Never operate the compressor without first checking the coupling guard. A compressor with a missing or incorrectly installed guard could cause serious or fatal injury.

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5. Maintenance

The following procedures apply to all configurations of the Sundyne LMC/BMC-311F centrifugal compressors. Refer to the specification sheet to determine the specific configuration and optional

equipment included in your unit. Parenthetical numbers in the text correspond to item numbers in the illustrations and parts lists.

Procedure for Disassembling Compressor

The following replacement parts will be required as a result of compressor disassembly and seal housing removal

Part Item Qty.

Thermal Barrier Gasket 87A 1

• O-Ring Seal 936B 1

• O-Ring Seal 936C 1

• O-Ring Seal 936D 1

• O-Ring Seal 936E 1

• O-Ring Seal 936F 1

• O-Ring Seal 936G 2

• O-Ring Seal 936J 3

• O-Ring Seal 936K 1

• O-Ring Seal 936P 1

• Single Seal 1

• Double Seal 2

• Tandem Seal 3

• O-Ring Seal 936H 2

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NOTE

An o-ring Repair Kit is available. This kit contains the o-rings required to replace the gearbox and compressor mechanical seals.

STEP 1

Vertical units with a driver stand. Remove bolts (909D) securing the coupling guard. Remove the coupling guard. Disengage both ends of the spacer coupling and remove the floating shaft. Remove nuts (914A) from the compressor casing studs and release the stiffening brackets. Attach the integral turnbuckles to the gearbox bearing plate (102). Using the turnbuckles, lift the gearbox and seal housing from the compressor casing. Exercise care to prevent damage to the impeller. Tip and block the gearbox.

Vertical units without a driver stand. Remove attaching hardware and lift driver from gearbox. Remove nuts (914A) from compressor casing studs. Lift the gearbox and seal housing from the compressor casing, taking care not to damage the impeller. Place the gearbox on a suitable support with the impeller inclined upward.

On all BMC units, disconnect the piping between the heat exchanger and filter. Attach a hoist to the gearbox housing and eyebolt in the tapped hole on the bearing plate. Remove nuts (914A) from the compressor casing studs and disconnect midriff braces. Remove the gearbox and seal housing from the compressor casing by moving them toward the driver until the impeller and inducer (if applicable) clear the casing. Place gearbox on a suitable support with the impeller facing upward.

Step 2 If diffuser removal is required, insert three eyebolts (customer furnished 1/2-13 UNC) into tapped holes in the surface of diffuser (13). Loosely thread a length of rope through these bolts and tie ends together. Grasp the rope between bolts and lift the diffuser. This step will require that o-rings 936B and 936C be replaced.

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NOTE

The gearbox can be worked on while in a horizontal position. However, the diffuser cover must be supported to prevent it from falling off when the impeller is removed.

STEP 3

Prevent impeller from rotating and remove impeller (2). Note that the impeller has a left-hand thread. Anti-rotation tools for both the input shaft and output shaft are available through Sundyne.

CAUTION The impeller is dynamically balanced and should be replaced or rebalanced if it shows any sign of damage.

Step 4 Lift diffuser cover (15) from seal housing.

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Step 5 Remove shim spacer (936G).

Step 6 Remove the seal rotating face (51A) of single or tandem seal arrangement or the lower shaft sleeve (50A) on units equipped with double seals.

Step 7 Remove the single seal (60A) of the single seal arrangement or the lower mechanical seal (60A) and seal spacer (52) of the double seal arrangement or the lower mechanical seal of the tandem seal arrangement. If the compressor has a single seal arrangement, remove seal housing (30) and gasket (87A). Remove hex head cap screws (905F) and washers (916B). Remove throttle bushing (21B).

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Step 7 (continued) If upper seal of double or tandem seal arrangement requires removal, detach seal housing (30) and gasket (87A) from the gearbox by removing hex head cap screws (905A). Double Seal – Remove hex head cap screws (905F), washers (916B), upper mechanical seal (60B), and seal rotating face (51C). Tandem Seal – Remove hex head cap screws (905F), washers (916B), upper mechanical seal (60B) and seal rotating face (51C).

Step 8 Carefully inspect the seals for abrasive particles, excessive seal face wear and any binding of the seal face washer. Replace or rebuild a faulty mechanical seal. Seals may be rebuilt by replacing the seal face washer, wedge rings, o-ring, and springs. A seal repair kit is available. Replace or lap the seal rotating face if the wear track is rough or worn to a depth greater than 0.0002 inch (0.005mm). A combined total of 0.010 inch (0.25mm) maximum may be removed from the surfaces of the compressor and gearbox seal rotating faces. Excess material removal will result in incorrect seal face loading causing increased seal leakage. Remove any high spots on the end surfaces of the lower shaft sleeve and impeller hub to insure that the seal rotating face will not be distorted by clamping force of the impeller bolt. Reassemble the seals, throttle bushing, if used, seal housing, and impeller using an O-ring Repair Kit. All o-rings that were disturbed by disassembly should be replaced. During re-assembly, carefully check the torque values listed in Table 1. The impeller may rub on the diffuser cover plate (15) until o-rings (936D and 936E) are compressed by tightening hex nuts (914A). Check the gearbox input shaft for freedom of rotation after the compressor is assembled and all bolts are tightened per Table 1.

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Diffuser Gap Setup and Impeller/Diffuser Cover Alignment

The following replacement items will be required as a result of compressor disassembly and diffuser removal:

Part Name Item No. Qty.

Impeller Spacer 158C Series As Required O-ring Packing 936C 1* O-ring Packing 936E 1 O-ring Packing 936F 1 O-ring Packing 936G 2 *Required only if diffuser is removed.

A. Remove impeller bolt (3) and impeller (2) as directed under “Compressor Mechanical Seal”.

B. Inspect impeller and procure a new one if required.

C. Inspect diffuser for signs of damage (i.e. gouging in bowl areas due to erosion or mechanical damage) and procure a new diffuser if necessary.

D. The diffuser shim (158A) is used to adjust diffuser gap. The impeller spacer (158C) is required to align the blade side of the impeller shroud flush with the diffuser cover (15). See Figure 2. The impeller spacer (158C) thickness (“D” dimension of Figure 3) and diffuser shim (158A) (“B” dimension of Figure 3) must be determined and the correct spacer installed during the replacement of any of the following components. (See photos on next page.)

• Gearbox Assembly • Gearbox High-Speed Shaft (130) • High-Speed Shaft Bearings (151A or B) • Impeller (2) • Seal Housing (30) • Diffuser Cover (15)

NOTE The original clearances for your compressors as shipped from the factory for the impeller and diffuser are recorded and supplied as part of the final data package. Figure 3 can be used to record values.

E. Align the impeller (2) with the diffuser cover (15) and verify diffuser gap as follows:

(1) Remove diffuser cover (15) and set it impeller side up on a work bench. Set impeller (2) in place on the diffuser cover and measure the distance from the outside flat surface of the diffuser cover to the front or blade side of the impeller shroud as close to the outside edge of the shroud as possible. The impeller should be recessed into the cover a minimum of 0.025 inch (0.063mm). If the dimension is less than

0.025 inch, please contact the factory. (See photos on next page.)

(2) Assemble the compressor complete, less o-rings and mechanical seals 60A, 60B. Do not install the compressor in the case. Use original impeller spacer (158C) and all other components. Don’t forget spacer/thermal barrier gasket (87A).

(3) Record the diffuser gap reading “C” from specification sheet and mark on Figure 3. Procure solder slightly thicker than the stated gap. For example; if the diffuser gap is .080 inch use .125 inch diameter solder. Form a ring at the diffuser gap location marked as “C” on Figure 3. Install the assembled compressor, less o-rings and mechanical seals (60A, B) in the case. Install four nuts (914A) and torque to 150 ft-lbs. (See photos on next page.)

(4) Remove nuts (914A) and lift compressor from case. Measure the crushed solder with a micrometer. Adjust shim (158A) until gap is within 10% of the value shown on the specification sheet. (See photos on next page.)

NOTE

Unless the diffuser (13) or cover (15) have been changed, the diffuser gap should not require adjustment.

(5) Turn gearbox bottom side up so that the seal housing is on top.

(6) Be sure that the high-speed shaft (130) is pushed in the “X” direction (see Figure 2) as far as possible, (i.e. the shaft is pushed against the upper thrust washer) (155B or tilt pad thrust bearing 151B). Measure the distance from the outside flat surface of diffuser cover to the front or blade side of the impeller shroud as before. Record this dimension and not its direction. This is the “E” dimension in Figure 2. Record on Figure 3.

(7) The impeller shroud must be aligned flush with the diffuser cover or be extended a maximum of 0.020 inch out from the cover. As shown in Figure 1, the “E” dimension is within tolerance when the original spacer (158C) is acceptable. If the measured distance is out of tolerance, remove the impeller and measure the thickness of the original spacer.

Determine the thickness of spacer required and select the size necessary to bring the “E” dimension within acceptable limits.

The impeller spacers (158C) listed on page 23 show the various thicknesses that are available.

22

Item D (previous page) The diffuser shim (158A) is used to adjust diffuser gap.

Item D (previous page). The impeller spacer (158C) is required to align the blade side of the impeller shroud flush with the diffuser cover (15).

Item E. 1 (previous page) Item E. 3 (previous page)

Item E. 3 (previous page) Item E. 4 (previous page)

23

Figure 1. Compressor Cross Section

Figure 2. Compressor Clearances

24

Part No. Thickness

SP01AD02XXF 0.018 (0.046mm)

SP01AD02XXA 0.030 (0.075mm)

SP01AD02XXG 0.040 (0.105 mm)

SP01AD02XXB 0.050 (0.127mm)

SP01AS02XXH 0.060 (0.152 mm)

SP01AD02XXC 0.075 (0.178 mm)

SP01AD02XXD 0.090 (0.230 mm)

SP01AD02XXE 0.105 (0.279 mm)

(8) Replace the impeller spacer (158C) with the new spacer if required. Again, check the alignment of the impeller (2) shroud to the diffuser cover (15).

(9) When alignment is correct, torque the impeller bolt (3) per Table 1.

(10) Record the new impeller spacer (158C) thickness (“D” dimension) and impeller shroud to diffuser cover alignment (“E” dimension) on Figure 2 for future records.

Impeller/Diffuser Clearance Calculation

The clearance between the impeller and diffuser must be checked and, if necessary, adjusted after the replacement of any of the following parts:

Gearbox Assembly

Gearbox High-Speed Shaft (130)

Gearbox High-speed Shaft Bearings (151A-151B)

Diffuser (15)

Impeller (2)

Compressor casing (1)

Seal Housing (30)

A. The required impeller to diffuser clearance is obtained by adjusting spacers (158C) between the impeller and mating ring. The recommended procedure for determining spacer requirements is as follows:

(1) Invert the gearbox assembly, carefully protecting the low-speed shaft (120), so that the impeller is on top.

(2) Torque the impeller bolt per Table 1

25

Customer

S/N

Model

Date Shift

Assembled By:

Name (Not Clock #)

A. Impeller Clearance

B. Shim Thickness

C. Diffuser Gap

D. Spacer Thickness

E. Shroud Ht.

F. Impeller Blade Ht.

Impeller Diameter

Figure 3. Sundyne Full Emission Compressor Build Record

(3) Make four solder clips and bend them over the tips of the impeller blade near the outside of the impeller. They may be held in place by tape. It is acceptable to use a ring of solder in the case instead of clips on the impeller. Install the completed compressor less seals and o-rings into the compressor case. Install four nuts (914A), in the seal housing and torque to 150 ft.-lbs. This will crush the solder between the impeller and the diffuser and indicate the gap, dimension “A”. Again, the solder will force the shaft up into the running position. Remove the seal housing bolts and pull the compressor from the case. Using a micrometer, measure the crushed area of the solder. This value should be .035-.055 inch. The impeller gap “A” is changed by adjusting the impeller shim thickness, (158C). However, this change must not result in lowering the impeller to the point where the face of the shroud is below the cover. If the adjustment required would recess the impeller below the cover, additional impeller blade gap (“A”) can be obtained by

making the diffuser shim (158A) thinner. Since you are using two shims to change three dimensions, some compromise may be necessary.

NOTE

The purpose of this step is to set the clearances between the impeller and the diffuser such that it will not rub, but is close enough that the machine will run efficiently. When the compressor is not running and no suction pressure is supplied, the high-speed shaft will be sitting against the lower thrust bearing. The gap must be sufficient to insure that the impeller will not touch the diffuser. If the compressor is set up with too large a clearance, the efficiency will be low.

When all gaps and clearances, “A”, “E” and “C” are within specifications, check Figure 3 to be sure all values are recorded. Disassemble compressor and reinstall all o-rings, mechanical seals, etc. Reassemble and install compressor into case.

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6. Procedure for Disassembling Gearbox

The following replacement items will be required as a result of the gearbox disassembly:

Part Item No. Qty.

Gearbox Oil Filter 185 1

Input Shaft Lip Seal 115 1

Housing O-Ring 936AG 2

O-ring Seal 936M 2

O-ring Seal 936N 2

O-ring Seal 936P 1

O-ring Seal 936T 2

* Shim Spacers 158 Series As Required

* Available in sets of five 0.005 inch (0.13mm), 0.010 inch (0.25mm), .05 inch (0.38mm), 0.020 inch (0.51mm), 0.030 inch (0.76mm)

NOTE:

In order to disassemble the gearbox, it is necessary to complete steps one through seven under “Procedure for Disassembling Compressor”. Step 1 Drain oil from the gearbox. Step 2 Remove upper shaft sleeve (50B) on double or tandem seal arrangements or sleeve (50) on single seal equipped units.

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STEP 3 Remove gearbox seal screws and gearbox seal. Removing three hex head screws. Note: The gearbox mechanical seal can be

replaced or rebuilt.

STEP 4 Remove gearbox seal O-ring. Use extraction tool to remove O-ring.

STEP 5 Remove gearbox seal mating ring. Remove mating ring with extraction tools.

STEP 6 Invert the gearbox and remove fill and vent fitting. Use a pipe wrench to remove the ¾ inch pipe elbow first. Next, use the pipe wrench to loosen the pipe and remove from the gearbox.

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Slide the fill and vent pipe out of gearbox.

STEP 7 Loosen and remove gearbox bolts, (7 total).

STEP 8 Loosen close tolerance alignment pin.

STEP 9 Drive close tolerance alignment pins out, (2 pins). Use hammer to tap pin out.

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STEP 10 Remove upper gearbox housing. A mallet can be used to tap around the edges of the housing to loosen the idler shaft and assist the housing in lifting off. Note: Use hooks or eyebolts and a hoist

when possible to avoid personal injury.

STEP 11 Remove idler shaft assembly. Removing the idler shaft assembly disengages the upper idler and input shaft gears. Technician is pointing to idler shaft.

STEP 12 Remove input shaft assembly.

STEP 13 Remove the lube pump spring and the lube pump.

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STEP 14 Inspect the condition of the lube pump anti-rotation pin. Extraction tool is touching anti-rotation pin.

STEP 15 Remove bearing plate.

STEP 16 Remove and inspect upper thrust washer. Washer will slide off of the shaft.

STEP 17 Remove idler shaft assembly.

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STEP 18 Remove high-speed shaft assembly.

STEP 19 Remove and inspect lower thrust washer.

STEP 20 Remove and inspect upper journal bearing after removing from bearing plate. Unscrew three hex head screws. Use fingers to remove journal bearing. Inspect the upper journal bearing for damage or signs of excessive wear.

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STEP 21 Remove input shaft lip seal.

STEP 22 Remove the sump tube. Remove lower journal bearing. Repeat step 20 for removal of lower journal bearing.

STEP 23 Remove lower bearing shims.

STEP 24 Remove lower bearing shims. Use hex key to remove the lube jets.

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STEP 25 Blow out lube passage. Using air tool to blow out lube passages. Blowing out lube passages.

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7. Gearbox Reassembly

The following replacement items will be required as a result of the gearbox disassembly:

Part Item No. Qty.

Gearbox Oil Filter 185 1

Input Shaft Lip Seal 115 1

Housing O-Ring 936AG 2

O-ring Seal 936M 2

O-ring Seal 936N 2

O-ring Seal 936P 1

O-ring Seal 936T 2

* Shim Spacers 158 Series As Required

* Available in sets of five 0.005 inch (0.13mm), 0.010 inch (0.25mm), .05 inch (0.38mm), 0.020 inch (0.51mm), 0.030 inch (0.76mm)

STEP 1 Insert shim under lower journal bearing.

STEP 2 Install lower journal bearing. Insert 3 hex head screws. Note: Torque to 40 in-lbs

Note: Above picture has thrust washer

already installed over journal bearing.

Note: Using a torque wrench to tighten

screws.

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STEP 3 Install lower thrust washer if not already in place.

STEP 4 Install high-speed shaft assembly.

STEP 5 Re-install the sump tube into the bearing plate.

STEP 6 Re-install the upper journal bearing into the bearing plate. Note: Tighten hex head screws to 40 in-lbs.

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STEP 7 Install new thrust washer. Thrust washer is silver disc in center.

STEP 8 Install bearing plate without gasket using alignment pins. Using alignment pin to install the bearing plate temporarily.

STEP 9 Clamp bearing plate to the lower gearbox housing. Clamping the bearing plate to housing. Note: “C” clamps can be utilized to perform

this task.

37

STEP 10 Inspect endplay of the high-speed shaft. Note: Endplay must fall within these

tolerances, 0.015” +/- 0.002”

Measuring endplay of High Speed Shaft. Note: For complete instructions for checking endplay refer to the “Procedure for Checking High Speed Shaft Endplay” later in this manual

STEP 11 Remove bearing plate and install lower housing gasket and o-ring at oil passage

STEP 12

Lubricate the journal bearings, high-speed shaft, journal/thrust face with standard gearbox lubricant. Lubricating the high-speed shaft.

38

STEP 13 Lubricate the lower idler bearing.

STEP 14 Install idler shaft assembly. Note: The idler shaft assembly sits at a

slight tilt to allow installation of the bearing plate.

STEP 15 Install the bearing plate.

39

STEP 16 Install lube pump.

STEP 17 Install lube pump spring. The lube spring sits inside the lube pump.

STEP 18 Lubricate the lube pump.

STEP 19 Install input shaft assembly. Note: Notice the input slots for the oil pump

drive pins.

40

STEP 20 Push on input shaft to verify engagement of drive pins.

STEP 21 Set idler shaft assembly in place and engage input gears.

STEP 22 Lube input shaft bearings and upper idler bearings.

STEP 23 Install upper housing gasket and o-ring.

41

STEP 24 Install upper gearbox housing. Note: Lower carefully in order to slide

bearings into bearing liners.

Note: Use hoist when available to prevent

personal injury.

STEP 25 Install close tolerance alignment pins. Note: Install first pin as noted on the bearing

plate.

STEP 26 Install new lip seal. Note: Use lip seal installation tool #T-

H006AA-47 to install lip seal.

Putting lip seal onto lip seal installation tool. Installing the lip seal.

42

STEP 27 Install remainder of gearbox hex head bolts. Installing washers and nuts onto gearbox bolts. Note: Torque to 65 ft-lbs.

STEP 28 Install fill and vent fitting. Note: Use pipe dope on all pipe threads.

Use pipe wrench to tighten fitting after sliding into place.

STEP 29 Install shaft anti-rotation device to prevent the impeller from spinning.

43

STEP 30 Turn gearbox over.

STEP 31 Install gearbox-mating ring.

STEP 32 Install gearbox-mating ring o-ring

44

STEP 33 Install gearbox seal o-ring onto gearbox seal.

STEP 34 Install gearbox seal.

STEP 35 Install three gearbox seal hex head screws. Note: Torque screws to 75-80 in-lbs.

45

Table 1. Torque Values Gearbox

Sundyne Standard Steel Screws & Bolts and NACE Compliant Steel Screws/Bolts (BG Material) Torque Values

Item # Location Size English Metric 905H Oil Filter Manifold 3/8 - 16 x 1/2 22 - 25 ft-lbs 30 - 34 N-m 905L Gearbox Seal 1/4 - 20 x 1/2 75 - 80 in-lbs 8.5 - 9.0 N-m 905M, N Journal Bearings #10 - 24 x 1 35 - 40 in-lbs 4.0 - 4.5 N-m 905T Chemical Barrier Gasket 1/4 - 20 x 5/8 75 - 80 in-lbs 8.5 - 9.0 N-m 909B Gearbox Halves 1/2 - 13 x4 60 - 65 ft-lbs 81 - 88 N-m 909C Gearbox Halves, Alignment 5/8 - 18 x 4 17/64 60 - 65 ft lbs 81 - 88 N-m 906B Sight Glass #8 - 32 x 1/2 10 - 12 in-lbs 1.0 - 1.4 N-m

Pumps & Compressors* Sundyne Standard Steel Screws and Bolts

Torque Values Item # Location Size English Metric

3 Impeller Bolt/Inducer: LMV/BMP-801, 802, 806, 322, 311, 331 1/2 - 20 36 - 40 ft-lbs 49 - 54 N-m LMV/BMP-341, 346 1/2 - 20 65 - 70 ft-lbs 88 - 95 N-m LMV-313, 343, BMP-338, 348 (High

Flow) 3/4 - 10 85 - 90 ft-lbs 115-122 N-m

LMC/BMC 3X1P, 3X1F, 3X3, 3X6P, 3X7 1/2 - 20 36 - 40 ft-lbs 49 - 54 N-m 906D Diffuser Attaching Screws 1/4 - 20 95 - 102 in-lbs 11 - 11.5 N-m 905E Mechanical Seal No. Spacer 1/4 - 20 x 12 95 - 102 in-lbs 11 - 11.5 N-m 905F Throttle Bushing/Mechanical Seal 1/4 - 20 x 12 9 5- 102 in-lbs 11 - 11.5 N-m 905G Double Seal with Spacer 1/4 - 20 x 3/4 95 - 102 in-lbs 11 - 11.5 N-m 914A Case Nuts 3/4 - 10 250 - 275 ft-lbs 340 - 375 N-m 914A Case Nuts 7/8 - 9 300 - 330 ft-lbs 405 - 445 N-m 905A Seal Housing to Gearbox 3/8 - 16 x 1 3/4 35 - 40 ft-lbs 47 - 54 N-m 905P Separator 1/4 - 20 x 5/8 95 - 102 in-lbs 11 - 11.5 N-m

Pumps & Compressors NACE Compliant Steel Screws / Bolts (BG Material)

Torque Values Item # Location Size English Metric

3 Impeller Bolt/Inducer: LMV/BMP-801, 802, 806, 322, 311, 331 1/2 - 20 36 - 40 ft-lbs 49 - 54 N-m LMV/BMP-341, 346 1/2 - 20 65 - 70 ft-lbs 88 - 95 N-m LMV-313, 343, BMP-338, 348 (High

Flow) 3/4 - 10 85- 90 ft-lbs 115 - 122 N-m

LMC/BMC 3X1P, 3X1F, 3X3, 3X6P, 3X7 1/2 - 20 36 - 40 ft-lbs 49 - 54 N-m 906D Diffuser Attaching Screws 1/4 - 20 70 - 75 in-lbs 8.0 - 8.5 N-m 905E Mechanical Seal No. Spacer 1/4 - 20 70 - 75 in-lbs 8.0 - 8.5 N-m 905F Throttle Bushing/Mechanical Seal 1/4 - 20 70 - 75 in-lbs 8.0 - 8.5 N-m 905G Double Seal with Spacer 1/4 - 20 70 - 75 in-lbs 8.0 - 8.5 N-m 914A Case Nuts 3/4 - 10 160 - 200 ft-lbs 217 - 270 N-m 914A Case Nuts 7/8 - 9 225 - 245 ft-lbs 305 - 332 N-m 905A Seal Housing to Gearbox 3/8 - 16 x 1 3/4 27 - 30 ft-lbs 47 - 54 N-m 905P Separator 1/4 - 20 x 5/8 70 - 75 in-lbs 8.0 - 8.5 N-m * When using Teflon® o-rings, allow 15 minutes between torquing for the Teflon® to cold flow. Repeat torquing until there is no change in torque.

46

Parts List

1. General

Assemblies, subassemblies and components of the Sundyne LMC/BMC-311F compressors are illustrated on the following exploded and cross sectional views. Refer to your Sundyne specification sheet for those options applicable to your compressor. The corresponding parts lists, keyed to each part by item number, identify detail parts by part name, quantity and location.

2. Recommended Spare Parts

Refer to pages 68 and 69 for recommended spares. The quantities listed are intended as general guidelines; actual quantities for a specific application will vary with operating conditions, process liquid, critical nature of service, and inventory considerations. You can obtain assistance for planning an adequate supply of spare parts from your Sundyne Corporation representative.

3. Gearbox Exchanger

A gearbox exchange can be arranged for a fixed price. A replacement gearbox, completely tested and with a full one year warranty can be shipped to anywhere in the continental United States within 48 hours after receipt of the expedited order in Arvada.

4. Repair Kits

Seal and o-ring repair kits are not illustrated herein, but may be purchased directly from Sundyne Corporation. Seal repair kits contain all normally wearing parts (springs, washers, o-rings, carbon faces, etc.) of the compressor or gearbox mechanical seals. O-ring repair kits contain all o-rings necessary for maintenance on overhaul of the compressor. The use of these kits reduces maintenance time, prevents assembly mistakes, simplifies stocking and inventory, and reduces delivery time.

5. Ordering Spare Parts

When ordering spare parts, give the compressor serial number and list each part by part number as shown on the parts list which is included with each compressor shipment (preferred method), or list each part by item number (as listed in this manual), part name and compressor model. Specify quantities desired. Order parts from your Sundyne representative or directly from Sundyne Corporation:

Sundyne Corporation 14845 West 64th Avenue Arvada, CO 80007 (USA) Phone: +1-303-425-0800 or refer to www.sundyne.com for your local representative

47

8. Troubleshooting

Gearbox and Compressor Many factors affect the performance of your compressor. Among them are suction pressure, temperature, molecular weight, driver speed, flow rate, and discharge control. You need to check all of these when there is a problem with the compressor and when you are analyzing the performance of the system. For details on the performance of the compressor including the performance curve. See final data package. Table 2 provides information for analyzing gearbox and compressor problems. Table 2 Troubleshooting for Gearbox and Compressor Trouble Possible Cause Investigative and Corrective Action The compressor produces no flow and no pressure at start-up

A component of the drive, such as the coupling or the impeller spline, has failed, or an item is missing from the assembly

Disassemble and inspect the component.

The drive shaft rotates in the wrong Direction

Make sure that the drive shaft is rotating in the direction shown by the arrow on the compressor gearbox.

The suction valve or the discharge valve is closed.

Check the valving (see section 3. Startup instructions).

The head rise is insufficient. The flow is too high. Check the head rise and the flow rate against the performance curve.

The driver shaft is rotating in the wrong direction.

Make sure that the drive shaft is rotating in the direction shown by the arrow on the compressor gearbox.

The suction pressure is low. Check the Sundyne specification sheets.

Recirculation from the discharge to the inlet is excessive.

Check the flow through the external piping, such as the bypass

The molecular weight is not that for which the compressor was designed.

Check the molecular weight against the value given on the specification sheet. Low molecular weight will cause low discharge pressure.

The driver speed is too low. Check the speed against the value listed on the Sundyne specification sheets.

The pressure gauges or the flow meters are in error

Calibrate the instrumentation.

The oil pressure in the gearbox is low. The pressure gauge is faulty. Check the accuracy of the gauge.

The main lubricating pump has failed. Remove the pump and coupling, and check them for damage.

Driver overloaded. Molecular weight higher than values listed on specification sheet

Check actual molecular weight against value listed on specification sheet.

Electrical failure in electric power unit. Check circuit breaker heater size and setting.

Check voltage.

Current for each phase should be balanced within three percent.

48

Trouble Possible Cause Investigative and Corrective Action Driver overloaded. (continued)

Mechanical failure in driver, gearbox, or compressor.

Disconnect spacer coupling and check for freedom of rotation of compressor, driver, and gearbox shafts.

Drain oil and remove gearbox oil level sight glass and inspect bottom of sump for wear particles. Bearings are probably not damaged if no wear particles are present.

Disassemble compressor end and search for any mechanical failure.

Corrosion pitting on surface of diffuser adjacent to impeller blades. Head rise is reduced by this condition.

Disassemble and inspect. Check diffuser bowl area, cover plate and diffuser throat for material buildup. Clean these areas of all obstructions and restore surfaces to a smooth polished finish (use emery cloth) free of all corrosion pitting. Edge of diffuser throat must be sharp. If damage is more severe (i.e. impeller is deformed or has come in contact with diffuser) replace the damaged parts.

High suction pressure. Check specification sheet. Increase suction pressure and corresponding mass flow rate will result in high horsepower consumption.

Excessive discharge pressure pulsation.

Flow rate too low (surge). Increase flow rate through compressor. Add controlled bypass to suction, if necessary.

Defective flow control valve. Check control valve.

Change of gearbox automatic transmission fluid color from normal color to milky pink or yellow.

Gearbox oil contaminated with water or process fluid.

Inspect gearbox heat exchanger for leakage.

Check for excessive compressor seal leakage.

Inspect shaft sleeve “O” rings.

Shaft sleeve rubs on inside diameter of seal.

Gearbox journal bearing failure. Install replacement exchange gearbox or repair gearbox as outlined under “MAINTENANCE.”

Excessive gearbox automatic transmission fluid consumption.

Low speed shaft seal (115) leakage. Check drain port for leakage. Replace shaft seal if required.

High speed shaft mechanical seal (60C) leakage.

Check for fluid leakage from port 1.

Leakage through heat exchanger into cooling fluid.

Pressure test heat exchanger and replace if required.

Excessive oil foaming. High oil level. Shut down the unit and check oil level.

Low gearbox temperature. Adjust coolant to heat exchanger, keeping oil temperature above 140°F. (60°C).

49

Compressor Mechanical Seals Table 3 provides information on problems with single units, as well as double and tandem seal units. Table 3 Troubleshooting for Gearbox and Compressor Trouble Possible Cause Investigative/Corrective Action Leakage around the seal suddenly increases

The system is operating at a low flow rate or a low inlet pressure, causing vibration of the high-speed shaft, bouncing on the face of the seal, and chipping on the nose of the carbon seal.

Make sure that the compressor always operates above the specified minimum flow rate and/or inlet pressure.

The action of the stationary face spring on the seal is rough and sticky

If contamination in the process gas (from entrained solids) causes a sticky seal, there may be need for a seal flush, double seals, or tandem seals.

The seal is worn or damaged. Disassemble the seal and rebuild or replace it by the instructions in Section 5.

The wear pattern on the rotating faces of the seal is not uniform.

Lightly lap the surfaces on the shaft sleeve and the impeller hub that contact the rotating face of the seal, to remove high spots. Install new seal faces. Do not remove more than 0.005 in. (0.12mm) from any surface.

The rotating face of the seal is cracked or broken. This may have been caused by damage at the assembly or by heating due to lack of leakage (cooling) past the seal.

Make sure that the system operates above the specified minimum flow rate at all times.

Check the seal environment to make sure that there is a leakage path of process or buffer fluid across the compressor seal(s) and that there is a differential across the seal(s) to force this leakage. Replace the damaged seal.

The seal faces, seal parts, or o-rings have become chemically attached.

Investigate the properties of the process gas, and replace the components with chemically resistant materials.

The seal on a low-temperature compressor is icing, or there is heavy condensation on the atmospheric side of the seal.

Purge the atmospheric side of the seal with dry nitrogen gas.

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9. Operation Some form of control is required for the majority of SUNDYNE compressor applications. The purpose of control is twofold: 1) to achieve the desired performance as required by process conditions, and 2) to protect the compressor from mechanical damage due to surge or overload conditions. This section is a general guideline on controls. A control system should be selected only after completion of a detailed analysis of the specific installation. Surge Control

It is recommended that a surge control system be installed whenever there is any chance that the process flow could decrease appreciably from design flow. In most surge control systems, a flow sensor is placed in the suction line to the compressor. The signal from this sensor is input to a controller which controls a valve in the bypass loop. When the minimum safe flow is reached, this valve opens and the flow through the compressor is kept above the surge point. Again, the recycled gas must be cooled to prevent heat build-up. Both pneumatic and electrical surge control systems are available.

Suction Throttling

Suction throttling is generally the most economical control method with a constant speed drive. Throttling the control valve on the suction side causes a reduction of inlet pressure to the compressor. Although the compressor creates the same compression ratio as if it were unthrottled, the discharge pressure is reduced. The net result is to lower the total head output to the system. The reduction of inlet pressure correspondingly decreases inlet gas density, and thus, power consumption. Suction throttling also has the advantage of slightly lowering the compressor surge point.

Discharge Throttling

Discharge throttling is controlled by means of a valve placed at the compressor discharge. A constant speed compressor will always operate on its design head-flow curve. For a given system operating point, the compressor will operate at the system flow rate, thus producing more head than the system requires. This excess head is throttled by the discharge valve. Since the throttling occurs downstream of the compressor, there are no power savings by this method. Discharge throttling offers no real advantages over suction throttling, but is nonetheless an acceptable control method.

Speed Control

Speed control is the most efficient means of compressor control. To operate at points below the design head-flow curve, the driver speed may be reduced accordingly. This creates an infinite “family” of head-flow curves on which the compressor may operate. Since consumed horsepower, assuming constant inlet conditions, varies as the cube of the speed, substantial power savings can be realized. Also, the compressor surge point is lowered proportional to the speed decrease. This method is used mainly on turbine driven units although variable speed motors or mechanical drives are available. Since the main lube oil pump in the SUNDYNE compressor is driven by the gearbox input shaft, provision must be made so the speed is not reduced to a point where adequate lube oil pressure is no longer present.

Flow Bypass

Flow bypass requires a recycle line from the compressor discharge to suction. The compressor is operated at the desired flow or discharge pressure and the excess flow not

51

required by the process is recycled through the bypass. A cooler is required in the loop to cool the recycled gas to normal suction temperature. This method is generally less efficient than other methods discussed, but may be warranted in some special situations.

Other aspects which should be considered in compressor operation are:

Series Compressor Control - Inlet throttling on the first stage is the most practical method of controlling compressor in series. It is necessary to throttle only the first stage, which in turn acts as a throttle for the second stage. Inlet throttling between stages offers no advantages and should be avoided. Efficiency gains by variable speed control of series units will seldom justify its cost and complexity.

Surge control on series units consists of a flow sensor and controller in the suction line of the first stage. This sends a signal to the control valve in a bypass loop around both compressors. It must be determined which compressor surges at the lowest inlet flow to the first unit so the flow controller can be set such that neither compressor will surge. A more complex system which offers maximum machine protection consists of separate bypass loops for each unit which are operated by separate flow controllers. Parallel Compressor Control - The control of two or more compressors operating in parallel would appear to be relatively simple. More than likely, though no two compressors ever operate identically across their flow range. To produce identical discharge pressures, one compressor could be operating at a different flow than the unit in parallel with it. As a result, the control system would have to include a separate flow controller for each unit. Either suction or discharge throttling may be used, but again, suction throttling is the preferred method. If variable speed drivers are used, extreme care must be taken to insure that the speeds can be precisely controlled. In any case, check valves must be installed in the discharge line of each compressor to prevent possible back flow due to any slight imbalance in the characteristics of the compressors. Separate surge control systems for each compressor should be considered for maximum unit protection.

10. Spare Parts

1. General

Assemblies, subassemblies and components of the Sundyne compressor are illustrated on the exploded and cross sectional views in Reference D. Refer to your Sundyne Compressor Specification Sheet for those options applicable to your compressor. The corresponding parts lists, keyed to each part by item number, identify detail parts by part name, quantity and location. A complete bill of materials list for the compressor and gearbox end is included in the final data package. Refer to the unit outline drawing for a list of the major kit bills of material.

2. Recommended Spare Parts Refer to your final data package for recommended spare parts identified for your particular unit.

These are provided as guidelines only.

52

3. Repair Kits Seal and o-ring repair kits are not illustrated herein, but may be purchased directly from

Sundyne Corporation. Seal repair kits contain all normal wearing parts (springs, washers, o-rings, carbon faces, etc.) of the compressor or gearbox mechanical seals.

O-ring repair kits contain all o-rings necessary for maintenance or overhaul of the compressor.

The use of these kits reduces maintenance time, prevents assembly mistakes, simplifies stocking and inventory, and reduces delivery time.

4. Ordering Spare Parts When ordering spare parts, give the unit serial number and list each part by the part number as

shown on the Bill of Material which is included with each compressor shipment (preferred method), or list each part by item number (as listed in this manual), part name and compressor model. Specify quantities desired.

Order parts from your Sundyne representative or directly from Sundyne Corporation at one of

the following locations. Sundyne Corporation Phone Number: +1-303-940-2989 14845 West 64th Avenue Fax Number: +1-303-940-2826 Arvada, Colorado 80007, USA Sundyne Corporation Europe Phone Number: +011-333-80-38-3300 (13-15 Boulevard Eiffel Fax Number: +011-333-80-38-3366 Zone Industrielle De Dijon-Sud 21600) B.P. 30 21604 Dijon (Longvic) France Or visit our Genuine Service and Parts site at www.sundyne.com.

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11. Sundyne Compressor Warranty Sundyne Compressors warrants to Purchaser for a period of 12 months from the date the line mounted compressor (LMC) is placed in service (not to exceed 18 months after shipment date) that the equipment at the time of shipment is free from defects of material and workmanship. If any defects occur during the warranty period, Sundyne’s sole obligation is limited to alteration, repair, or replacement at Sundyne’s expense, F.O.B. factory, of parts and equipment, which upon Sundyne’s examination prove to be defective. Non-Sundyne equipment and accessories are warranted only to the extent of and by the original manufacturer’s warranty. Sundyne is not liable for damage or wear to equipment caused by abnormal conditions, vibration, improper lubrication, failure to provide proper inlet conditions or flow, corrosives, abrasives, or foreign objects. This warranty is exclusive and in lieu of all other warranties, whether expressed or implied, including any warranty of merchantibility or fitness for any purpose. In no event shall Sundyne be liable for consequential or incidental damages. COPYRIGHT All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise without the prior permission of Sundyne Compressors.

EUROPEAN UNION MACHINERY DIRECTIVE (CE Mark System) (where applicable) This document incorporates information relevant to the Machinery Directive 89/392/EEC. It should be read prior to the use of any of our equipment. Individual maintenance manuals which also conform to the EU Directive should be read when dealing with specific models. SAFETY WARNING Sundyne Compressors manufactures centrifugal process gas compressors to exacting International Quality Management System Standards (ISO 9001 - 1987) as certified and audited by Lloyd's Register Quality Assurance Limited. Genuine parts and accessories have been specifically designed and tested for use with these products to ensure continued product quality and performance. As Sundyne Compressors cannot test all parts and accessories sourced from other vendors, incorrect design and/or fabrication of such parts and accessories may adversely affect the performance and safety features of these products. Failure to properly select, install or use authorized Sundyne Compressor parts and accessories is considered misuse and damage or failure caused by misuse is not covered by Sundyne’s warranty. Additionally, modification of Sundyne Compressor products or removal of original components may impair the safety of these products and their effective operation.

54

Reference A

Critical Start-up Checklist Know Your Machine Before servicing and starting up the Sundyne line mounted compressor (LMC), carefully review the specification sheet, the outline drawings, the performance curves, and this instruction manual. You should be familiar with the configuration of the compressor before you start and operate it. Driver Instructions Carefully follow the installation and starting instructions provided by the manufacturer of the driver. This is included in the final data package. Auxiliaries 1. Check the utility connections. 2. Verify that the auxiliary piping conforms to Sundyne’s drawings. 3. Verify the connections of the switches, the instruments, and the set points. 4. Calibrate the flow instruments and the other transmitters. Environmental Control System Install a system to control the environment of the seal, if required, and verify that port 1 is properly vented. Drain the compressor casing. (Maximum back pressure = 10 psig) Pressurize Fluid Loop Pressurize double seal buffer fluid loop or external seal flush, if required, prior to admitting fluid into compressor casing. Check Driver Rotation Make sure that the gear shaft rotates in the direction indicated by the arrow stamped on the gearbox of the compressor. Start Compressor 1. Suction throttling (preferred method): Start the compressor with the discharge valve open while

throttling the suction valve, to bring the compressor to the design operating point. See specification sheets for the inlet conditions and flow rate.

2. Discharge throttling: Start the compressor with the suction valve completely open while throttling

the discharge valve, to bring the compressor to the design operating point. 3. Variable speed (as applicable): Start the compressor with the suction valve and the discharge

valve open. Check the pressure in the system. If it exceeds the surge point of the compressor (see the specification sheet and the performance curve), you will need a bypass to protect the compressor from surging during ramp-up to speed. Never operate the compressor above the maximum design speed.

Heat Exchanger If a heat exchanger for the gearbox is installed, adjust the cooling flow to keep the temperature of the gearbox sump at 120°-180°F (49°-82°C).

55

Check Check the following items. Each of these parameters significantly affects the performance of the system. Head rise, Flow rate, Power consumption, Inlet pressure, Temperature; and Molecular weight. Coupling There are two types of connections between the motor and gearbox; a splined shaft or a coupling. For splined connections, the splined shaft must be lubricated with the supplied spline grease and the two o-rings installed prior to mounting the motor. It is recommended that the input shaft be rotated by hand prior to mounting the motor. If the unit has a coupling, be sure coupling gap is correct and bolting between coupling halves is tight. The instruction manual contains coupling set-up information. Process Conditions Do process conditions; suction pressure, suction temperature, discharge header pressure, and mole weight agree with specification sheet information? Check with your Sundyne Corporation representative if you must test a different gas than shown on the specification sheet. Auxiliary Lube Pump If you have an auxiliary lubrication pump, unlock the electrical circuit and start it in the “hand” position. Check for oil leaks and recheck the oil level. Piping Connections Are the following bolted/threaded connections tight: a. Compressor flange bolts? b. Seal environment piping and port connections? c. Cooling water connections to heat exchanger? (if applicable) d. Gearbox oil drain plug? e. Compressor case drain plug? Reference B Lock-out/Tag-out Guidelines Follow Your Company’s Lock-Out / Tag-Out Procedure When Servicing Sundyne Compressors. Never remove a lock or tag applied by someone else. Additional locks or tags should be applied if multiple groups are working on the equipment. Each responsible work group leader should apply a lock or tag. Always treat conductors and equipment as if they are energized. Reference C Seal Arrangement Drawings for Single, Double and Tandem Configurations

56

Item No.

Part Name

Qty.

Item No.

Part Name

Qty.

21B Throttle Bushing 1 158C Shim Spacer 1 50 Slinger Sleeve Assembly 1 905E Hex Head Cap Screw 3

51A Sal Rotating Face 1 905F Hex Head Cap Screw 3 51D Seal Rotating Face (Gearbox) 1 905L Hex Head Cap Screw 3 60A Mechanical Seal (Lower) 1 916A Washer 3 61A • Retainer & Drive Sleeve Assembly 1 916B Washer 3 62A • Seal Face Washer 1 916K Washer 3 65A • Coil Spring Set 1 936G O-Ring Packing 2 68A • Backing Ring 2 936H O-Ring Packing 2 69A • O-ring Packing 1 936J O-Ring Packing 1 60C Mechanical Seal (Gearbox) 1 936K O-Ring Packing 1 61C • Retainer & Drive Sleeve Assembly 1 936P O-ring Packing 1 62C • Seal Face Washer 1 64C • Seal Retaining Ring 1 65C • Coil Spring Set 1 69C • O ring Packing 1

Figure 4. SINGLE SEAL ARRANGEMENT

57

Item No.

Part Name

Qty.

Item No.

Part Name

Qty.

50A Shaft Sleeve (Lower) 1 60B Mechanical Seal (Liquid Seal) 1 50B Shaft Sleeve (Upper) 1 61B • Retainer & Drive Sleeve Assembly 1 51C Seal Rotating Face 1 62B • Seal Face Washer 1 51D Seal Rotating Face (Gearbox) 1 63B • Seal Spring Backup Disc 1 52 Seal Spacer 1 64B • Seal Retaining Ring 1

65B • Coil Spring Set 1 60A Mechanical Seal (Gas Seal) 1 68B • Seal Wedge Ring 1 61A • Retainer & Drive Sleeve Assembly 1 62A • Seal Face Washer 1 60C Mechanical Seal (Gearbox) 1 65A • Coil Spring Set 1 61C • Retainer & Drive Sleeve Assembly 1 63A • Backing Ring 2 62C • Seal Face Washer 1 68A • Seal Retaining Ring 1 64C • Seal Retaining Ring 1 69A • O-Ring Packing 1 65C • Coil Spring Set 1

69C • O-Ring Packing 1 60A Mechanical Seal (Liquid Seal) 1 61A • Retainer & Drive Sleeve Assembly 1 158C Shim Spacer 1 62A • Seal Face Washer 1 905F Hex Head Cap Screw 3 63A • Seal Spring Backup Disc 1 905G Hex Head Cap Screw 3 64A • Seal Retaining Ring 1 905L Hex Head Cap Screw 3 65A • Coil Spring Set 1 916A Washer 3 68A • Seal Wedge Ring 1 916B Washer 3

916K Washer 3 60B Mechanical Seal (Gas Seal) 1 936G O-Ring Packing 2 61B • Retainer & Drive Sleeve Assembly 1 936H O-Ring Packing 2 62B • Seal Face Washer 1 936J O-Ring Packing 1 65B • Coil Spring 1 936K O-Ring Packing 1 63B • Backing Ring 2 936P O-Ring Packing 1 68B • Seal Retaining Ring 1 69B • O-Ring Packing 1

Figure 5. DOUBLE SEAL ARRANGEMENT

58

Item No.

Part Name Qty. Item No.

Part Name Qty.

50A Shaft Sleeve (Lower) 1 60C Mechanical Seal (Gearbox) 1 50B Shaft Sleeve (Upper) 1 61C • Retainer & Drive Sleeve Assembly 1 51A Seal Rotating Face 1 62C • Seal Face Washer 1 51C Seal Rotating Face 1 64 C • Seal Retaining Ring 1 51D Seal Rotating Face (Gearbox) 1 65C • Coil Spring Set 1

69C • O-Ring Packing 1 60A Mechanical Seal (Lower) 1 61A • Retainer & Drive Sleeve Assembly 1 158C Shim spacer 1 62A • Seal Face Washer 1 905E Hex Head Cap Screw 3 64A • Seal Retaining Ring 1 905F Hex Head Cap Screw 3 65A • Coil Spring Set 1 905L Hex Head Cap Screw 3 68A • Backing Ring 2 916A Washer 3 69A • O-Ring Packing 1 916B Washer 3

916K Washer 3 60B Mechanical Seal (Upper) 1 936G O-Ring Packing 2 61B • Retainer & Drive Sleeve Assembly 1 936H O-Ring Packing 2 62B • Seal Face Washer 1 936J O-Ring Packing 3 64B • Seal Retaining Ring 1 936K O-Ring Packing 1 65B • Coil Spring Set 1 936P O-Ring Packing 1 68B • Backing Ring 2 69B • O-Ring Packing 1

Figure 6. TANDEM SEAL ARRANGEMENT

59

Reference D Compressor/Gearbox

Figure 7

60

Figure 8. Compressor Exploded View

61

Figure 9. 200 HP Gearbox Exploded View

62

Item No.

Part Name

Qty.

Item No.

Part Name

Qty.

116 Coupling 1 914G Hex Nut 4 117 Input Coupling 1 914H Hex Nut 4 118 Coupling Housing 1 916E Washer 4 119 Hub 1 916M Washer 4

904A Screw 4 916N Washer 4 905J Hex Head Cap Screw 4 916P Washer 4 905R Hex Head Cap Screw 4 916R Washer 4 909D Hex Head Bolt 4 916AC Washer 4 914D Hex Nut 4 920E Key 4

Figure 10. Flexible Coupling

Item No.

Part Name

Qty.

106 107

905T 916V

Chemical Barrier Gasket Seal Spacer Hex Head Cap Screw Seal Washer

1 1 3 3

See Pages 56 and 57 for Recommended Spare Parts.

Figure 11. Chemical Barrier Gasket

63

Figure 12. Flexitalic Gasket

• ANSIMAG • CASTER • GSP • HMD/KONTRO • MASO/SINE • SCMP • COMPRESSORS • SUNDYNE • SUNFLO •

14845 W. 64th Avenue • Arvada, Colorado 80007 USA • +1-303-425-0800 • FAX: +1-303-425-0896 • www.sundyne.com Sundyne Europe • Dijon (Longvic) • France • +33 (0) 3.80.38.33.00 • FAX: +33 (0)3.80.38.33.66 Sundyne Nikkiso • 27-10, Ebisu 2-Chome, Shibuya-Ku • Tokyo 150-0013, Japan • +81-3-3444-6475 • FAX: +81-3-3444-6806