SUNDYNE LMC/BMC-313/333 Compressors

Instruction and Operation Manual

August 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 Compressor Disassembly ..............................................................................................16 Diffuser Gap Setup and Impeller/Diffuser Cover Alignment ...........................................21 Impeller/Diffuser Clearance Calculation .........................................................................23 Gearbox Disassembly ....................................................................................................25 Checking High-Speed Shaft End Play ...........................................................................33 Gearbox Assembly.........................................................................................................36 6. Troubleshooting ......................................................................................................47 7. Operation .................................................................................................................50 8. Spare Parts ...............................................................................................................51 9. Sundyne Compressor Warranty .............................................................................55 Critical Start-up Checklist ...........................................................................................56 Lock-out/Tag-out Guidelines ......................................................................................57 Single Seal Arrangement ............................................................................................58 Double Seal Arrangement ...........................................................................................59 Tandem Seal Arrangement .........................................................................................60 Compressor/Gearbox Drawings .................................................................................61

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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 pump 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-313/333 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. Troubleshooting Provides tables for the following: a) Looking up a problem. b) Identifying the possible cause. c) Selecting the corrective action. 7. Operation

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

8. Spare Parts

Contact and reference information.

9. Sundyne Compressor Warranty Provides a warranty statement for the compressor/gearbox unit.

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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.

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.

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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 USA at (303)-425-0800 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 possibly 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 as 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. Table 1: 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/cm^2) 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 units 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. See Reference A for Critical Startup Check List.

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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 manufacturers 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. SFHC recommended 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,331F 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.

Compressor Disassembly

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 936A 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 1

• O-Ring Seal 936J 1

• O-Ring Seal 936K 2

• O-Ring Seal 936P 1

• O-Ring Seal 936V 1

• O-Ring Seal 936Z 1

• Single Seal 1

• Double Seal 2

• Tandem Seal 3

*O-Rings 936B and 936C are NOT INCLUDED in the O-ring Repair kit. Must be purchased separately.

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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.

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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 2

Prevent impeller from rotating and remove inducer (9). Note that impeller has a left-hand thread.

STEP 3

Remove impeller (2).

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

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

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Step 5 If diffuser removal is required, insert three eyebolts (customer furnished 5/16-18 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.

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.

NOTE For specific seal arrangement, see Reference C, Seal Arrangement Drawing.

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 9. 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 9.

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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.

• 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.

(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.

(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.

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 below show the various thicknesses that are available:

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Figure 1. Compressor Cross Section

Figure 2. Compressor Clearances

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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 9.

(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 9.

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

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(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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Gearbox Disassembly

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 hex head cap screws (905L) and washers (916K). Remove gearbox mechanical seal (60C) rotating face (51D), and o-ring (936P). The gearbox mechanical seal may be rebuilt or replaced as described in Step 8 under “Compressor Disassembly”. Replace or lap the seal rotating face if the wear track is rough or worn to a depth greater than 0.002 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. During re-assembly, install the gearbox seal rotating face with the large chamfer on the inside diameter inserted toward the gearbox to clear the radius on the shaft shoulder. Remove any high spots on the end surfaces of the shaft sleeve to insure that the seal rotating face will not be distorted by the clamping force of the impeller bolt.

Step 4 Remove the fill vent piping by unscrewing the ¾-inch pipe elbow (947A). Step 5 Remove bolts (909B and 909C) and remove the gearbox input housing (101B) by lifting the tapping on the underside of the input housing with a soft mallet.

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Step 6 Using a hammer and punch, remove input shaft lip seal (115). Exercise care to avoid damaging the gearbox housing.

NOTE If the aluminum housing bore, for lip seal, is scratched, apply a light coat of oil-proof gasket cement to the outside diameter of the new shaft seal before replacing.

Step 7 Lift the idler shaft (140) out of the lower bearing liner, disengaging upper idler and input shaft gears. Step 8 Remove the low speed shaft (120) from the gearbox bearing plate (102)

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Step 9 Inspect anti-friction bearing (125C and 125D) for smooth rotation, worn outside diameter of outer races and snugness of the inner races on the shafts. Replace if bearings have been in operation for more than one year, if rotation is not smooth, or if outside or inside diameters are worn. CAUTION It is essential to replace anti-friction bearings with the manufacturer’s approved replacement bearings. Non-approved replacement bearings may jeopardize mechanical integrity of the gearbox/compressor. Anti-friction bearings should be pressed onto the shaft using a press which contacts only the inner race. Bearing damage will occur by pressing or pulling the outer race. No more than 0.001 inch (0.03mm) gap should exist between bearings, spacers, gears and shaft shoulders. Do not use heat to assemble bearings to the shaft. Inspect the inside of the anti-friction bearing liners, see Figure 4. If a bearing liner inside diameter is more than referenced in Figure 4, replace the gearbox input housing (101B), gearbox output housing (101A), or bearing plate (102), whichever contains the worn liner. Bearing liners are not replaceable in the field.

Step 10 Inspect the low speed shaft (210) spherical roller bearing contact areas, (See Figure 4). If the outside diameter of either shaft is less than 1.5748 inches (40.00mm), install a new shaft. Step 11 Remove the high-speed shaft (130) from the gearbox output housing (101A).

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Step 12 Remove the internal lube oil compressor (160).

Step 13 Remove gearbox bearing plate (102).

STEP 14 Remove idler shaft (140).

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Step 15 Remove the upper journal bearing (151B) and thrust washer (155B) if used. Remove the lower journal bearing (151A) and thrust washer (155A) if used.

NOTE Upon removal of the upper and lower journal bearing assemblies, tag the bearings so that they can be reinstalled in their proper location.

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Step 16 Inspect upper and lower thrust washers (155B and 155A) or tilting pad bearing assembly (151B). If metal is smeared into radial lube grooves of the washer face, install a new washer. If tilting pads do not tilt freely, or if they show signs of metal pickup or overheating, install a new bearing assembly. Inspect the thrust runner (133B) and high-speed shaft at thrust washer and journal bearing contact areas. If the outside diameter of the shaft is less than 1.4960 inches (38.00mm), or if the shaft has bearing or washer material on its surface, or shows signs of overheating or wear to a depth greater than 0.001 inch (0.03 mm), install a new shaft and gear assembly.

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Step 17 Visually inspect helical gear (122A), spur gear (122C) and pinion gears (132B and 132C) for pits, chips, gear tooth wear or excessive wear between gear and shaft. The thrust runner and gears are shrink fitted to the shaft. Use a 10 ton hydraulic press or equivalent for gear removal. A new gear can be installed on the low speed shaft by heating the part to 250°F (121°C) and pressing it into position on the shaft. Using a 10 ton press, the part should be pressed rapidly into place to avoid heating of the shaft. In 400 hp gearboxes heat the gear to 375° - 400°F (190° - 204°C) and cool the shaft to 0°F (-18°C) No more than 0.001 inch (0.03mm) gap should exist between the shaft shoulder, gears, spacers, and bearings. The high-speed shaft assembly is dynamically balanced; high-speed shaft gears cannot be replaced in the field.

NOTE

Remove lube jets and journal bearings. Clean all lube passages with solvent and blow dry with clean air. Clean all other parts thoroughly and lubricate with ATF or light turbine oil. Reinstall jets into housings immediately.

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Checking High-Speed Shaft End Play

Step 1 Install the lower journal bearing (151A) into the gearbox output housing (101A). With no shim spacers installed, tighten screws (905M).

Step 2 Install the upper journal bearing or bearing assembly (151B) into the bearing plate (102). With no shim spacers installed, tighten screws (905N). CAUTION Shims are never installed behind the upper journal bearing.

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Step 3 If used, place both upper and lower thrust washers (155B and 155A) into lower journal bearing. Place the high-speed shaft assembly (A130) into the gearbox output housing.

Step 4 With the aid of two large-diameter alignment bolts (909C), install bearing plate (102) without o-rings. Clamp the bearing plate to output housing with two “C” clamps or bolts.

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Step 5 With the shaft in a vertical position, move the shaft up and down while measuring the total end play with a dial indicator or depth micrometer. Shaft end play must be 0.015 + 0.002-inch (0.38 + 0.05mm). If end play is not within this limit, calculate the shim thickness required to place the shaft within the proper clearance range. Select the required thickness shim using 158 Series shim spacer sizes.

Step 6 Remove the alignment bolts (909C) and bearing plate (102) with upper journal bearing (151).

Step 7 Remove high-speed shaft (A130), thrust washers (if used) (155A & B) and lower journal bearing (151A).

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Gearbox Assembly

Step 1 Install the required shim spacers in place on the gearbox output housing and replace the lower journal bearing. Install attaching bolts (905M) and tighten.

Step 2 Install the lower thrust washer (155A - if used) with the flat side on the bearing surface and replace the high- speed shaft. Step 3 Install the upper thrust washer (155B - if used) with the flat side on the upper journal bearing surface. A light grease may be used to hold the thrust washer in place.

Step 4 In the lower gearbox housing, install lower idler journal bearing (151D), washers (154AB) and screws (905B). Tighten to proper torque values. Install thrust washer (155D)

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Step 5 Prepare bearing plate for final assembly. Install relief valve (175). Note: The LMC-313 unit does not have an external relief valve.

Step 6 Install lube pump (160), 3 screws (905BU) with washers (154Z) and tighten. Install lube jet (174D) in the bearing plate. Note: On 313 models, a smaller lube pump and spring are used in place of lube pump shown here. Ensure contact with anti-rotation pin and place spring on top of pump.

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Step 7 Continue re-assembly of the gearbox by placing idler shaft (140) in the lower half of the gearbox.

Step 8 Position the lube passage o-ring (936T) and housing o-ring (936AG). Position bearing plate (102) on the lower half of the gearbox. Note: On 313 models, a cork gasket is used in place of the housing o-ring.

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Step 9 With the bearing plate in place, lift the idler shaft and tilt to the side.

CAUTION Do not damage gears or thrust washer.

Install the low speed shaft assembly into the bearing plate, bearing liner with the shaft aligned so that the lube compressor drive pin slips into the slot in the low speed shaft. Top surface of the bearing should be even with the top of the bearing liner. At this time the idler shaft should be lowered into the lower idler bearing engaging the four gears. NOTE: The input and upper idler gears are helical and will require a slight rotation to engage the gears. The upper and lower input bearings are spherical roller bearings. In order to install the upper gearbox housing, the input shaft must be vertical and the bearing retainers horizontal and square. A machinist’s level is useful in positioning the shaft and bearing retainers.

40

Step 10 Assemble the upper idler journal bearing (151C), screws (905AA) and washers (916AB) into the upper gearbox housing (101B). This is a very tight fit. It is recommended that the bearing be frozen to facilitate assembly. Install lube jet (174C) into the upper housing at the upper input bearing location.

Step 11 Install the sump tube(173), and pipe connectors (944A & B) into the bearing plate.

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Step 12 Install the lube galley o-ring (936T) and the housing split line o-ring (936AG). Note: On 313 models, cork gasket is used in place of the housing o-ring.

Step 13 Pre-lubricate the upper idler journal and the input shaft bearings.

Step 14 Lower the upper gearbox housing (101B) onto the bearing plate. Align the upper idler bearing over the upper idler shaft journal. Use a machinist’s level to keep the housing level as it is lowered over the input shaft. It is a very tight fit between the upper input bearing race and the upper housing bore. It may take several attempts to assemble the upper housing. Do not use force. It will not work and damage to the bearings may occur.

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Step 15 Install and tighten the 2 close tolerance alignment bolts (909C) and washers (916J), and the 7 housing bolts (909B) and washers (916H). Assemble and tighten to the proper torque value the alignment nuts (914F) and washers (916J) and the housing nuts (914E) and washers (916H).

Step 16 Install the fill and vent fitting.

Step 17 Install a new input shaft lip seal (115), using tool number TO06AA47. If the tool is not available, place tape over the input shaft keyway to protect the lip seal, and carefully tap the lip seal into the housing bore. Install the rubber dust cover (98)

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Step 18 Turn the gearbox over and install the gearbox seal rotating face (51D).

Step 19 Install o-ring (936K) over the gearbox seal retainer and install the gearbox seal (60C), washers (916A) and hex head cap screws (905E). Tighten to the proper torque values.

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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.

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Idler Shaft Upper Bearing (400 HP Gearbox Only)

Lower Idler Bearing and Shaft Clearances

Input Shaft Upper Bearing

Minimum OutsideDiameter of UpperLowSpeed Shaft1.9684 Inches (49.99mm)

H006AG04

Maximum InsideDiameter ofBearing Liner4.3326 Inches (110.02mm)

Input Shaft Lower Bearing

Maximum InsideDiameter of Bearing Liner3.5460 Inches (90.07 mm)

Minimum OutsideDiameter of LowerLow Speed Shaft1.5752 Inches (40.00 mm)

Figure 4. Bearing and Shaft Clearance

Minimum Outside Diameter of Upper Low-Speed Shaft

1.9684 inches (49.99mm)

Maximum Inside Diameter of Bearing Liner 3.5460 Inches (90.07 mm)

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Journal Bearing and High-Speed Shaft Clearances

Tilting Pad Thrust Bearing and High- Speed Shaft Clearances

Tilting Pad Radial and High-Speed Shaft Clearances

H005AD13

Figure 4. Bearing and Shaft Clearances

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6. 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, final data package sections 1 and 2 and specification sheets. 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.

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

Electrical failure in electric power unit. (cont’d)

Current for each phase should be balanced within three percent.

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).

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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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7. 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 control 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 required by the process is recycled through the bypass. A cooler is required in the loop to cool the recycled gas

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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.

8. 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.

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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 Fluid Handling representative or directly from Sundyne Corporation at one of

the following locations. Sundyne Corporation Phone Number: +1-303-940-2989 14845 West 64th 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 Longvic Cedex France Or visit our Genuine Service and Parts site at www.sundyne.com.

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Sundyne Compressor Recommended Spare Parts 200 HP Gearbox: 313

Class 1 Class 2 Class 3

Item No. Part Name Qty. Qty. Qty. 3 Impeller Bolt 0 1 1 4 Impeller Key 1 1 1 87A Barrier Gasket 1 2 2 60A Mechanical Seal (Lower) 1 1 2 60B Mechanical Seal (Upper) 1 1 2 Seal Repair Kit Lower) + + + Seal Repair Kit (Upper) + + + 50A Shaft Sleeve (Lower) 0 1 1 50B Shaft Sleeve (Upper) 0 1 1 51A Rotating Face (Lower) 1 1 2 51C Rotating Face (Upper) 1 1 2

O-Ring Repair Kit 1 2 2

400 HP Gearbox: 333

Class 1 Class 2 Class 3 Item No. Part Name Qty. Qty. Qty.

3 Impeller Bolt 0 1 1 87A Barrier Gasket 1 2 2 60A Mechanical Seal (Lower) 1 1 2 60B Mechanical Seal (Upper) 1 1 2 Seal Repair Kit (Lower) + + + Seal Repair Kit (Upper) + + + 50A Shaft Sleeve (Lower) 0 1 1 50B Shaft Sleeve (Upper) 0 1 1 51A Rotating Face (Lower) 1 1 2 51C Rotating Face (Upper) 1 1 2 O-Ring Repair Kit 1 2 2

+ These are alternate items and may be purchased according to user’s preference. Notes: Class 1 Spares – Minimum recommended spare parts necessary to perform a start-up and inspection of a new unit. Class 2 Spares – Minimum recommended spare parts necessary to cover 1-2 years of normal operation. Class 3 Spares – Minimum recommended spare parts stock necessary for critical services or unit which will be installed in remote locations. TERMS: NET 30 DAYS F.O.B. POINT: Arvada, Colorado

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Sundyne Gearbox Recommended Spare Parts 200 HP Gearbox: 313

Class 1 Class 2 Class 3

Item No. Part Name Qty. Qty. Qty. 60C Gearbox Mechanical Seal 0 1 1 Repair Kit for Gearbox Seal 0 + + 51D Gearbox Seal Rotating Face 0 1 1 185 Oil Filter 2 5 5 115 Input Shaft Seal 1 1 1 A130 High-Speed Shaft Assembly 0 + 1 151A Journal Bearing (Lower) 0 0 1 151B Journal Bearing (Upper) 0 0 1 155A Thrust Washer (Lower) 0 0 1 155B Thrust Washer (Upper) 0 0 1* 105 Housing Gasket 1 2 2 936N O-Ring 2 4 4 936T O-Ring 2 4 4 125A Bearing, Ball 0 1 1 125C Bearing, Ball 0 1 1 125D Bearing, Ball 0 1 1 125B Bearing, Ball 0 1 1 0 Spline Lube 1 1 1 936M O-Ring 2 4 4

400 HP Gearbox: 333

Class 1 Class 2 Class 3

Item No. Part Name Qty. Qty. Qty. 60C Gearbox Mechanical Seal 0 1 1 Repair Kit for Gearbox Seal 0 + + 51D Gearbox Seal Rotating Face 0 1 1 185 Oil Filter 2 5 5 115 Input Shaft Seal 1 1 1 A130 High-Speed Shaft Assembly 0 + 1 151A Journal Bearing (Lower) 0 0 1 151B Journal Bearing (Upper) 0 0 1 155A Thrust Washer (Lower) 0 0 1 155B Thrust Washer (Upper) 0 0 1* 105 Housing Gasket 1 2 2 936N O-Ring 2 4 4 936T O-Ring 2 4 4 151C Journal Bearing, (Idler) 0 0 1 125C Ball Bearing 0 1 1 125D Ball Bearing 0 1 1

125A Ball Bearing 0 1 1 * Not Applicable with use of tilting pad thrust bearings in upper position. + These are alternate items and may be purchased according to users preference. NOTES: Class 1 Spares – Minimum recommended spare parts necessary to perform a start-up and inspection of a new unit. Class 2 Spares – Minimum recommended spare parts necessary to cover 1-2 years of normal operation. Class 3 Spares – Minimum recommended spare parts stock necessary for critical services or units which will be installed in remote locations.

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9. 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 sale obligation is limited to alteration, repair, or replacement at Sundyne’s expense, F.O.B. factory, of parts of 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 expresses 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.

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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).

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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 the 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? f. Gearbox Servicing Reference B Lock-out/Tag-out Guidelines Follow Your Companies Lock-Out / Tag-Out Procedure When Servicing Sundyne Compressors. Never remove a lock or tag applied by someone else. 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

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Figure 5. SINGLE SEAL ARRANGEMENT

59

Figure 6. DOUBLE SEAL ARRANGEMENT

60

Figure 7. TANDEM SEAL ARRANGEMENT

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Reference D Compressor/Gearbox Drawings

62

Figure 8. LMC-313 Cutaway

63

Fibure 9. Exploded View Compressor

64

Figure 10. 200 HP Gearbox Used with LMC/BMC-313

65

Figure 11. 400 HP Gearbox Used with LMC/BMC-333

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Item No. Part Name Qty. Item No. Part Name Qty. 116 Coupling Housing Cover 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 920E Key 914D Hex Nut 4

Figure 12. Flexible Coupling

Item Number Part Name Qty

106 Chemical Barrier Gasket 1 107 Seal Spacer 1 905T Hex Head Cap Screw 3 916V Seal Washer 3

Figure 13. Chemical Barrier Gasket

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

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