Intermech BBR- 3516 Bedienungsanleitung

Compressor Service Manual

Customer :

Company

Address

City/State

ZIP Code

Phone

Fax

Email Address

Site Location

Product Compressor BBR- 3516 Vol. 2 (J1705)

Model No CO-BBR-3516

Serial No

INTERMECH LTD.

88 Leonard Road, Penrose

PO Box 12284, Penrose

Auckland, New Zealand

Ph 64 (9) 525 2220

Fax 64 (9) 579 3900

Email [email protected]

Compressor Operation & Maintenance Manual Page 2 of 79

Revisions Record

Revision

No.

Date Description of Revision

August, 2006 First edition

Intermech Ltd. BBR-3516 Compressor Service Manual

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Table of Contents

1GENERAL.....................................................................................................................................6

1.1 INTRODUCTION.......................................................................................................................6

2SAFETY.........................................................................................................................................8

2.1 GENERAL SAFETY ..................................................................................................................8

2.2 MAINTENANCE SAFETY..........................................................................................................9

3COMPRESSOR SPECIFICATION..........................................................................................11

3.1 MODEL.................................................................................................................................11

3.2 DESIGN SPECIFICATION ........................................................................................................11

3.3 MANUFACTURER’S PLATE & LABEL INFORMATION.............................................................11

3.3.1 Specification Plate..........................................................................................................11

3.3.2 Cylinder Identification Plate ..........................................................................................12

3.3.3 Suction Identification Plate ............................................................................................ 12

3.3.4 Discharge Identification Plate........................................................................................ 12

3.3.5 Warning Plate.................................................................................................................13

3.3.6 Rotation Plate .................................................................................................................13

3.4 CLEARANCES .......................................................................................................................13

3.4.1 Original Running Clearances.........................................................................................13

3.4.2 Piston Ring Side Clearances / End Gaps........................................................................14

3.4.3 Piston to Cylinder Clearances........................................................................................16

3.4.4 Torque Settings ...............................................................................................................16

3.4.5 Rhino Compressor Tools ................................................................................................ 18

3.5 OPERATING PROCEDURES ....................................................................................................19

3.5.1 Start Up Check List Contents..........................................................................................19

3.5.2 Package Details..............................................................................................................19

3.5.3 Prior to Starting..............................................................................................................20

3.5.4 After Starting ..................................................................................................................21

3.5.5 Maximum Allowable Working Pressure .........................................................................21

3.6 LUBRICATION.......................................................................................................................22

3.6.1 General Description .......................................................................................................23

3.6.2 Oil Specification .............................................................................................................23

3.6.3 Before Starting................................................................................................................24

3.6.4 Top Up With Oil .............................................................................................................24

3.6.5 Primary Starting .............................................................................................................24

3.6.5.1 Priming the lubrication system using priming pump........................................................... 25

3.6.6 Oil Filter......................................................................................................................... 26

3.6.7 Lube Oil Pressure Adjustment ........................................................................................26

3.6.8 Oil Relief Valve Setting................................................................................................... 26

3.6.9 Compression Cylinder Injection Lubrication System .....................................................27

4MAINTENANCE........................................................................................................................28

4.1 GENERAL .............................................................................................................................28

4.2 OIL PUMP (CRA-357) & OIL PUMP HOUSING (CRA-352-1)................................................29

4.2.1 Oil Pump Housing Drawing (CRA-352-1) .....................................................................29

4.2.2 Oil Pump Housing (CRA-352-1) Parts List ....................................................................30

4.2.3 Oil Pump Assembly Drawing (CRA-357) .......................................................................31

4.2.4 Oil Pump Assembly (CRA-357) Parts List...................................................................... 32

4.2.5 Oil Pump Relief Valve Drawing (CRA-333)................................................................... 33

4.2.6 Oil Pump Relief Valve (CRA-333) Parts List..................................................................34

4.2.7 Disassembly – Oil Pump Housing .................................................................................. 35

4.2.8 Disassembly – Oil Pump Relief Valve ............................................................................ 35

4.2.9 Disassembly – Oil Pump.................................................................................................35

4.2.10 Assembly – Oil Pump.................................................................................................36

4.2.11 ............................................................................................................................................36

4.2.12 Oil Pump Relief Valve................................................................................................ 36

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4.2.13 Assembly – Oil Pump Housing (CRA-352) ................................................................37

4.3 RHINO CRANKCASE (CRA-3603).........................................................................................38

4.3.1 Rhino Crankcase Drawing (CRA-3603) .........................................................................38

4.3.2 Rhino Crankcase Drawing (CRA-3602) .........................................................................39

4.3.3 Rhino Crankcase (CRA-3603) Parts List........................................................................40

4.3.4 Rhino Crankcase (CRA-3602) Parts List........................................................................40

4.3.5 Taper Lock Bearing Housing Assembly Drawing (CRA-3640) ......................................41

4.3.6 Taper Lock Bearing Housing Assembly Parts List (CRA-3640).....................................42

4.3.7 Rhino Crankcase Filler Bowl Drawing (CRA-820)........................................................43

4.3.8 Rhino Crankcase Filler Bowl (CRA-820) Parts List ......................................................44

4.3.9 Disassembly – Crankshaft (CR-3253) ............................................................................45

4.3.10 Assembly – Crankcase (CRA-3603)...........................................................................46

4.4 DRIVE END BEARING HOUSING / MECHANICAL SEAL ASSEMBLY (CRA-356)....................49

4.4.1 Drive End Bearing Housing / Mechanical Seal Drawing (CRA-356 RevB)...................49

4.4.2 Mechanical Seal Housing (CRA-356) Parts List ............................................................50

4.4.3 Disassembly / Assembly - Mechanical Seal ....................................................................51

4.5 CONNECTING ROD ASSEMBLY .............................................................................................53

4.5.1 Connecting Rod Assembly Drawing (ROA-8525)........................................................... 53

4.5.2 Connecting Rod Assembly Parts List (ROA-8525) .........................................................54

4.6 CROSS HEAD CYLINDER/PISTON (CYXA-6003) ..................................................................55

4.6.1 6” Cross Head / Cylinder Drawing (CYXA-6003) .........................................................55

4.6.2 6” Cross Head / Cylinder (CYXA-6003) Parts List........................................................56

4.6.3 Disassembly - Cross-Head Cylinder/Piston ...................................................................57

4.6.4 Assembly - Cross-Head Cylinder/Piston ........................................................................57

4.7 1ST STAGE CYLINDER/PISTON / PISTON ROD ASSEMBLY ......................................................59

4.7.1 Cylinder Assembly Drawing (CYA-3500-3)....................................................................59

4.7.2 Cylinder Assembly (CYA-3500-3) Parts List ..................................................................60

4.7.3 Disassembly ....................................................................................................................62

4.7.4 Assembly .........................................................................................................................62

4.8 ROD SEAL HOUSING ASSEMBLY ..........................................................................................65

4.8.1 Rod Seal Housing Drawing (SEA-3503).........................................................................65

4.8.2 Rod Seal Housing (SEA-3503) Parts List .......................................................................66

4.8.3 Disassembly ....................................................................................................................67

4.8.4 Assembly .........................................................................................................................67

4.9 2ND / 3RD STAGE CYLINDER/PISTON/PISTON ROD ASSEMBLY ................................................68

4.9.1 Cylinder Assembly Drawing (CYA-3216-4)....................................................................68

4.9.2 3.25”x 1.625” Cylinder Assembly (CYA-3216-4) Parts List ..........................................69

4.9.3 Piston 3.25” x 1.625” Assembly Drawing (PIA–3216-2)...............................................71

4.9.4 Piston 3.25” x 1.625” Assembly (PIA–3216-2) Parts List .............................................72

4.9.5 Disassembly – Final Stage Cylinder / Piston .................................................................73

4.9.6 Disassembly – 2nd Stage Cylinder / Piston ....................................................................73

4.9.7 Assembly- 2nd / 3rd Stage Cylinder / Piston ..................................................................74

4.10 ROD SEAL HOUSING ASSEMBLY SEA-3250.........................................................................76

4.10.1 Rod Seal Housing Assembly Drawing (SEA-3250: Sheet 1)......................................76

4.10.2 Rod Seal Housing Assembly Drawing (SEA-3250: Sheet 2)......................................77

4.10.3 Rod Seal Housing Assembly (SEA-3250) Parts List ..................................................78

4.10.4 Disassembly ...............................................................................................................78

4.10.5 Assembly ....................................................................................................................78

4.11 COMPRESSOR VALVES .........................................................................................................79

4.11.1 Removal .....................................................................................................................79

4.11.2 Installation.................................................................................................................79

Table of Figures

Figure 1 Plan and Elevation of Three-Stage Compressor____________________________________7

Figure 2 Specification Plate _________________________________________________________11

Figure 3 Cylinder Specification Plate __________________________________________________12

Figure 4 Suction Identification Plate __________________________________________________12

Figure 5 Discharge Identification Plate ________________________________________________12

Figure 6 Warning Plate_____________________________________________________________13

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Figure 7 Rotation Plate _____________________________________________________________13

Figure 8 Compressor Tools__________________________________________________________18

Figure 9 Oil Circulation Schematic ___________________________________________________22

Table of Tables

Table 1 Specification Chart__________________________________________________________11

Table 2 Original Running Clearance __________________________________________________13

Table 3 Piston Ring End Gaps _______________________________________________________14

Table 4 Piston Ring Side Clearances __________________________________________________15

Table 5 Piston to Cylinder Clearances _________________________________________________16

Table 6 Torque Settings_____________________________________________________________17

Table 7 The Maximum Allowable Working Pressure ______________________________________21

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1 General

1.1 Introduction

The Rhino compressor has been developed specifically for CNG/NGV with

the following features :

 Gas tight pressurised crankcase, up to 40 bar (600 psig).

 Hoerbiger valves for specific performance and reliability.

 Double row spherical roller main bearings.

 Heavy duty crankcase.

 High strength crankshaft, 100-80-3 ductile iron, 89mm (3.5" journals.

 Full flow, filtered, pressurised lubrication.

 Generous integral cross-head piston bearing surface.

 Standardized design, 22 - 200 kW (30 - 270 hp), 0.5-30 bar, (8 - 435psig)

inlet pressure.

 High quality oil flooded mechanical crankcase seals.

 Double acting two, three or four stage design.

 Exclusive low friction cylinder treatment.

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Figure 1 Plan and Elevation of Three-Stage Compressor

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2 Safety

2.1 General Safety

!!! WARNING !!!

COMPRESSED GAS IS A HIGHLY DANGEROUS

SUBSTANCE

READ AND UNDERSTAND THIS SECTION OF

MANUALS

IT IS ESSENTIAL FOR THE SAFE OPERATION

OF EQUIPMENT

2.1.1. Systems must be entirely vented before repair or maintenance is carried

out.

2.1.2. The installation, operation, maintenance and repair shall be carried out

only by qualified personnel and in accordance with the corresponding

regulations for operation and safety.

2.1.3. No smoking or naked lights within 10m of any gas installation.

2.1.4. Do not adjust, remove or bypass any protective device.

2.1.5. Rotating machine parts represent a special danger. Covers and guards

must not be removed whilst the machine is operating.

2.1.6. Persons operating the compressor should use hearing protection.

2.1.7. Do not store flammable materials e.g. oily rags near the compressor

unit or engine drive.

2.1.8. Supply pipework and other components, which may not be included in

scope of supply, must be suitable for the respective working pressure.

2.1.9. If necessary they have to be tested and protected by a pressure-

unloading device.

2.1.10. Electrical cable must be Flameproof and must not be linked, or allowed

to contact rotating parts.

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2.2 Maintenance Safety

!!! WARNING !!!

COMPRESSED GAS IS A HIGHLY

DANGEROUS SUBSTANCE.

BEFORE DISMANTING ANY PART OF

THE COMPRESSOR, ENSURE THAT THE

UNIT IS COMPLETELY DEPRESSURED

2.2.1. Maintenance and repair may be carried out only on the shutdown and

entirely vented compressor unit. If necessary isolate all storage

systems and blow-down all condensate traps and heat exchanger

collectors. Open all manual drain valves.

2.2.2. Isolate the equipment electrically by pad-locking the main switch in the

"OFF" position and fixing a corresponding warning sign.

2.2.3. Only use original spare parts and recommended products for

maintenance and repair works on the compressor unit.

2.2.4. Never do work that will produce heat, like welding near oil or gas

systems. Before working on oil or gas tanks empty them and clean

them carefully eg. by a steam jet or purge with nitrogen.

2.2.5. During maintenance and repair work observe strict cleanliness. Keep

impurities away, by covering dismounted parts and free openings with

a clean rag, paper or adhesive tape.

2.2.6. After having finished the works be sure that no tools, loose parts or

cleaning rags have been left on or in the compressor unit, or near the

engine air cleaner.

2.2.7. Do not use easily flammable solving agents for cleaning of parts, until

the unit has cooled thoroughly. After the use of solving agents

carefully rinse the parts and clean them with compressed air.

2.2.8. Be very careful, use eye protection, when working with compressed air

for cleaning equipment.

2.2.9. After modification or repair work on pressure vessels and safety

equipment, such as relief valves, all work must be tested and accepted

by the inspection authority concerned.

2.2.10. The switchboard may be opened only by qualified and authorized

persons. Even if the main switch is set to the "OFF" position, the poles

of the switch and feed cables of the terminal strip are alive. Therefore

do not touch anything on the switchboard, and do not carry out work,

with the mains current supply is not disconnected. Before starting

work check if the system is entirely free of power.

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2.2.11. Do not touch bare wires and live (current-carrying) parts, when the

electrical system is energized.

2.2.12. After modification or repair work to compressor, and before power is

supplied to machine, always manually turn compressor over by hand to

ensure compressor is running free.

2.2.13. Intermech takes no responsibility for personal injury or damage on the

unit, caused by the non-observance of the safety precautions during

handling, operation, maintenance or repair of compressor units or other

equipment.

Intermech Ltd. BBR-3516 Compressor Service Manual

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