Mounting and operating
instructions
Designation
Type
Project
Customer
Order no.
Siemens order no.
Ident no.
Year of manufacture
: Turbo compressor unit
: 3(2) VRZ 250/430/14 G
: Xinfa II China
: Shandong Xinfa Chemical Co., Ltd.
: SDYZ20071102
: 5207251
: 5207251
: 2008
BA5207251E.DOC, Rev.0, January 2009
Preface
These Mounting and Operating Instructions contain all important instructions for commis-sioning, operation and maintenance of the 3(2) VRZ 250/430/14 G turbocompressor.
Please read these Mounting and Operating Instructions as well as the LCP operating in-structions carefully prior to initial commissioning in order to ensure the safe and efficient use of the turbo-compressor.
Furthermore it is important to follow the operating instructions of essential components of the unit, such as drive motor, gearbox, oil cooler, oil filter or oil pumps.
Necessary repair work shall be carried out by experts only.
In case of negligent or improper maintenance we are not able to fulfil our guarantee obli-gations in accordance with the terms and conditions of sale.
Our customer service will be pleased to assist you in case of any problems occurring de-spite these Mounting and Operating Instructions.
We wish you a trouble-free and faultless operation of our plant.
The Location Management
Siemens Turbomachinery Equipment GmbH / Location Leipzig
Telephone : 03 41 / 49 92 - 0 Postal address:
Siemens Turbomachinery Fax : 03 41 / 49 92 460 (Management department)
Fax : 03 41 / 49 92 362 (Sales department) Fax : 03 41 / 49 92 203 (Technical department)
BA5207251E.DOC, Rev.0, January 2009
Equipment GmbH Klingenstraße 15
D - 04229 Leipzig
PF 310761 / D -04211 Leipzig
Page 2 of 75
Table of contents
LIST OF TABLES......................................................................................................................................................6 LIST OF ILLUSTRATIONS.....................................................................................................................................6 SHORT DESCRIPTION............................................................................................................................................7 USE...............................................................................................................................................................................7 1. SAFETY REGULATIONS/ INSTRUCTIONS....................................................................................................8 1.1 SAFETY REGULATIONS.............................................................................................................................................8 1.2 SAFETY INSTRUCTIONS.............................................................................................................................................8 1.3 EMPHASIS..............................................................................................................................................................10 2. TECHNICAL DATA............................................................................................................................................11 2.1 COMPRESSOR.........................................................................................................................................................11 2.2 GAS COOLER WITH CONNECTING PIPELINES TOWARDS THE COMPRESSOR..............................................................16 2.2.1 Gas cooler.....................................................................................................................................................16 2.2.2 Connecting pipelines.....................................................................................................................................16 2.2.3 Spring insulators for the gas coolers............................................................................................................16 2.3 MOTOR..................................................................................................................................................................16 2.4 GEAR UNIT.............................................................................................................................................................17 2.5 COUPLING..............................................................................................................................................................17 2.6 BASE FRAME..........................................................................................................................................................17 2.7 LUBRICATING OIL SUPPLY SYSTEM.........................................................................................................................18 2.7.1 Lubricating oil storage tank..........................................................................................................................18 2.7.2 Lubricating oil unit.......................................................................................................................................18
2.7.2.1 Auxiliary oil pumping set........................................................................................................................................19 2.7.2.2 Oil cooler..................................................................................................................................................................19 2.7.2.3 Oil filter....................................................................................................................................................................19
2.8 FITTINGS FOR BASE FRAME, OIL UNIT AND GAS COOLER.........................................................................................20 2.9 CONSUMABLES......................................................................................................................................................20 2.9.1 Lubricating oil...............................................................................................................................................20 2.9.2 Seal gas.........................................................................................................................................................22 2.9.3 Consumption of electrical energy.................................................................................................................22
2.9.3.1 Drive motor...............................................................................................................................................................22 2.9.3.2 Auxiliary oil pump motor.........................................................................................................................................22 2.9.3.3 Heating for lubricating oil storage container............................................................................................................22 2.9.1.1 Oil quantities.............................................................................................................................................................20 2.9.1.2 Oil quality.................................................................................................................................................................21
3. DESCRIPTION AND FUNCTIONING OF THE COMPRESSOR UNIT.....................................................23 3.1 COMPRESSOR.........................................................................................................................................................23 3.1.1 General information on the compressor.......................................................................................................23 3.1.2 Constructional design...................................................................................................................................27
3.1.2.1 Rotor.........................................................................................................................................................................33 3.1.2.2 Housing.....................................................................................................................................................................33 3.1.2.3 Guide wheels and labyrinth seals..............................................................................................................................33 3.1.2.4 Arrangement of bearings for the compressor rotor...................................................................................................33
3.1.3 Intermediate cooler and aftercooler.............................................................................................................34 3.2 DRIVE....................................................................................................................................................................34 3.2.1 Driving motor................................................................................................................................................34 3.2.2 Gear unit.......................................................................................................................................................34 3.2.3 Coupling........................................................................................................................................................34 3.3. LUBRICATING OIL SUPPLY....................................................................................................................................35 BA5207251E.DOC, Rev.0, January 2009 Page 3 of 75
3.4 MEASUREMENT AND CONTROL TECHNOLOGY........................................................................................................39 3.4.1 Measuring points - sealing – switching off...................................................................................................39 3.4.2 Controls.........................................................................................................................................................39
3.4.2.1 Inlet guide vane........................................................................................................................................................39 3.4.2.2 Surge limit control....................................................................................................................................................39 3.4.2.3 Seal gas control.........................................................................................................................................................40
3.4.3 Vibration and axial thrust monitoring..........................................................................................................40 4. INSTALLATION OF THE UNIT.......................................................................................................................41 4.1 INSTALLATION OF THE COMPRESSOR UNIT.............................................................................................................41 4.2 INSTALLATION OF THE AUXILIARY UNITS...............................................................................................................41 4.3 LAYING OF THE GAS, OIL AND COOLING WATER PIPELINES.....................................................................................41 4.4 ALIGNMENT...........................................................................................................................................................42 4.4.1 Coupling between gear and compressor.......................................................................................................42 4.4.2 Coupling between drive motor and gear.......................................................................................................44 5. COMMISSIONING AND OPERATION OF THE COMPRESSOR UNIT...................................................46 5.1 PREPARATION OF FIRST COMMISSIONING...............................................................................................................46 5.2 FIRST COMMISSIONING...........................................................................................................................................48 5.2.1 Mechanical trial run.....................................................................................................................................48 5.2.2 Functional run with nitrogen........................................................................................................................48 5.3 NORMAL COMMISSIONING......................................................................................................................................48 5.4 COMMISSIONING WITH CHLORINE..........................................................................................................................50 5.5 SHUTTING DOWN....................................................................................................................................................51 5.5.1 Scheduled shutting down...............................................................................................................................51 5.5.2 Shutting down in case of failures..................................................................................................................52 5.6 SERVICING.............................................................................................................................................................53 6. INTERRUPTION OF OPERATION..................................................................................................................54 6.1 DRIVE....................................................................................................................................................................54 6.1.1 Drive motor does not start up:......................................................................................................................54 6.1.2 Drive motor switches off:.............................................................................................................................54 6.2 GEAR.....................................................................................................................................................................54 6.2.1 Oil return temperature too high:...................................................................................................................54 6.2.2 Bearing temperature too high:......................................................................................................................54 6.2.3. Sudden appearance of abnormal running noises in the gear:.....................................................................54 6.3 COMPRESSOR.........................................................................................................................................................55 6.3.1 Disturbance during running..........................................................................................................................55 6.3.2 All bearing temperatures increase:...............................................................................................................55 6.3.3 Bearing temperatures in one bearing increase:............................................................................................55 6.3.4 Final compressor temperature increases:.....................................................................................................55 6.3.5 Seal gas pressure drops:...............................................................................................................................55 6.4 LUBRICATING OIL SYSTEM.....................................................................................................................................55 6.4.1 Oil pressure after filter drops:......................................................................................................................55 6.4.2 Oil temperature after cooler too high:..........................................................................................................55 7. MAINTENANCE, INSTRUCTIONS REGARDING REMOVAL AND INSTALLATION.........................56 7.1. COMPRESSOR........................................................................................................................................................56 7.2 INSPECTION............................................................................................................................................................61 7.3 COUPLINGS............................................................................................................................................................62 7.4 GAS COOLER..........................................................................................................................................................62 7.5 DRIVE MOTOR........................................................................................................................................................62 7.6 GEAR.....................................................................................................................................................................62 7.7 OIL COOLER...........................................................................................................................................................62 7.8 OIL FILTER.............................................................................................................................................................62 7.9 OIL PUMPS..............................................................................................................................................................62 7.10 OIL CONTAINER....................................................................................................................................................63 BA5207251E.DOC, Rev.0, January 2009 Page 4 of 75
7.11 APPENDICES.........................................................................................................................................................63 8. TRANSPORTATION...........................................................................................................................................70 9. SPARE AND WEARING PARTS.......................................................................................................................73 9.1 WEARING PARTS....................................................................................................................................................73 9.1.1 Compressor...................................................................................................................................................73 9.1.2 Gearbox.........................................................................................................................................................73 9.2 SPARE PARTS..........................................................................................................................................................73 9.2.1 Compressor...................................................................................................................................................73 9.2.2 Gearbox.........................................................................................................................................................74 9.2.3 Couplings......................................................................................................................................................74 9.2.4 Oil cooler......................................................................................................................................................74 9.2.5 Oil filter.........................................................................................................................................................74 9.2.6 Connecting lines............................................................................................................................................74 9.3 MEASURING AND CONTROL EQUIPMENT.................................................................................................................74 10. COPYRIGHT......................................................................................................................................................75
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List of tables
TABLE 1 PARTS LIST FOR COMPRESSOR UNIT...............................................................................................24 TABLE 2 PARTS LIST FOR COMPRESSOR..........................................................................................................28 TABLE 3 PARTS LIST FOR THE INITIAL GUIDE DEVICE, ADJUSTABLE....................................................30 TABLE 4 PARTS LIST OF THE OIL SUPPLY SYSTEM.......................................................................................36
List of illustrations
ILLUSTRATION 1 CHARACTERISTIC DIAGRAM - COMPRESSOR................................................................15 ILLUSTRATION 2 COMPRESSOR UNIT...............................................................................................................25 ILLUSTRATION 3 COMPRESSOR UNIT...............................................................................................................26 ILLUSTRATION 4 SECTIONAL VIEW OF COMPRESSOR.................................................................................29 ILLUSTRATION 5 INITIAL GUIDE DEVICE, ADJUSTABLE.............................................................................31 ILLUSTRATION 6 INITIAL GUIDE DEVICE, ADJUSTABLE.............................................................................32 ILLUSTRATION 7 OIL SUPPLY SYSTEM............................................................................................................37 ILLUSTRATION 8 OIL SUPPLY SYSTEM............................................................................................................38 ILLUSTRATION 9 ALIGNMENT OF COUPLING BETWEEN GEAR AND COMPRESSOR............................44 ILLUSTRATION 10 ALIGNMENT OF COUPLING BETWEEN DRIVE MOTOR AND GEAR.........................45 ILLUSTRATION 11 BLOCKING DIAGRAM.........................................................................................................49 ILLUSTRATION 12 DISENGAGING THE CONNECTING ROD.........................................................................56 ILLUSTRATION 13 COMPRESSOR TEST SHEET...............................................................................................59 ILLUSTRATION 14 COMPRESSOR TEST SHEET...............................................................................................60 ILLUSTRATION 15 INSTALLATION POSITION OF TILTING PAD RADIAL BEARINGS............................. ILLUSTRATION 16 DISMANTLING THE TILTING PADS.................................................................................66 ILLUSTRATION 17 THRUST BEARING...............................................................................................................67 ILLUSTRATION 18 VIEWS OF THE THRUST BEARING COMPONENTS.......................................................68 ILLUSTRATION 19 RADIAL BEARING HEAT SENSOR....................................................................................69 ILLUSTRATION 20 THRUST BEARING HEAT SENSOR....................................................................................69 ILLUSTRATION 21 TRANSPORTATION INSTRUCTIONS FOR THE COMPRESSOR UNIT.........................70 ILLUSTRATION 22 TRANSPORTATION INSTRUCTIONS FOR COMPRESSOR............................................71 ILLUSTRATION 23 TRANSPORTATION INSTRUCTION OIL UNIT................................................................72
BA5207251E.DOC, Rev.0, January 2009
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Short description
The compressor unit consists of a 2-stage centrifugal compressor with intermediate cool-ing, a turbo-planetary gear system, a drive motor, a joint base frame for the compressor, the gear unit and the drive motor, one intermediate cooler and an aftercooler with the connecting pipelines, a lubricating oil system, a seal gas system and the required meas-uring and control technology.
The compressor unit is only suitable for installation in an enclosed machine room in which there is no explosion hazard.
A table foundation made of reinforced concrete is required for installation.
Use
The field of use of the compressor unit comprises pumping and compressing of techni-cally dry chlorine gas.
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1. Safety regulations/ instructions
C A U T I O N
Read these safety regulations and instructions carefully!
1.1 Safety regulations
Observe the safety regulations which are effective at the place of use of the device!
Observe the environmental regulations which are effective in the specific state.
1.2 Safety instructions
The following instructions have to be complied with during operation of the turbo com-pressor in order to ensure safety at work as well as general safety:
- The safety regulations specified in section 1.1.
- During operation of the system the laws and regulations in force at the place of use of the system have to be complied with. In the interest of a safe work flow the opera-tor, supervising staff and the plant operator are responsible for compliance with the regulations.
- Prior to commissioning of the turbo compressor all basic safety technology require-ments must have been fulfilled and checked in order to ensure trouble-free opera-tion of the system.
- During operation the turbo compressor generates heat, therefore allow the turbo compressor to cool down before maintenance activities or inspections can be car-ried out or use protective equipment.
- All safety devices have to be checked for proper functioning from time to time.
- The labels on the machine have to be observed.
- Removing protective devices or rendering these ineffective are prohibited.
- The turbo compressor should never be operated above the maximum design pres-sures as per the identification plate. - The turbo compressor should never be operated at speeds above the rotational speeds specified on the identification plate on the drive motor.
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- Do not carry out any repair activities while the turbo compressor is in operation.
- Do not remove any protective cover or screening device while the turbo compressor is in operation.
- Prior to any maintenance activities the system has to be disconnected from the power supply and all pressure pipes have to be depressurised. The chlorine gas pipelines and the compressor have to be flushed with inert gas.
- Pressurized lubricating oil or chlorine gas can cause serious injuries and are haz-ardous. Prior to the removal of any caps or plugs the turbo compressor has to be switched off and those parts of the system which contain chlorine gas have to be flushed with inert gas.
- In case oil mist or chlorine gas are emitted during defects, do not inhale these; if ap-plicable, wear respiratory equipment.
- Only open control cabinet if the main switch is in the “off“ position.
- The operating staff must have the required degree of expert knowledge.
- During maintenance activities as well during an oil change the lubricating oil has to be gathered in suitable containers and to be disposed of in accordance with the regulations. Avoid skin contact with the lubricating oil, if applicable wear protection for hands and eye protection.
- During operation activities on the running turbo compressor wear hearing protector and protective helmet.
- Do not use any flammable solvents during cleaning of parts of the plant.
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1.3 Emphasis
The following forms of emphasis are use in the text in order to point out special features or risks.
C A U T I O N
This headline is used in case imprecise compliance or non-compliance with operating instructions, work instructions, prescribed work procedures and the
like can lead to injuries or even to fatal accidents.
A T T E N T I O N
This headline is used in case imprecise compliance or non-compliance with operating instructions, work instructions, prescribed work procedures and the
like can lead to damage to the device.
NOTE
This headline is used to draw attention to a special feature.
BA5207251E.DOC, Rev.0, January 2009 Page 10 of 75
2. Technical data
2.1 Compressor
Sort: turbo compressor, radial design
Type: 3(2) VRZ 250/430/14 G
Manufacturer: SIEMENS Turbomachinery Equipment GmbH Leipzig
Device number: M 5207251
Registration no.: 5207251
Year of construction: 2008
Mass: 6800 kg
Operating data max.:
Volume flow in intake state = 11,209 m3/h
Pressure in inlet side = 1.055 bar (a)
Temperature in inlet side = 45 °C
Density in standard condition = 3.200 kg/m3
Pressure on outlet side = 2.650 bar (a)
Rotational speed = 9,449 rpm
Coupling capacity on compressor = 493 kW
BA5207251E.DOC, Rev.0, January 2009
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Data regarding the compressor impeller
Direction of rotation with reference to coupling
= left side Overspeed
= 10,870 rpm Duration of speed = 5 min
Compressor bearing data: Required oil quantity l/min at bar (g) Radial bearing, drive side
≈ 10.5 0.6 ... 0.8 Radial
bearing, output side ≈ 10.5 0.6 ... 0.8 Axial
thrust bearing ≈ 44 1.3 ... 1.8 Surface loading of the axial thrust bearing = 0,47 N/mm2
Data regarding sealing of gland: Seal
gas requirement 36 Nm³/h Differential pressure compared to the internal gland chambers = 0.025 bar
BA5207251E.DOC, Rev.0, January 2009
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Execution:
Housing: divided horizontally, intake and pressure pipe joint point downwards
Intake pipe joint DN 350 PN 10 according to DIN 2632
Pressure pipe joint DN 250 PN 10 according to DIN 2632
Material
= GG - 25 DIN 1691 Guide wheels: divided horizontally
Material = GG - 25
Glands:
Glands with gas seal Labyrinths
rotating in shaft Material
= Gland body GG-25 Wearing
layer Epoxy resin - filler Labyrinths Caulking
strips X5CrNi X6CrNiTi 1810 1810 Packing rings and packing inserts for step seal:
Labyrinth glands
Material
= Basic body GG-25 Labyrinths
CUZN37 F37 Caulking
strips CUZN37 F37 Wearing layer: Epoxy resin - filler
Impellers: solid, radial, closed, welded, shrunk onto shaft,
number of items 3
Material = Carrier and cover disks X3CRNI134 V Blades
X3CRNI134 V Shaft:
Material = C 45 BA5207251E.DOC, Rev.0, January 2009 Page 13 of 75
Bearings: 2 tilting segment – radial sleeve bearing
1 double-sided axial sleeve bearing
Bearing diameter 70 mm
Material = body of bearing GG-25
Tilting segments C 15
Outlet SnSb12Cu6ZnAg
Inlet guide device: Pneumatically adjustable Hermetic design, sealing with metal expansion bellows
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Illustration 1 Characteristic diagram - Compressor
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2.2.1 Gas cooler
1 intermediate cooler after the 1st compressor stage 1 aftercooler after the 2nd compressor stage
Execution: in horizontal position
Not part of the scope of delivery of Siemens!
2.2.2 Connecting pipelines
The intermediate cooler and the aftercooler are connected with the compressor with the help of pipelines.
Material: C steel
Not part of the scope of delivery of Siemens!
2.2.3 Spring insulators for the gas coolers
The gas coolers are mounted on spring insulators.
Model: UPM/12113; Quantity per cooler: 2; admissible load: 92 kN per insulator
2.2 Gas cooler with connecting pipelines towards the compressor
2.3 Motor
Type: Three-phase asynchronous motor
Model: HKG-545 C04
Manufacturer: ELIN EBG
Mass: 3800 kg
Output: 580 kW
Rotational speed: 1,494 rpm
Voltage: 10,000 V
Frequency: 50 Hz
BA5207251E.DOC, Rev.0, January 2009
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2.4 Gear unit
Type: Planetary gear
Model: RHP 20 i.G. 25
Manufacturer: BHS Getriebe
Mass: ca. 560 kg
Output: 700 kW
Speed of driving motor: 1,494 1/min
Output speed: 9,448 1/min
Transmission requirement: 6.324
Oil requirement: 35 l/min
Oil pressure: 1,8 – 2,2 bar (g)
2.5 Coupling
(between motor and gear unit)
Type: ARPEX coupling
Model: ARS-6 JEN 255-6
Supplier: Flender
Mass: 59 kg
Nominal torque: 7.600 Nm
Speed max: 4.100 rpm
2.6 Base frame
Joint frame for compressor, gear unit and drive motor. The frame is made of welded steel profiles.
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2.7 Lubricating oil supply system
The lubricating oil supply system consists of:
Lubricating oil storage tank (heated electrically), double oil cooler, double oil filter, auxil-iary oil pump and connecting pipelines with various valves mounted onto a joint base frame.
Oil balance: V (l/min)
Compressor bearing ≈ 65
Gear unit ≈ 35
____________ ≈ 100
============
2.7.1 Lubricating oil storage tank
Content (no-load volume): 2.00 m³
Mass, empty: 1,112 kg
Execution: An oil-level gauge glass and a level switch are used in order to indicate the filling level.
Heating: 1 electrical radiator
2.7.2 Lubricating oil unit
Mass: ≈ 3,500 kg
Execution: 1 rotary screw pumping set,
1 double oil cooler,
1 double oil filter
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2.7.2.1 Auxiliary oil pumping set
Type: Rotary screw pump
Model: 210R40U8.6-V-W115
Manufacturer: Allweiler AG
Volume flow: 160 l/min
Operating pressure: 6 bar
Operating voltage: 380 - 420 V
Output: 4 kW
2.7.2.2 Oil cooler
Number of items: 1 double oil cooler, reversible
Model: 2-W2AQ2214 4A040 050 X11
Manufacturer: AEL
Cooling surface: 16.6 m²
Oil quantity: 10,850 kg/h
Cooling output: 39,553 kcal/h
Quantity of cooling water: 18,000 kg/h
Operating pressure: 6 bar (g)
Mass, empty 1,512 kg
2.7.2.3 Oil filter
Type: Double oil filter DU.401.10G.30.E.P.-.FS8.-.-.OE
Manufacturer: Internormen
Oil quantity: up to 300 l/min
Operating pressure: 6 bar (g)
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2.8 Fittings for base frame, oil unit and gas cooler
Base frame:
- 10 anchor bolts M 24 x 1400 according to DIN 797 with nuts Material: Rst 37-2
- 10 anchor plates KL 180 according to DIN 795 Material: GG-25 - 40 levelling screw pins
Gas cooler:
- 16 foundation bolts CM 20 x 250 according to DIN 529 with nuts Material: 4.6
- 4 vibration insulators (2 per cooler)
Oil unit:
- 4 foundation bolts CM 20 x 250 according to DIN 529 with nuts Material: 4.6
2.9 Consumables
Consumables are not part of the delivery scope of Siemens Leipzig.
2.9.1 Lubricating oil
2.9.1.1 Oil quantities
Lubricating oil quantity for one filling = rinsing oil quantity
≈ 2,000 l
Oil requirement 100 l/min
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2.9.1.2 Oil quality
The turbine oil to be used has a high compression and ageing resistance.
The oil should correspond to the VG 46 viscosity class with a FZG load carrying capability of ≥ 8 according to DIN 51354.
The oil must be free of zinc-dithiophosphate (ZnDTP) and should have the properties listed in the table herein below: Designation Unit
Kinematic viscosity at 40°C mm²/s 44.5
at 100°C mm²/s 6.,6
Density at 15°C kg/m³ 868
Open cup flash point (Clev.) °C 210
Pourpiont °C
Neutralisation figure mgKOH/g 0.16
Ash (oxide) g / 100 g <
Ageing behaviour, in-
crease of the neutral. fig after 4000 hours mg KOH / g
Boiling point °C >316
Air release property at 50°C min 3
BA5207251E.DOC, Rev.0, January 2009 Measured value -12 0.01 0.1 Page 21 of 75
< 2.9.2 Seal gas
Seal gas for gland sealing: 36 Nm³/h
Seal air for bearing, gear unit and oil container: 12 Nm³/h
2.9.3 Consumption of electrical energy
2.9.3.1 Drive motor
Output: 580 kW
Voltage: 10,000 V three-phase current
Frequency: 50 Hz
2.9.3.2 Auxiliary oil pump motor
Output each: 4 kW
Voltage: 380 - 420 V three-phase current
Frequency: 50 Hz
2.9.3.3 Heating for lubricating oil storage container
Output: 8 kW
Voltage: 380 - 400 V
Frequency: 50 Hz
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3. Description and functioning of the compressor unit
3.1 Compressor
3.1.1 General information on the compressor
The compressor is a two-stage centrifugal flow compressor of radial construction with intermediate cooling. The constructional structure of the compressor is illustrated in the sectional drawing.
ITEM QTY DESIGNATION
10 1 Turbo-compressor 20 1 Oil supply system 30 1 Base frame 40 1 Electric motor 50 1 Planetary wheel gear 60 1 Coupling 70 6 Sensor 80 6 Balancing cable 90 1 Oil suction pipeline, main oil
pumpe
100 1 Oil pressure pipe, main oil
pump
110 1 Oil return pipe
compressor/ gear unit T1
115 1 Oil return pipe
compressor/ gear unit T2
120 1 Oil feed pipe
compressor and gear unit T1
125 1 Oil feed pipe
compressor and gear unit T2
130 1 Adapter for seal gas pipe 140 1 Adapter for seal gas pipe 150 1 Seal gas pipe 160 1 Seal air line compressor/gear
unit
165 1 Seal air line oil unit 170 1 Discharge line 180 1 Suction line 190 1 Coupling guard 200 2 Side bearing compressor 210 2 Side bearing 220 2 Hexagon head bolt 230 4 Taper pin 240 2 Hexagon head bolt 250 4 Taper pin 260 4 Hexagon head bolt 270 4 Disk 280 6 Hexagon head bolt 290 6 Disk 300 2 Shim compressor 310 2 Shim compressor BA5207251E.DOC, Rev.0, January 2009
SIEMENS REMARKS
PART NO. M5207251 3(2) VRZ 250/430/14 G 4210747 Steel / stainless steel 4212636 RSt37-2 3025099 HKG-545 C04 3024469 RHP20 i.G. 25 3023684 ARS-6 JEN 255-6
3025087 TM0180-A07-B00-C06-D10 3025088 TM0181-A80-B00
4212207 RSt37-2 4212208 RSt37-2 4215803 RSt37-2 4215805 RSt37-2 4215806 1.4571 4215807 1.4571 4206772 RSt37-2 4206773 RSt37-2 42123 RSt37-2
4215808 RSt37-2 4215809
4211666 42125 4210301 4004769
4004295 3-353601-061 3-357301-030 3-353601-315 3-357301-014 3-353601-209 00035830551 3-353601-174
3-358301-014 4012400 4012401
RSt37-2
RSt37-2 RSt37-2 Aluminium RSt37-2
RSt37-2 M 12x45, 8.8 B-10x45, steel M 16x60, 8.8 B-16x60, steel M36x100, 8.8 AOP
37, St AOP M20x90, 8.8 AOP A21-200 HV 5x180x220, RSt37-2 5x180x220, RSt37-2
Page 23 of 75
ITEM QTY DESIGNATION
320 4 Shim motor 330 2 Shim gear unit 340 14 Alignment bolts 350 14 Hexagon head bolt 360 1 Company label SIEMENS 370 8 Half-round groove pin 380 1 Type plate 390 3 Earthing symbol 400 1 Flange 410 2 Flange 420 1 Flange 430 1 Flange 440 1 Flange 450 2 Console for junction box 460 1 Console for local panel 470 1 Support for IGV actuator
SIEMENS REMARKS
PART NO. 4210725 200x200x5, RSt37-2 4207626 5x286x75, RSt37-2 4213278 4-KT 40x115, S235JRG2 42114 M16x1.5x100, 8.8 3-415008-003 240xx2 3-415004-003 3x8, A2 3-357705-013 148x105x0,8 3018213 DM40 3-325011-035 DN350 PN10; 1.0460 3-325011-021 DN300 PN10; 1.0460 3-325011-020 DN250 PN10; 1.0460 3-325101-037 DN250 PN10; 1.0460 3-325101-059 DN250 PN25; 1.0460 4209968 RSt37-2 4216003 RSt37-2 4210027 RSt37-2
Table 1 Parts list for compressor unit
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Illustration 2 Compressor unit
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Illustration 3 Compressor unit
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3.1.2 Constructional design
The housing, the guide wheels, the glands, the packing rings and inserts are divided hori-zontally. Once the upper part of the housing is removed, the rotor, which consists of the two impellers and the shaft, is accessible.
Before the impeller of the 1st stage an initial guide device is positioned which allows for restricted adjustment of the quantity conveyed by the compressor. A drive positioned on the upper part of the housing, which is sealed hermetically and which can be adjusted pneumatically, is used for the purpose of adjustment. The setting of the respective degree of the initial guide blades can be read of a scale.
The guide wheels of the 1st and the 2nd stage are designed as spirals and spring-cushioned separately in the housing. The individual stages are sealed against one an-other with the help of translucent sealings which are fitted into the guide wheels.
Sealing of the shaft bushing on the suction and on the pressure side is carried out with the help of triple glands. The internal gland chambers (positioned towards the impellers of the 1st and 2nd stage) are connected with one another by means of a balancing pipe and with the intake fitting.
This way equal pressure situations are achieved on the suction and on the pressure side and, at the same time, the glands are relieved. The outer chambers of the glands are al-ways connected by means of a pipe into which the seal gas is fed. By means of sealing of the glands with a dry inert gas leakage of the medium to be pumped from the compressor into the machine hall is prevented. The mixture of the seal gas and chlorine gas is re-moved via the central gland chambers. This prevents seal gas from entering into the me-dium to be transported.
Hylomar jointing compound is used as sealing material for the housing parting line.
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ITEM QTY DESIGNATION
10 1 Rotor, 2 stages 20 1 Compressor housing, complete 30 1 Tilting pad journal radial bearing 40 1 Radial / Axial sleeve bearing 70 50 2 Labyrinth gland 60 1 Labyrinth gland 70 1 Labyrinth gland 80 1 Labyrinth seal 90 1 Labyrinth seal 100 1 Labyrinth seal 110 2 Labyrinth seal 120 1 Initial guide device, adjustable 130 1 Guide wheel, 1st stage 140 1 Guide wheel, 2nd and 3rd stage 150 1 Sealing cap 160 1 Instruction plate V 170 1 Label 14 180 4 Half-round groove pin 190 2 Half-round groove pin 200 3 Resistance thermometer 210 1 Resistance thermometer
SIEMENS
PART NO. 4212704 4212707 4005715 4213823
4011534 4003481 4014045 4014046 4014047 4011504 4011911 4211653 4013625 4212710 4206000 3017905 3018219 3-357705-007 3-357705-002 3021963 3021961
REMARKS GG-25 70 70 98 108 108 RI310 Ri265 Ø300xØ215x26
80
74 X 37 X 0.,8 52 X 13 X 0,5 2,5 X 6 1,6 X 6
2Pt100 (three-wired) 2Pt100 (three-wired)
Table 2 Parts list for compressor
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Illustration 4 Sectional view of compressor
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Table 3 Parts list for the initial guide device, adjustable
ITEM QTYDESIGNATION .
10 1 Inlet guide vanes insert 20 1 Fastening flange 30 1 Connecting rod 40 11 Inlet guide vane 50 11 Bushing 60 1 Ring gear 70 11 Adjusting pinion 80 11 Sleeve 90 4 Sliding key 100 1 Hexagon head screw 110 11 Seal ring 120 11 Seal ring 130 1 Scale 140 1 Lock washer 150 1 Seal 160 1 Hexagon nut 170 1 Clevis 180 1 Bolt with head 190 22 Deep groove ball bearing,
single row
200 11 Shaft snap ring 210 11 Bore snap ring 220 11 Setscrew 230 11 Hexagon head screw 240 8 Stud bolt 250 4 Cylinder head screw 260 1 Washer 270 4 Screw retention washer 280 8 Screw retention washer 290 1 Split-pin 300 2 Hexagon head screw 310 8 Cylinder head screw 320 2 Half-length reserve taper
grooved dowel pin
330 1 Washer 340 11 Screw retention washer 350 1 Pointer 360 1 Actuator, pneumatic 370 8 Hexagon nut
SIEMENS REMARKS PARTS NO.
4013973 GG-25 4004512 RSt37-2 4014052 St 50-2 4013974 G X6CrNi18 9 4004515 St 50-2 4011544 St 52-3 4011545 St 50-2 4004516 St 50-2 4004559 CuZn37 F37 4004517 M 12x1,5x30, 8.8
4004518 17x40x10, PTFE 4004519 20x35x7, PTFE 3018356 82x20x2, 1.4541 3-358404-003 A12, DIN128, steel 3-803202-007 DN 125, Klinger Sil 4400 3-355104-003 M 16x1,5, 04 3-359405-004 G 16x32 FG, 1.0715 3-357601-014 BNL 16x45x36,5, free-cutting steel3-400101-004 6003, DIN 625, Steel 3-407001-009 17x1, Ferder steel 3-407101-011 35x1.5 Ferder steel 3-353301-010 M 5x8, 45H 3-353601-255 M 6x8, 8.8 3-353901-073 M 16x50, 8.8 AOP 3-351901-167 M 5x20, 10.9 3-3501-009 13-200HV, steel 3-407802-022 NL5, steel, galvanised 3-407802-013 NL16, steel, galvanised 3-357201-002 4x25 , A4-70 3-353601-214 M 4x8, 8.8 3-351901-199 M 10x40, 8.8 3-357703-005 5x20, steel 3-3501-011 17-200 HV, steel 3-407802-007 10,8x6,5x1,8, steel, galvanised 4012824 1x74, high-grade steel 3021632 MFIII-60.12C, TYPE 812 00035500450 M 16, 8 AOP
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Illustration 5 Initial guide device, adjustable
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Illustration 6 Initial guide device, adjustable
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3.1.2.1 Rotor
The rotor consists of a forged shaft and the two impellers made of high-quality steel which are shrunk onto the shaft. The impellers are welded on a special device and submitted to overspeed testing after completion of processing. The entire rotor is balanced dynami-cally at operating speed. In this way a low-vibration operating of the compressor rotor is achieved.
3.1.2.2 Housing
The material used is GG-25. The diffuser which is spring-cushioned in the housing behind every impeller facilitates a relatively simple design of the housing.
3.1.2.3 Guide wheels and labyrinth seals
The guide wheels, packing rings, inserts and glands are made of grey cast iron. The laby-rinths are made of SS steel. The sealing profiles are caulked into the base body with the help of caulking strips. The labyrinths are scraped in accordance with the clearances specified in the test sheet.
3.1.2.4 Arrangement of bearings for the compressor rotor
The rotor is equipped with two tilting segment journal bearings with forced oil lubrication. The inner surface (borehole) as well as the external diameter of the tilting segments must not be damaged or reworked.
The bearing housing consists of GG-25. The tilting segments are made of steel and babit-ted with SnSb12Cu6ZnAg bearing metal.
The bearing housing is secured against twisting with the help of a grooved dowel pin in the bracket of the bearing and is kept together by the bracket of the bearing. Care has to be taken to ensure that the bearing housing is locked perfectly with the bracket of the bearing; however, it must not become distorted.
In order to achieve a tight seat an initial tension of 0.05 mm is admissible.
The axial thrust of the rotor is taken up by a double-sided compressor thrust bearing whose tilting segments are also made of steel and a filling compound made of SnSb12Cu6ZnAg bearing metal.
Normally, the rotor is pressed against the tilting blocks by the axial thrust in the direction of the suction side. Operation of the compressor in the partial load area as well as unfa-vourable pressure conditions during starting up and shutting down of the system can lead to a temporary change of the direction of the axial thrust. To provide a solution for this case the axial bearing is also equipped with tilting blocks on the opposite side. The quan-tity of the lubricating oil is dimensioned in such a way that the frictional heat which devel-ops in the bearing can be removed and a sufficient thickness of the oil layer between the sliding surfaces is achieved.
The oil throughput can be controlled with the help of screens in the oil feed pipes.
Monitoring of the bearing temperatures is carried out with resistance thermometers 2 x PT - 100 in the tilting segments.
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3.1.3 Intermediate cooler and aftercooler
The chlorine gas is cooled after every compressor stage.
The coolers which are installed in a horizontal position are positioned on separate foun-dations in part below the compressor foundation and connected with the compressor with the help of pipelines.
Gas pipings and gas coolers are not part of the delivery scope of Siemens Leipzig!
3.2 Drive
3.2.1 Driving motor
The driving motor is mounted on the joint base frame.
For further information see operating instructions by the manufacturer.
3.2.2 Gear unit
Transformation of the motor speed into the rotational speed required for the compressor is carried out with the help of a planetary wheel gear. Said gear is connected to the com-pressor shaft with the help of a internal tooth coupling. The compressor and the gear unit are mounted on the joint base frame.
For further information see operating instructions by the manufacturer.
3.2.3 Coupling
Connection between the motor and the gear is ensured by means of a maintenance-free lamination coupling.
For further information see operating instructions by the manufacturer.
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3.3. Lubricating Oil Supply
The lubricating oil system comprises the oil collecting tank, the double oil cooler, the dou-ble oil filter, the auxiliary oil pump and the connecting oil pipelines with several valves, completely mounted on a joint baseframe.
On the oil tank flanges are mounted for the supply and degassing openings as well as branches to the buffer gas connection and connections for the oil return pipes. On the tank side the liquid level meter and the filling level switch are mounted.
On one side wall of the oil tank there is a connecting flange for the oil intake line. At the lowest point of the oil tank bottom there is the oil drain. The oil tank is electrically heated.
The oil pipelines from the oil tank are made from stainless steel. Upstream of the com-pressor bearings orifice plates are installed, by means of which the correct bearing oil pressures are set during initial commissioning.
The oil system is protected against inadmissible pressure increase by means of pressure relief valves installed downstream of the oil pumps.
For the commissioning of the compressor unit an oil temperature of at least 20°C is nec-essary.
The oil flow pressure is constantly controlled by an oil pressure regulator, operated with-out auxiliary energy. The oil flow temperature is constantly controlled by a temperature regulating valve in a bypass to the oil cooler that is operated without auxiliary energy.
An oil mist separator is on the oil tank installed. Before putting into operation the rubber pipe has to be absolutely filled with oil to ensure the function. This takes information sign into account one on the separator.
ITEM QTYDESIGNATION PGW REMARKS BA5207251E.DOC, Rev.0, January 2009
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. 10 1 Components for
Oil supply unit (oil tank, oil
cooler)
20 1 Double oil filter 30 1 Oil level indicator 40 1 Flanged heating element 50 1 Screw pump unit 60 1 Oil intake line - Auxiliary oil
pump
70 1 Oil pressure line for auxiliary
oil pump
80 1 Oil return line, Safety valve 1 90 1 Oil return line, Safety valve 2 100 1 Oil feeding line for oil filter 110 1 Oil return line, control valve 120 1 Oil vent piping - oil filter 130 1 Oil drain piping - oil filter 140 1 Oil vent line - oil cooler 150 1 Oil drain line - oil cooler 160 2 Ball valve 170 1 Seal 180 8 Hexagon head screw 190 4 Hexagon head screw 200 8 Screw retention washer 210 20 Hexagon nut 220 4 Cheese-head screw 230 4 Flat gasket 240 16 Hexagon head screw 250 1 U beam 260 2 Pipe clamp 270 2 Flat gasket 280 8 Hexagon head screw 290 8 Hexagon nut
PARTS NO. 3023978 AEL 3021639 DU.401.10G.30.E.P.-.FS8.-.-.AE30184 KSR BYPASS DN15 PN16 3021638 TYPE HF-8 30213 TRILUB 210R40U8.6-V-W115 42080 RSt37-2 42082 RSt37-2 42078 RSt37-2 42079 RSt37-2 42084 RSt37-2 42085 1.4571 42086 1.4571 42087 1.4571 42088 1.4571 420 1.4571 3017297 DN15/PN16, High-grade steel 3-803201-017 DN100/PN16, AF 400 3-353601-103 M16x35, 8.8 A0P 3-353601-066 M12x55, 8.8 A0P 3-407802-010 NL 12, steel 00035500011 M12, 8 AOP 00035356241 M12x35, 8.8 A0P 3-803201-037 DN15/PN40, AF 400 00035365169 M 12x45, 8.8 A0P 00013010600 RSt37-2 3-323402-059 RCP 1-460; polypropylene 3-803201-121 DN40/PN40, AF 400 3-353601-113 M16x55, 8.8 A0P 00035500450 M16, 8 AOP
Table 4 Parts list of the oil supply system
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Illustration 7 Oil supply system
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Illustration 8 Oil supply system
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On the one hand measurement and control technology is used to maintain stable operat-ing conditions and on the other hand its purpose is to protect the compressor unit against damage in case of malfunctions.
3.4.1 Measuring points - sealing – switching off
A number of temperature, pressure and other measurement devices, the arrangement of which is provided in the technological illustration, are used as sensors. The designation of the measurement points as well as the operating values are summarized in the list of the measurement and control points.
The technological illustration and the list of measurement and control points provides in-formation on the functional connections and the interaction of the control and measure-ment technology of the compressor unit. This also provides information on the conditions for locking and switching-off which are decisive for operating safety.
Further information on this is provided in the documentation regarding the control and measurement system.
3.4.2 Controls
3.4.2.1 Inlet guide vane
With the help of the inlet guide vane in the inlet chamber before the first compressor stage the operating point of the compressor can be adjusted within certain limits in accor-dance with the requirements. The section can be seen in the characteristic diagram (illus-tration 1).
3.4.2.2 Surge limit control
The calculatory characteristic diagram provides information on the position of the “surge limit“ (unstable area). A so-called surge limit control is provided in order to prevent the compressor from travelling into the “area of the pump“ on account of the respective oper-ating conditions.
The “surge limit control“ is executed as a so-called “surplus regulation“, i.e. the difference between consumption and the minimum output is de-stressed in the control valve and lead to chlorine destruction.
3.4 Measurement and control technology
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3.4.2.3 Seal gas control
Leakage of the product from the compressor into the machine hall is prevented by means of sealing the gland with nitrogen. The seal gas inflow pressure must always be kept higher than the gas pressure in the internal gland chambers by the control.
Without any seal gas pressure the main motor is locked and/ or in case of a failure of seal gas it is switched off and an alarm is issued at the same time. During continuous opera-tion safety of the glands is ensured up to a differential pressure of ∆p = 10mbar.
Control is carried out depending on the pressure difference between the relieving line and the seal gas feed line.
3.4.3 Vibration and axial thrust monitoring
Vibration monitoring of the compressor is carried out on the shaft directly next to the bearings within the housings of the bearings. The sensor for measuring of the axial shaft position of the compressor is located on the end of the shaft (thrust bearing side). For setting of this sensor the rotor has to be pushed towards the 1st stage until the stop on the thrust bearing is reached. Please refer to the operating instructions of the vibration and axial position monitoring system for information on the precise procedure for setting of the sensor.
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4. Installation of the unit
4.1 Installation of the compressor unit
The base frame of the unit is aligned in terms of height and distance as well as in an ex-actly horizontal position by means of adjusting of the levelling screws below the base frame near the foundation bolts. When placing the unit on the frame special care has to be taken to ensure a parallel and centred position of the shaft. On principle, anchor bolts are supplied along with the product for our compressor units. In this way a stable connec-tion with the foundation can be created right away. Casting of the base frame with con-crete can be carried out subsequently after alignment of the unit has been completed.
4.2 Installation of the auxiliary units
The dimensions specified in the machine installation plan Z L5207251Mp have to be complied with with regard to the installation of the lubricating oil unit and of the gas cool-ers. The lubricating oil unit is placed directly on the floor of the hall (± 0 level). Fastening of said unit by means of screwing it onto the floor of the hall is possible; however, this is not required. Casting with concrete is not provided for.
4.3 Laying of the gas, oil and cooling water pipelines
Pipe sockets as well as the sockets on the components have to be kept closed during installation. Adjustment and finishing of the pipelines by welding has to be carried out in such a way that assembly of these is possible without distortions.
Laying of the pipelines which form part of the scope of supplies has to be carried out in accordance with the assembly drawings contained in the documentation. The same also applies with regard to subsequent treatment and testing after completion.
The oil pipelines have to be supported on the foundation in such a way that there is no load on the compressor unit.
Before final adjustment of the gas pipelines between the compressor and the gas cooler the water chambers on the gas cooler have to be filled with water so that there is a suffi-cient load on the vibration insulators below the coolers (operating state).
During laying of the connection lines to the gas coolers the maximum forces and mo-ments admissible on the compressor sockets specified in the drawing for the compressor unit must not be exceeded in any case. The same also applies analogously with regard to the connection of the suction and of the pressure line.
After all the pipelines have been connected it must be possible to turn the unit just as easily as before. After adjustment has been carried out, all the pipelines have to be dis-mantled and cleaned accordingly.
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4.4 Alignment
4.4.1 Coupling between gear and compressor
The initial alignment of the high-speed clutch between gearbox and compressor is carried out in the shop. The compressor unit - motor, gearbox and compressor - is delivered mounted on the joint frame.
The compressor is delivered with installed alignment bearings. The compressor rotor is axially fixed and clamped in its radial position between alignment bearing and shaft by means of foils.
First the compressor - gearbox - baseframe subassembly shall be aligned, paying atten-tion to the given shaft end positions. These positions provide for the insertion of the jour-nals and the thermal expansion of the housings.
When preparing the alignment of the compressor and the gearbox the clutch protection of the high-speed clutch shall be dismantled.
ATTENTION
The positions of all clutch components to each other are marked and shall be observed
during the installation.
When aligning fast-running shafts it shall be taken into account that under operation the gearbox shaft shall
Engage 0,02 mm
The compressor shaft with original bearings shall engage
0,04 mm.
ATTENTION
In relation to the compressor journal the gearbox shaft shall be aligned 0,02 mm (0,04mm – 0,02mm) higher (with original bearings). With alignment bearings the gear shaft is 0,05 mm deeper than the compressor shaft to align.
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ATTENTION
The admissible alignment tolerances amount to the following values for
Radial displacement +/-0.03 mm
Angle displacement +/-0.02 mm in case of a measuring circuit radius of 200 mm (in case of a radius of r 200 mm the tolerances change proportionately to the measuring radius).
The base frame must only be connected firmly with the foundation once alignment has been carried out in accordance with the specifications herein above. After that, fine align-ment has to be checked once again.
The drive motor must only be aligned after that.
Assembly after the alignment process has to be carried out in reversed order.
ATTENTION
All flanged joints have to be equipped with a suitable sealant.
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Illustration 9 Alignment of coupling between gear and compressor
4.4.2 Coupling between drive motor and gear
During alignment of low-speed shafts care the fact that the gear drive shaft floats
0.07 mm in the operating state has to be taken into account.
Heat expansion and floating of the motor shaft amount to
0.25 mm.
Attention
For this reason the motor has to be aligned in a position which is 0.18 mm (0.25 mm –
0.07 mm) lower than the gear.
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Attention
The admissible alignment tolerances also amount to the following values for
Radial displacement +/-0.03 mm
Angle displacement +/-0.02 mm in case of a measuring circuit radius of 200 mm
(in case of a radius r200 mm the tolerances change proportionately to the measur-ing radius )
After fastening of the drive motor by means of screwing, both of the coupling alignments have to be checked once again. After that the drive motor has to be fastened with pins.
Illustration 10 Alignment of coupling between drive motor and gear
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5. Commissioning and operation of the compressor unit
Commissioning and operation of the drive motors and of the auxiliary units have to be carried out in accordance with the manufacturer’s instructions.
5.1 Preparation of first commissioning
5.1.1
Check gas pipelines for stress-free assembly by means of disconnecting the flanged joints on the connection pieces of the compressor.
5.1.2
Check control and safety devices.
5.1.3
Check proper functioning of the control fittings.
5.1.4
Carry out leak test on the oil coolers.
5.1.5
Rinse the entire lubricating oil system under observance of the strictest compliance pos-sible with the following requirements:
- Use the same type of oil for rinsing which is also provided for as operating oil filling.
- The halves of the alignment bearings of the compressor have to be disassembled prior to the commencement of rinsing with oil.
- The oil feed line to the gear has to be disconnected from the housing of the gear and has to be connected to the oil return pipe and/ or the oil container by means of a hose pipe.
- The entire quantity of oil has to be circulated with the oil pump. Upon commissioning the oil chambers, the oil cooler and the oil filter have to be vented.
- The rinsing oil should have a temperature of between 40°C and 50°C.
- Both oil coolers have to be operated alternately.
- Rinse via an oil filter, the screen of which should be exchanged or, if possible, cleane-d after oil rinsing or to replace by new.
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- The duration of oil rinsing depends on the quantity of dirt in the oil filter.
Rinsing can only be stopped if there is no dirt in the filter any more for a period of two hours. After that the rinsing oil has to be let off entirely (also from coolers and filters) and the oil container has to be cleaned.
- After rinsing with oil the compressor bearings (operating bearings) have to be in-stalled and the bearing has to be connected to the oil feed line once again.
5.1.6
Fill with operating oil.
5.1.7
Leak test of the water sides of the intermediate coolers and the aftercooler.
5.1.8
Close suction, pressure and flare slide valve. Fill machine with coolers and appertaining pipelines with air or inert gas to approx. 1.0 to 2.0 bar(Ü) via the rinsing connection and brush all flanged joints with a solution which forms a foam.
5.1.9
Commission oil pump and set bearing oil pressures with the help of the orifice disks.
5.1.10
Carry out test of the sense of direction of the drive motor in a disengaged state.
ATTENTION
The coupling sleeve has to be pushed in the direction of the gear in this case and the packing ring of the coupling on the side of the motor has to be pushed towards the motor and to be attached to the housing of the motor without any contact with
the motor shaft.
5.1.11
Adjust axial shaft position monitoring. In this process the rotor has to be pushed in the direction of the suction side towards the tracking blocks until it reaches them. See de-tailed description by the manufacturer.
5.1.12
Adjust shaft vibration monitoring. See detailed description by the manufacturer.
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5.2 First commissioning
5.2.1 Mechanical trial run
Once the test of the sense of direction of the drive motor has taken place, the unit has to be disengaged. After that it is started up analogously to item 5.3 for a 30-minute trial run (bearing test) with nitrogen.
After switching off of the machine it is recommended to uncover the compressor bearings and to submit them to a visual inspection. In case of abnormal measured values of the bearing temperatures or vibrations an inspection of the bearings is absolutely required.
5.2.2 Functional run with nitrogen
In case no defects are detected during the inspection of the bearings, the bearings can be mounted again.
Afterwards the compressor system can be started up again for a functional run with N2. Commissioning is carried out as described under item 5.3. The duration of the test run should not exceed 72 hours; however, it should amount to at least 24 hours. During the functional run the entire measurement and control technology has to be set and tested. After the end of trial operation it is recommended that the bearings be checked once again. All deficiencies which have occurred during the functional run have to be removed. Once these work activities have been completed the plant can be started up for continu-ous duty.
5.3 Normal commissioning
The following approach has to be complied with for commissioning of the compressor system:
5.3.1 Check the measurement and control devices as well as the alarm and switching-off conditions in accordance with the blocking diagram (illustration 12).
5.3.2 Check the electrical installation. Carry out cold switching activities.
5.3.3 Switch on electrical heating and auxiliary oil pump until an oil temperature of t = 20°C is reached in the oil container.
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Illustration 11 Blocking diagram
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5.3.4
Bleed oil pump, oil filter and oil cooler on the oil side.
Attention! Also bleed reserve unit!
5.3.5
Switch on drive motor.
5.3.6
Adjust seal gas supply to the glands. Set required differential pressure between the seal gas line and the relieving line.
5.3.7
After stabilization of operation throttle bypass valve until a final pressure of 1...2 bar(g) has been achieved.
5.3.8
Adjust cooling water for the gas and oil cooler as required. Stage suction temperatures of approx. 50°C should be aimed at in order to remove any residual moisture which might still be present in the system.
5.4 Commissioning with chlorine
Steps of commissioning as outlined under item 5.3 (5.3.1 - 5.3.8).
5.4.1
Open cooling water valves on all coolers including oil coolers.
ATTENTION!
Before commissioning with chloric gas the moisture content in the small circuit of the gas system has to be tested. It must not exceed a value of 200 mgH2O/m³N, else the circuit has to be dried.
(Mode of operation as outlined under 5.3.1 - 5.3.8)
5.4.2
Open flare slide valve a little. Open suction valve slowly.
Throttle bypass valve a little until operating pressure is reached on the pressure side. The system has to be operated in this state for several minutes in order to remove the inert gas from the compressor.
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5.4.3
Open pressure valve. Close flare slide valve.
5.4.4
Commission surge limit control, suction pressure and seal gas control.
5.4.5
Close bypass valve.
Reading should take place at intervals of one hour and of at maximum two hours. After re-commissioning the values have to be read off at shorter intervals. Moreover, the fol-lowing maintenance and control activities are required:
- check lubricating oil for lubricity and state of ageing.
For the first time after approx. 1,000 operating hours, afterwards after 3,000 operating hours each. In case of negative values carry out an oil change.
- Drain sludge and condensation water by means of brief opening of the oil container drain after a period of 2 months each.
- In case of an oil filling level which is too low refill oil.
The instructions in the separate operating instructions provided by the respective manu-facturers have to be complied with with regard to the maintenance activities on the gear unit and on the auxiliary units.
5.5 Shutting down
5.5.1 Scheduled shutting down
5.5.1.1 Open bypass valve. Close pressure valve.
5.5.1.2 Switch off main motor. Close suction valve.
5.5.1.3
5.5.1.4
Open flare slide valve.
Flush compressor with dry inert gas. Switch off controls.
Switch off seal gas supply after chloric gas has disappeared from the com-pressor plant in its entirety. The auxiliary oil pump can be switched off approx. 15 minutes after standstill of the compressor. Close cooling water supply.
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5.5.1.5
5.5.1.6
5.5.1.8
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5.5.2 Shutting down in case of failures
In case of certain failures which can lead to a danger for the unit and/ or people, an auto-matic switch-off of the unit has to be provided for. The following failures in particular should trigger an automatic switch-off:
• Drop of oil pressure
• Increase of the temperatures of the bearings on the compressor, the gear and the mo-tor as well as the coil
• Increase of the oil temperature before the oil filter
• Increase of the gas temperature before the intermediate coolers • Increase of the gas moisture
• Reduction of the seal gas pressure
• Inadmissible axial displacement of the compressor rotor • Increase of the shaft vibrations of the compressor rotor • Failure of the control voltage
5.5.2.1
In case the compressor unit breaks down on account of a failure or of a power outage, the flare slide valve has to be opened immediately, the suction and the pressure valves of the compressor have to be closed right away and at the same time the bypass valve has to be opened.
Afterwards the same procedure as that outlined under items 5.5.1.6 ... 5.5.1.8 has to be applied.
5.5.2.2
In case of a switch-off, the quantity of oil pumped by the main oil pump is reduced con-tinuously. The auxiliary oil pump is then switched on automatically. In case the pump does not start, e.g. on account of a failure of the low voltage, the residual quantity of oil pumped by the main oil pump is sufficient for safe phasing out.
In case such a malfunction has occurred, we recommend that you submit the bearings of the gear and of the compressor to a visual inspection prior to re-commissioning.
5.5.2.3
In case of a break-down of the compressor unit on account of a failure, the cause of such malfunction has to be established and removed prior to re-commissioning. In case the failure was triggered by an activation of the shaft position monitoring system, the com-pressor thrust bearing has to be submitted to an inspection in any case and in case of inadmissible wear, the tilting segments have to be replaced.
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5.6 Servicing
During operation the compressor unit has to be serviced continuously.
The measurement values specified herein below have to be registered:
1. Bearing temperatures compressor bearings
2. Bearing temperature gear
3. Oil return temperature gear
4. Gas suction temperature
5. Gas temperature before and after the coolers
6. Oil temperature after oil cooler
7. Oil pressure after oil filter
8. Differential pressure oil filter
9. Oil pressure before compressor bearings
10. Gas pressure in the inlet line
11. Gas pressure in the pressure pipe
12. Differential pressure between the relieving line and the seal gas line
13. Seal gas pressure before entry into glands
14. Quantity of seal gas in glands
15. Humidity of the gas in the inlet line
16. Axial shaft position
17. Shaft vibration
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6. Interruption of operation
The list herein below comprises the most important interruptions of operation which might occur in accordance with the experience gathered so far. However, this list does not lay claim to completeness by any means.
6.1 Drive
6.1.1 Drive motor does not start up:
Causes: a. Oil temperature in the container ≤ 20 °C b. Oil pressure ≤ 1,2 bar (g) c. Differential pressure seal gas ≤ 15 mbar d. Control voltage missing e. High voltage missing
6.1.2 Drive motor switches off:
Causes: a. Power outage
b. Emergency switch-off by one of the safety devices c. Actuation of the motor protection device
6.2 Gear
6.2.1 Oil return temperature too high:
Causes: a. Temperature of oil too high upon entry b. Oil pressure too low
c. Damage to the bearings or to the toothing
6.2.2 Bearing temperature too high:
Causes: a. Oil inlet temperature too high b. Insufficient oil throughput c. Damage to the bearing
6.2.3. Sudden appearance of abnormal running noises in the gear:
ATTENTION
Stop compressor unit immediately!
Causes: a. Damage to the toothing b. Damage to the bearing
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6.3 Compressor
6.3.1 Disturbance during running
Causes: a. Damage to the bearing.
b. Balance error of the running parts on account of deposits. c. Change in the alignment. d. Housing distorted by pipelines.
e. Compressor working in area of unstable pumping (area of the pump).
6.3.2 All bearing temperatures increase:
Causes: a. Oil inlet temperatures too high. b. Oil pressure too low.
6.3.3 Bearing temperatures in one bearing increase:
Causes: a. Damage to bearing. b. Inflow of oil insufficient.
6.3.4 Final compressor temperature increases:
Causes: a. Suction temperature has increased. b. Cooler contaminated. c. Too little cooling water.
6.3.5 Seal gas pressure drops:
Causes: a. Controller failed. b. Labyrinth clearances have increased. c. There is not enough seal gas.
6.4 Lubricating oil system
6.4.1 Oil pressure after filter drops:
Causes: a. Wear on the oil pump.
b. Wear on compressor or gear bearings. c. Filters and/ or coolers contaminated.
6.4.2 Oil temperature after cooler too high:
Causes: a. Cooling water too warm. b. Too little cooling water. c. Oil cooler contaminated.
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7. Maintenance, instructions regarding removal and installa-tion
Attention: Before the activities for dismantling can commence, an employee in charge has to grant clearance for opening of the compressor, of the gas coolers and of the gas pipelines as well as of the gas fittings.
7.1. Compressor
The working steps listed herein below are required for complete dismantling for the pur-pose of an inspection/ or of maintenance of the compressor.
7.1.1 Remove partial flange nuts and taper pins with the device for removing of these supplied with the product.
7.1.2 Remove rectangular lid on the upper part of the housing.
7.1.3 Reach through opening created this way and disengage the rods of the initial guide device (unscrew SW 19 hexagon head bolt with a fixed spanner).
Illustration 12 Disengaging the connecting rod
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7.1.4 Lift off upper part of housing (use guide bolts).
7.1.5 Remove hexagon socket head cap screw and taper pins from the lids of the bearing and take off lid of bearing.
7.1.6 Unscrew partial flange screws of the housing of the coupling between the gear and the compressor, unscrew and lift off upper part of the housing of the coupling from the compressor.
7.1.7 Remove hexagon head nuts and taper pins from the bracket of the bearing and take off bracket of the bearing.
7.1.8 Remove upper part of the housing of the bearing.
7.1.9 Take out rotor with the entire initial guide device (attach with hemp rope and put into wooden frame).
7.1.10 Pull coupling from rotor. (Take section 7.2 into account.)
7.1.11 Pull initial guide device off rotor and check initial guide device for movability.
7.1.12 Disassemble lower part of the housings of the bearings.
Attention!
Unscrew terminals for cables of the thermometers before the work activities.
7.1.13 Dismantle glands, packing rings and inserts.
7.1.14 Replace radial and axial tilting segments, labyrinth glands, packing rings and in-serts if required.
7.1.15 The installation of new tilting segments (wear and tear parts) has to be carried out in accordance with the “Instructions regarding the installation and disassembly of tilting segment bearings – Appendix 1“ enclosed.
7.1.16 Marking and forming of the notches for mounting of the halves in the upper part of the compressor.
7.1.17 During installation of new packing rings and inserts (spare parts) scraping of the labyrinths has to be carried out using the alignment bearings; in this context, the labyrinth tolerances entered in the test sheet ZM5207251-Mb have to be complied with.
7.1.18 Dismantle the halves of the packing rings and inserts and the alignment bearings.
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7.1.19 Installation of the original bearings
7.1.20 Insert lower half of one of the two glands.
Rotate the rotor until the shaft labyrinths have become marked on the epoxy resin layer. Strongly marked points have to be processed using a scraper. Repeat procedure several times until the shaft labyrinths are marked as evenly as possible throughout the entire surface. Turn the rotor for some time until it moves easily.
Comment: In case of fast turning of the rotor by hand, it has to trail slightly.
7.1.21 Place upper part of the gland on top and follow the same procedure as under 7.1.20.
7.1.22 Treat second gland in accordance with 7.1.20 and 7.1.21.
The first gland has to be removed before that in order to ensure that there are the same conditions for checking for soft running.
7.1.23 Installation of all halves of glands, packing rings and packing inserts. Fasten upper halves in the upper part of the compressor.
7.1.24 Lower upper part of the compressor with the inserted alignment pins until they al-most touch the partial areas.
7.1.25 Place sheets with a thickness of 0.1 mm in four positions, put down upper part, slightly fix alignment pins, rotate rotor. If required, hard carrying markings have to be re-scraped after lifting off of the upper part. Free movement of the rotor has to be achieved.
7.1.26 Same procedure as under 7.1.25 with shims with a thickness of 0.05 mm.
7.1.27 Same procedure as under 7.1.25 with upper part of housing in place without shims. As a result of this, it has to be possible to turn the rotor easily.
7.1.28 Screw partial flange connection hand-tight and check rotor for free movement. If required, turn rotor for some time until it trails slightly during fast turning.
7.1.29 Seal housing parting line with sealant.
7.1.30 After assembly has taken place, alignment has to checked also by using the align-ment bearings.
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Illustration 13 Compressor test sheet
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Illustration 14 Compressor test sheet
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7.2 Inspection
A minor inspection has to be carried out or has to be commissioned to be carried out every 8,000 operating hours (annually). The extent of the required checks during a minor inspection is listed herein below:
Compressor:
- Inspection of bearings
COMMENT
Seal packing surfaces of the bearing lids with the sealant HYLOMAR SQ 32M dur-ing assembly. Take the operating instructions regarding the sealant into account.
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7.3 Couplings
All couplings are executed with a cylindrical bore. Pulling off of the coupling hubs is only admissible provided a device for pulling-off is used.
The clearance between the hub and the shaft is : hub H 7
shaft m6
Before fitting on, the hubs have to be warmed to up to 80°C in an oil bath.
7.4 Gas cooler
See operating instructions by the manufacturer.
7.5 Drive motor
See operating instructions by the manufacturer.
7.6 Gear
See operating instructions by the manufacturer.
7.7 Oil cooler
See operating instructions by the manufacturer.
7.8 Oil filter
See operating instructions by the manufacturer.
7.9 Oil pumps
See operating instructions by the manufacturer.
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7.10 Oil container
Cleaning of the oil container
During trouble-free operation cleaning of the oil container is not required.
The sludge which collects at the lowest point of the oil container can be removed by opening the oil container drain for a short period of time.
In case an oil change becomes necessary on account of contaminated oil or of oil which cannot be used any more, the container can be flushed with steam or suitable solvents after all the lids have been dismantled.
7.11 Appendices
Instructions for the installation and dismantling of tilting-pad bearings
Instructions for the installation and dismantling of tilting-pad bearings
1. Installation instructions
- The tilting-pad faces and contact surfaces shall be wetted with oil prior to installation. - Thoroughly install the bottom half with the two tilting pads by lifting the rotor when in-serting the bottom half, as the tilting pads may get jammed due to their pivoted instal-lation in the bearing.
- After installing the two bottom halves the rotor shall be rotated in order to ensure the
proper position of the tilting pads.
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1.1 Tilting pad radial bearings
When installing the bearing the bearing geometry shall be observed. The proper installa-tion position is shown in Illustration 15.
Illustration 15 Installation position of tilting pad radial bearings
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In order to avoid that the bearing is installed laterally reversed when replacing the entire bearing, the bearing is marked by means of a set screw sticking into the oil canal of the bearing.
Prior to drilling the pinhole into the top bearing half, its tight seat shall be checked after tightening the nuts for the bearing clamp.
If the bearing is not fixed tightly, the bearing clamp joint shall be re-worked.
The exact clearance may be determined by inserting lead wire. Please do not exceed a preload of 0.05 mm.
If the bearing is fixed tightly and the installation direction is correct, the pinhole shall be drilled and reamed.
1.2 Tilting pad radial thrust bearing (double-sided)
When replacing the tilting pads or the entire bearing, please follow the instructions de-scribed under Items 1 and 1.1. However, due to the bearing design a wrong installation is excluded. In any case, the proper bearing geometry, i.e. swivelling of the bearing at an angle of 5° towards the compressor joint in accordance from the sense of rotation, shall be observed.
Refer to Illustration 15.
2. Changing the radial tilting pads
The bearing is designed in a way that the bearing housing is not considered a wearing part.
In case of natural wear of the tilting pads, these are only replaced as complete set. When changing the radial tilting pads it shall be observed that the fastening screws are secured by means of lock washers.
If the bearing journal of the shaft is damaged and needs re-working, a set of tilting pads with respectively adjusted bore shall be inserted.
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3. Changing the axial tilting pads
When changing the axial tilting pads due to pad wear, please proceed as follows:
Illustration 16 Dismantling the tilting pads
Swivel the pressure rings with the damaged pads out of the bottom and top bearing halves.
The tilting pads are completely replaced by a new set of completely mounted pads. In order to avoid bearing damage, the pads must not be mixed up.
The “tilting pad, right” is located on the bearing side pointing towards the rotor bearing, the \"tilting pad, left” is located on the bearing side pointing to the rotor end (see Illustra-tion 17).
Insert the pressure ring of the bottom half into the bottom bearing shell and the top pres-sure ring into the top bearing shell. Replace bearing half and tighten the bearing clamp. Measure the axial clearance and compare to the required clearance in accordance with the measuring sheet.
If the clearance is too low, re-turn the pressure ring on the tilting pad side in accordance with Illustration 18 by the difference - 0.05 mm. (0.05 mm = dimension for touching up and re-carving). Next, screw on the pads, swivel in the pressure rings and tighten the bearing clamp. Prior to doing so apply some touch-up paste on one place of the axial bearing collar. In order to carry out the touching up, the rotor shall be rotated in the bear-ings by 360°, simultaneously pressing the rotor on the pressure ring with the tilting pads screwed on. The contact pattern obtained shall be improved by carving, until a good rest of all pads - simultaneous bearing - is reached.
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Prior to finally mounting the radial thrust bearing, each screw in the axial tilting segment shall be secured by gluing. Thus an automatic loosening of the oval-head screws is ex-cluded. Please observe, that the threads (screws and tilting pads) shall be free from grease and oil! Then apply some glue to the screw thread and screw on the pads.
If the axial bearing collar of the shaft is damaged and needs re-working, complete sets of axial tilting pads with higher pressure rings are installed.
Illustration 17 Thrust bearing
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Distinction:
On the “tilting pad, right” there is the tilting edge - when looking at the white-metal to the right of the bore; in case of “tilting pad, left” - to the left of the bore.
Illustration 18 Views of the thrust bearing components
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4. Tilting pad bearings with heat sensor
ATTENTION
Loosen the cables of the heat sensors prior to dismantling the bottom bearing
halves.
Cautiously pull out the bottom halves, passing after the cables.
Prior to removing the retaining ring and the tilting pads, the heat sensor of tilting pad ra-dial bearings shall be cautiously pulled off. (Illustration 19)
In tilting pad radial thrust bearings the retaining ring shall be removed, the screw of the radial tilting pad with heat sensor unscrewed and the tilting pads cautiously pulled out. (Illustration 20)
Prior to taking out the axial tilting segments, the heat sensor shall be cautiously pulled out. (Illustration 20)
Illustration 19 Radial bearing heat sensor
Illustration 20 Thrust bearing heat sensor
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8. Transportation
In accordance with the character of the compressor unit shipment is carried out as a compact unit, i.e. in an installed state.
The unit has to be attached to the base frame on the four suspension eyes in accordance with the instructions regarding transportation.
C A U T I O N
The remaining frame constructions are not strong enough to carry
the turbo-compressor!
Turbo-compressor unit
Illustration 21 Transportation instructions for the compressor unit
Net mass: ≈ 15,000 kg
Diameter of rope (wire): Length of rope, left side: Length of rope, right side: Angle of rope admissible
24 mm 5 m (per line) 5 m (per line) α:≤ 30°
Slinging tools: 4 edge protectors
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Turbo- compressor
Illustration 22 Transportation instructions for compressor
Net weight: 6800 kg
Diameter of rope (wire): Length of rope, left side: Length of rope, right side:
20 mm 4 m 4 m
Admissible angle of rope α: ≤ 45°
Admissible angle of rope β: ≤ 45°
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Oil unit
Illustration 23 Transportation instruction oil unit
Net mass: ≈ 3500 kg
Diameter of rope (wire): Length of rope, left side: Length of rope, right side:
16 mm
4 m (per strand) 4 m (per strand)
Admissible angle of rope β: ≤ 60°
Slinging tool: 4 protectors for edges
The transportation instructions for the motor and the gear are provided in the operating instructions by the manufacturers.
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9. Spare and wearing parts
We recommend to keep the following parts on stock.
9.1 Wearing parts
9.1.1 Compressor
for tilting pad radial bearing 70, right
1 set = 2 retaining rings 1 set tilting pads, radial 70
for tilting pad radial thrust bearing 70
1 retaining ring 1 emergency ring
1 set tilting pads, radial 70
1 set tilting pads, axial 70, right )completely mounted 1 set tilting pads, axial 70, left )on thrust collar
9.1.2 Gearbox
1 set radial sliding bearings 1 set planetary bolts
9.2 Spare parts
9.2.1 Compressor
1 three-stage rotor
1 set labyrinth stuffing boxes 1 set seal washers 1 set seal inserts
1 end plate for tilting pad radial thrust bearing 1 set of seals
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9.2.2 Gearbox
1 set of gearwheels, complete 1 screw pump 1 set of seals
9.2.3 Couplings
1 multiple-disc clutch between motor and gear, ready for operation 1 claw clutch between gear and compressor, ready for operation
9.2.4 Oil cooler
2 sets of seals
9.2.5 Oil filter
2 sets of seals
2 sets of filter elements
9.2.6 Connecting lines
1 set of seals
9.3 Measuring and control equipment
2 shaft vibration sensors 1 shaft position sensors
1 speed control sensor
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Siemens Turbomachinery Equipment GmbH holds the copyright for these operating in-structions.
This document is intended for use by mounting, operating and supervision staff.
It contains technical instructions and details that must not be copied, distributed, used for competitive aims or disclosed to third parties partly or as a whole without our prior con-sent.
Purchasers, planners and operating companies of our product are deemed to have ob-tained the authorisation for preparing additional documents.
10. Copyright
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