1. Manuals
  2. Brands
  3. Sundyne Manuals
  4. Air Compressor
  5. LMC 341F
  6. Instruction and operation manual

Sundyne LMC 341F Instruction And Operation Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

SUNDYNE
LMC 341F COMPRESSOR
Instruction and Operation Manual
August 2007
Effective: August 2007
Visit our website at
www.sundyne.com

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the LMC 341F and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Summary of Contents for Sundyne LMC 341F

  • Page 1 SUNDYNE LMC 341F COMPRESSOR Instruction and Operation Manual August 2007 Effective: August 2007 Visit our website at www.sundyne.com...
  • Page 2 © 2007 Sundyne Corporation WARRANTY Sundyne Corporation warrants to Buyer for a period of twelve (12) months from the date of being placed in service (but not to exceed eighteen (18) months after the date of shipment) that the equipment at the time of shipment will be free from defects of design, material and workmanship.

  • Page 3: Table Of Contents

    Equipment and Safety Precautions ........................1 EXPLOSION/FIRE HAZARD ..................2 USING THIS MANUAL: ....................3 1. INSTALLATION ......................4 INTRODUCTION TO THE SUNDYNE COMPRESSOR ..........5 Inspection ...................................5 Short-term Storage..............................5 Long-term Storage ..............................5 Installing the Suction and Discharge Piping - Guidelines ................6 Seal Environment Control System ........................7...
  • Page 4 9. GEARBOX AND PROCESS END REASSEMBLY..........50 Gearbox Auxiliary Hardware Installation......................53 10. TROUBLESHOOTING.................... 54 11. OPERATION ......................57 12. SPARE PARTS....................... 58 13. SUNDYNE COMPRESSOR WARRANTY .............. 62 Critical Start-up Checklist ............................62 Lock-out/Tag-out Guidelines ..........................64 SINGLE SEAL ARRANGEMENT ..........................65 DOUBLE SEAL ARRANGEMENT ........................66 TANDEM SEAL ARRANGEMENT........................67...

  • Page 5: Introduction And Safety

    Note: Safety procedures must be applied features of these products. Failure to properly prior to any installation, maintenance, select, install or use authorized Sundyne pump or repair of a Sundyne compressor. parts and accessories is considered misuse and Failure to follow safety precautions may...

  • Page 6: Explosion/Fire Hazard

    Sundyne equipment. Any residual process gas or liquid that is flammable can result in an explosion or fire with Note: Sundyne recommends that a Lock- potential for serious injury or death. out/Tag-out program be followed prior to altering the equipment. Locks or...

  • Page 7: Using This Manual

    Using This Manual: Organization This manual is part of the final data package for the Sundyne LMC/BMC Phoenix compressor. In addition to this manual, the final data package includes such information as the following: Drawings, Sundyne specification sheet with test performance curves, test data, inspection data, material certificates if required;...

  • Page 8: Installation

    Provides general guidelines for controlling a compressor such as surge control, suction throttling, discharge throttling, and speed control. Spare Parts Contact and reference information. Sundyne Compressor Warranty Provides a warranty statement for the compressor/gearbox unit. Reference A Critical Start-up Checklist...

  • Page 9: Introduction To The Sundyne Compressor

    Inspection 1. When you receive the Sundyne LMC/BMC compressor, check for any damage. If you find any, inform the carrier and Sundyne promptly. 2. Use Outline drawings in the final data package to ensure that all auxiliary items are properly included.

  • Page 10: Installing The Suction And Discharge Piping - Guidelines

    Because storage location and unknown factors at the site or storage are beyond our control, Sundyne does not accept any liability for damage to the equipment during storage, nor do we guarantee the quality of the equipment during and after the storage period. An Extended Warranty will be null and void if the proper equipment preparation is not maintained.

  • Page 11: Seal Environment Control System

    Step 10: Use block valves on both suction and discharge pipes to isolate the compressor during shutdown, minimize process leakage, and reduce the likelihood of backflow through the compressor, which can cause reverse rotation. Seal Environment Control System For the seal used with the compressor, always maintain the environment shown on the specification sheet for your unit.
  • Page 12 D. PORT 1 PIPING – Units equipped with gas seals must vent case drain port 1 to atmospheric pressure and allow it to gravity drain properly. Otherwise oil could contaminate the outboard gas seal. This port can be attached to a flare line, but should not have back-pressure in excess of 5 psi.

  • Page 13: Baseplate Grouting

    UNITS WITH VERTICAL OR HORIZONTAL STANDS - ALIGNMENT-- If other than Sundyne supplied couplings are used, they must be flexible disc or gear type couplings capable of tolerating parallel and angular misalignment of .005 inch maximum as well axial end play of .060 inch maximum.
  • Page 14 The additives in the new formulations of ATF, such as Dexron III, have been found to have negative effects on Sundyne gearboxes and could compromise mechanical integrity and reliability of the equipment.
  • Page 15 Recommended ISO VG 32 gearbox lube oil specifications: Gravity, API 28 - 37 Pour Point, °C (°F) -7 (20) max. Flash Point, °C (°F) 204 (400) min. Viscosity, 28.8 to 35.2 cSt at 40°C 5.2 min. cSt at 100°C 150 to 180 SUS at 100°F 44 min.
  • Page 16 Lube Oil System The integral Sundyne lube oil system consists of the following major components: gearbox sump, main lube pump, oil heat exchanger (if necessary), and oil filter. Oil is taken from the sump by the lube pump, then passed through internal passages to an external integrally mounted manifold, through the heat exchanger, then through the filter and back into the gearbox to the bearings.

  • Page 17: Start-Up

    3. Start-up If a Sundyne supplied control panel is to be used with the Sundyne LMC/BMC compressor, use the control panel recommended start-up procedure in addition to the steps below. Before starting the LMC/BMC compressor, complete the following procedure in the order in which the steps are...

  • Page 18: Compressor Control During Start-Up

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

  • Page 19: Servicing

    4. Servicing General Requirements To increase the operating life of your compressor and keep it in good operating condition, you should inspect and service it regularly. Measure all of the operating parameters documented in the specific maintenance procedures and log your measurements. Make sure that all major equipment, such as lubricating pumps, heat exchangers, and instrumentation, perform according to the manufacturer’s recommendations.

  • Page 20: Maintenance Of The Seals And Process End Disassembly

    Item numbers refer to the numbers in Reference D, gearbox module drawings. The following procedures apply to all configurations of the Sundyne LMC/BMC compressors. Refer to the specification sheet to determine the specific configuration and optional equipment included in your unit.

  • Page 21: Vertical Units Without A Driver Stand

    Step 1 Remove the driver and gearbox from the compressor housing as follows: (3X2 compressor case shown in photo) Vertical units without a driver stand (shown here) Remove attaching hardware and lift driver from gearbox. Remove nuts (914A) from compressor casing studs.
  • Page 22 NOTE The gearbox can be worked on while in a horizontal position. However, the diffuser cover must be prevented from falling off when the impeller is removed. If the cover falls from its location severe damage to cover and output shaft (high speed shaft) will occur.

  • Page 23: Tandem Seal Disassembly

    Tandem Seal Disassembly Step 1 Remove the seal rotating face (51a). NOTE: Tandem Seal Arrangement shown here. See Reference C, Seal Arrangement Drawings, for single and double arrangements. Step 2 Remove hex head cap screws (905E), washers (916A) and remove lower mechanical seal (60A) of the tandem seal arrangement from the seal housing.
  • Page 24 Step 3 Remove spacer sleeve (60A). Step 4 Remove o-ring (936J). Step 5 Remove upper seal rotating face (51C). Use two small screw drivers to lift up the rotating face.
  • Page 25 Step 6 Remove the hex head cap screws (905A), lock washers (154AT), flat washers (916AG), and seal washers (916S) from seal housing (30). Step 7 Install two 3/4” eye-bolts, approximately 180° from each other, through the seal housing flange face.
  • Page 26 Step 8 Use hoist and equal length chain hooks to lift seal housing off the gear box. Step 9 Turn seal housing (30) over so you can see the upper Tandem seal, and remove the Thermal Barrier Gasket (87A). It may help to have to people on hand to help rotate seal housing.
  • Page 27 Step 10 If upper seal from Tandem seal arrangement requires removal; remove hex head cap screws (905F), and lock washers (916B). Step 11 Remove upper mechanical seal (60B). & Carefully inspect the seals for abrasive particles, excessive seal face in the retainer. Replace or rebuild any faulty mechanical seal.

  • Page 28: Impeller/Diffuser Cover Alignment

    Impeller/Diffuser Cover Alignment The following replacement items will be required as a result of compressor disassembly and diffuser removal: Table 5.2 PART DESCRIPTION ITEM NUMBER QUANTITY Impeller Spacer 158C Series O-Ring Packing 936A O-Ring Packing* 936C O-Ring Packing 936E O-Ring Packing 936F O-Ring Packing 936G...
  • Page 29 0.025”. If the dimension is less than 0.025”, contact Sundyne Compressors in Arvada, Colorado. Place the gearbox upside down on a workbench or gearbox stand so the end of the high speed shaft (A130) protrudes upward.
  • Page 30 NOTE: Steps 5d-5g serve to check that all stacked components are tight and not loose during assembly. There is no way to check these stacked components with the seal housing installed. Since the impeller to shaft fit is not a loose or slip fit, it is possible to assemble the stacked components and achieve the required torque, even though the stacked components could remain loose and free to turn in relation to the shaft.

  • Page 31: Impeller/Diffuser Clearance Calculation

    When the impeller is completely cooled, remove the impeller bolt (3) and the soft metal washer and then reinstall the impeller bolt, without the soft metal washer and torque per Table 8.1. Record the thickness of the impeller spacer (158C) and the impeller shroud to diffuser cover alignment (Dimension “E”...
  • Page 32 Figure 5.1. Compressor Cross-Section and Clearances...
  • Page 33 NOTE: The shim spacers are available in sets of five, including one each of: Table 5.4 0.005 inch (0.13 mm) 0.010 inch (0.25 mm) 0.015 inch (0.38 mm) 0.020 inch (0.51 mm) 0.030 inch (0.76 mm) Step 7 Install the spacers (158A) in compressor case (1). Step 8 Install O-Ring (936C) on the diffuser (13).

  • Page 34: Gearbox Disassembly

    Step 17 Reassemble the compressor installing all the O-Rings into the proper positions. Tighten the compressor case nuts to the proper torque listed in Table 8.1. CAUTION: When PTFE O-Rings are being used, special consideration must be taken to allow for cold flow. Retorquing may be required to obtain proper torque value. 6.
  • Page 35 Step 3 Carefully inspect the seals for abrasive particles, excessive seal face wear and any binding of the carbon seal nose. Replace or rebuild any faulty mechanical seal. Seals may be rebuilt by replacing the carbon seal nose, o-ring, and spring providing the retainer is not damaged or heavily worn.
  • Page 36 Step 6 Rotate gearbox in holding device so that the input shaft (A120) is now pointing up. Make certain that the gearbox is steady and held in place by clamps. Remove nuts (914F) and (914E), remove flat washers (916J) and (916H). Next remove bolts (909C) and (909B), and flat washers (916H) and (916J) making sure that the alignment bolts are removed first.
  • Page 37 Step 8 Remove the input shaft assembly (A120). To accomplish this the mechanic must first lift up the idler shaft assembly (A140) and tilt it away from the input shaft assembly (A120). The mechanic should grasp the input shaft assembly by the top of the shaft and lift straight up and away from the bearing plate (102).
  • Page 38 Step 10 a. Remove the sump tube (173). First loosen the nut on the compression fitting (944C) with a wrench. NOTE: If dry sump design, unit will not have an internal lube pump and sump tube. Step 10 b. Then hand spin the nut free. Pull the sump tube (173) out of the compression fitting (944C).
  • Page 39 Step 11 b. Hand spin the fitting off the 2.0” x 3/4” pipe nipple (944B). Step 12 Remove the 2.0” x 3/4” pipe nipple (944B) using a pipe wrench. Be careful the pipe nipple (944B) screws into the aluminum lube pump housing (A160) and do not force the pipe nipple (944B) or you may strip or pull the threads in lube pump assembly (A160).
  • Page 40 Step 14 Install two 1/4-20 screws into the top of the lube pump assembly (A160). These screws are used to turn the lube pump assembly (A160) around in the bearing plate (102). Note: with the dry sump gearbox, a spacer with O-ring seal is installed instead of the lube pump.
  • Page 41 Step 15 b. Remove the o-ring (936Z) after you can see it through the hole in bearing plate (102). Use a sharp scribe or needle vise and poke the point into the o-ring (936Z) and twist it out of its seat in the lube pump (A160) and through the hole in bearing plate (102).
  • Page 42 Step 18 Remove the bearing plate (102) from the lower gearbox housing (101A). Make certain you use the 5/8” eye bolts to lift It is a good idea to use a hoist with equal length chains and hooks to facilitate an even lift of the bearing plate (102).
  • Page 43 Step 18 a. Remove and inspect the upper high speed journal bearing (151B) and the upper thrust washer (155B) from the bearing plate (102). First remove hex head cap screws (905N) and lock washers (154E). Next pull high speed journal bearing (151B) from bearing plate (102).
  • Page 44 Step 20 Remove the high speed shaft (A130). Step 21 Remove socket head cap screws (905AA) from lower idler journal bearing (151C).
  • Page 45 Step 22 Insert a 1/2” square drive 1.0” socket down into the center of the lower idler journal bearing. This socket is used as a spacer/guide for the jack screw. Make certain the 1/2” square drive hole is pointing toward the thrust face of the lower idler journal bearing (151C).
  • Page 46 Step 23 (continued) Step 24 Remove socket head cap screws (905M) and lock washers (154D) from lower high speed journal bearing (151A). Remove thrust washer (155A) by lifting up and off the lower high speed journal bearing (151A). Inspect the thrust washer for any burns, scratches or rubs.
  • Page 47 Step 26 Remove the oil filter (185) if applicable. Step 27 Remove the 1/4” NPT socket pipe plugs (924GB) and (924G) from the lower gearbox housing (101A) Step 28 Remove o-rings (936TT) and (936T) and (936YA) from the lower gearbox housing (101A) and replace with new items (936TT), (936T), and (936YA).

  • Page 48: Inspection Of Disassembled Hardware

    7. Inspection of Disassembled Hardware Step 1 Remove lube jets, then clean and wash all gearbox housings (101B), (102), and (101A) with solvent and blow dry with clean high pressure air. Step 2 Make certain to flush out all lube passages and blow dry with clean high pressure air. Reinstall lube jets into housings immediately.
  • Page 49 .00002” flatness. Install a seal repair kit for the specified seals in your unit. See your Sundyne Compressor Specification Sheet or Recommended Spare Parts List Bill of Materials for the part numbers.
  • Page 50 Idler Shaft Upper Bearing (400 HP Gearbox Only) Maximum clearance for replacement: 0.0085 inches (.22 mm) Lower Idler Bearing & Shaft Clearances Maximum clearance for replacement: 0.0063 inches (.16 mm) Input Shaft Upper Bearing Input Shaft Lower Bearing...
  • Page 51 Journal Bearing and High-Speed Shaft Clearances Maximum clearance for replacement: 0.0055 inches (.14 mm) Tilting Pad Thrust Bearing and High-Speed Shaft Clearances Maximum clearance for replacement: 0.0055 inches (.14 mm) Tilting Pad Radial and High-Speed Shaft Clearances Maximum clearance for replacement: 0.0055 inches (.14 mm)

  • Page 52: Checking And Setting High Speed Shaft End Play

    8. Checking and Setting High Speed Shaft End Play If a new high speed shaft assembly, lower gearbox housing, upper or lower high speed journal bearings, or thrust washers are installed high speed shaft end play must be measured and reset. NOTE: For accurate checking of shaft end play, all parts must be dry and free of oil.
  • Page 53 Table 8.1 Torque Values Gearbox Sundyne Standard Steel Screws & Bolts and NACE Compliant Steel Screws/Bolts (BG Material) Torque Values Item # Location Size English Metric 905H Oil Filter Manifold 3/8 - 16 x 1/2 22 - 25 ft-lbs 30 - 34 N-m...

  • Page 54: Gearbox And Process End Reassembly

    Gearbox and Process End Reassembly Step 1 Wash all gearbox housings and be certain the lubrication galleys are open. Step 2 Attach the sight glass (191). Step 3 Put pipe plugs in lower gearbox housing (101A). Step 4 Freeze lower idler journal bearing (151C) in dry ice for 1/2 hour and install into lower gearbox housing (101A) with socket head cap screws (905AA).
  • Page 55 Step 16 Install lower input shaft roller bearing race into the top of the bearing plate (102) so it locates against the lube pump (A160). Step 17 Install the sump tube (173) into the sump tube fitting (944C). Step 18 Install input shaft assembly (A120) into lower input shaft roller bearing.
  • Page 56 Step 36 Install rotating face (51C) over high speed shaft (A130). Step 37 Install o-ring (936J) over high speed shaft (A130). Step 38 Install sleeve (50A) over high speed shaft (A130). Step 39 Install o-ring (936J) over high speed shaft (A130 ASSY). Step 40 Install o-ring (936H), lower process seal (60A) into seal housing (30).

  • Page 57: Gearbox Auxiliary Hardware Installation

    Gearbox Auxiliary Hardware Installation (as applicable) Step 1 Thermocouple Wires Install thermocouple wires into the bearing assembly before installing bearings in the lower housing or bearing plate. Refer to job outline drawing for appropriate thermocouple locations. The thermocouples are typically installed in the thrust position of the upper bearing (151B) and in the radial position of the lower bearing (151A).

  • Page 58: Troubleshooting

    The suction pressure is low. Check the Sundyne specification sheets. Recirculation from the discharge to Check the flow through the external piping, the inlet is excessive. such as the bypass...
  • Page 59 Trouble Possible Cause Investigative and Corrective Action Drain oil and remove gearbox oil level sight glass and inspect bottom of sump for wear particles. Bearings are probably not damaged if no wear particles are present. Disassemble compressor end and search for any mechanical failure.
  • Page 60 Compressor Mechanical Seals Table 10.2 provides information on problems with single units, as well as double and tandem seal units. Table 10.2 Troubleshooting for Gearbox and Compressor Trouble Possible Cause Investigative/Corrective Action Leakage around the seal suddenly The system is operating at a low flow Make sure that the compressor always increases rate or a low inlet pressure, causing...

  • Page 61: Operation

    11. Operation Some form of control is required for the majority of SUNDYNE compressor applications. The purpose of control is twofold: 1) to achieve the desired performance as required by process conditions and 2) to protect the compressor from mechanical damage due to surge or overload conditions.

  • Page 62: Spare Parts

    General Assemblies, subassemblies and components of the Sundyne compressor are illustrated on the exploded and cross sectional views in Reference D. Refer to your Sundyne Compressor Specification Sheet for those options applicable to your compressor. The corresponding parts lists, keyed to each part by item number, identify detail parts by part name, quantity and location.
  • Page 63 Repair Kits Seal and O-ring repair kits are not illustrated herein, but may be purchased directly from Sundyne Corporation. Seal repair kits contain all normal wearing parts (springs, washers, o- rings, carbon faces, etc.) of the compressor or gearbox mechanical seals.
  • Page 64 LMC-341F TYPICAL RECOMMENDED SPARES LIST FLUID END ITEMS TYPICAL CLASS LOC NO. OPTION PART NUMBER DESCRIPTION BO03AD07DB3 BOLT, IMPELLER GK01AW01 GASKET, THERMAL JM01AD87DD6800 IMPELLER,COMPRESSOR DS,TS SL01AD16DD SLEEVE, LOWER 50B,50 DS,TS,SS SL01AD02DD SLEEVE, UPPER DS,TS RJ09AD20RE RING, MATING, UPPER SS,TS SE04AD21F SEAL, LOWER DS,TS SE04AD21F...
  • Page 65 LMC-341F TYPICAL RECOMMENDED SPARES LIST GEARBOX ITEMS TYPICAL CLASS LOC NO. OPTION PART NUMBER DESCRIPTION A160 PU04AW02 PUMP, LUBE, REVERSIBLE 20-314 SEAL, ASSY, INPUT 22-141 FILTER, OIL, HILCO 125C 21-108 BEARING, INPUT, UPPER 125D 21-108 BEARING, INPUT, LOWER 151A BT20AD0860B BEARING, HIGH SPEED, LOWER 151B BT20AD0860B...

  • Page 66: Sundyne Compressor Warranty

    13. Sundyne Compressor Warranty Sundyne Compressors warrants to Purchaser for a period of 12 months from the date the line mounted compressor (LMC) is placed in service (not to exceed 18 months after shipment date) that the equipment at the time of shipment is free from defects of material and workmanship.
  • Page 67 This is included in the final data package. Auxiliaries 1. Check the utility connections. 2. Verify that the auxiliary piping conforms to Sundyne’s drawings. 3. Verify the connections of the switches, the instruments, and the set points. 4. Calibrate the flow instruments and the other transmitters.

  • Page 68: Lock-Out/Tag-Out Guidelines

    Process Conditions Do process conditions; suction pressure, suction temperature, discharge header pressure, and mole weight agree with specification sheet information? Check with your Sundyne Corporation representative if you must test a different gas than shown on the specification sheet. Auxiliary Lube Pump If you have an auxiliary lubrication pump, unlock the electrical circuit and start it in the “hand”...

  • Page 69: Single Seal Arrangement

    SINGLE SEAL ARRANGEMENT...

  • Page 70: Double Seal Arrangement

    DOUBLE SEAL ARRANGEMENT...

  • Page 71: Tandem Seal Arrangement

    TANDEM SEAL ARRANGEMENT...

  • Page 72: Phoenix Compressor Drawings

    Reference D Phoenix Compressor/Gearbox Cross-section Drawing Phoenix Gearbox Module Drawing – GB01AY01...
  • Page 73 Phoenix Compressor / Gearbox Cross-Sectional View...
  • Page 75 PHOENIX GEARBOX MODULE DRAWING – GB01AY01...
  • Page 82 Sundyne Europe • Dijon (Longvic) France • +33 (0) 3.80.38.33.00 • FAX: +33 (0) 3.80.38.33.66 Sundyne Nikkiso • 27-10, Ebisu 2-Chome, Shibuya-Ku • Tokyo 150-0013, Japan • +81-3-3444-6475 • FAX: +81-3-3444-6806 • ANSIMAG • CASTER • GSP • HMD/KONTRO • MASO/SINE • COMPRESSORS • SUNDYNE • SUNFLO •...

Table of Contents

Save PDF