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Table of Contents
Summary of Contents for Rotary Compression Technologies LeROI HG10
- Page 1 LeROI Gas Compressors By Rotary Compression Technologies, Inc. ISO 9001-2000 Installation – Operations Maintenance and Service Guide Rotary Screw Compressor Models: HG10 HGF10 HG12 HGF12 HGS17 HGSF17 HG17 HG24 LG30 LGL30 RCT-INST001 Rev 6 -8/08 ECN 48316...
- Page 2 ROTARY COMPRESSION TECHNOLOGIES , INC . THANKS YOU FOR PURCHASING LEROI GAS COMPRESSORS , MODULES AND PARTS...
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Page 3: Table Of Contents
T able of Contents Safety Information and Warnings________ _________________1 Protecting Your Compressor Before Service_________________2 Identifying Your Compressor_____________________________3 Understanding Your Compressor_________________________4 The Compressor System______________________________5-6 Oil Flow and Orifice Sizing____________________________7-10 Variable Vi Adjustment______________________________11-13 Versatrol (Capacity Control)__________________________14-15 Oil and Related Items_________________________________16 Installation________________________________________17-18 Installation – Component Location________________________19 Operation and Preventive Maintenance____________________20 Service Procedures - Components_____________________21-29 Rebuild Kits_________________________________________30... -
Page 4: Safety Information And Warnings
Safety Information and Warnings LeROI gas compressors are designed with safety in mind. However, there is no substitute for safe operating procedures. Throughout this manual, there will be additional “Notes”, “Cautions” and “Warnings” intended to protect the operator and the equipment. These additions are not all inclusive. -
Page 5: Protecting Your Compressor Before Service
Protecting Your Compressor Before Service THIS COMPRESSOR IS SHIPPED WITHOUT OIL. ALTHOUGH RESIDUAL OIL FROM THE FACTORY TEST IS SUFFICIENT TO PREVENT RUST DURING SHIPPING, IT DOES NOT PROVIDE ADEQUATE PROTECTION FOR STORAGE. IF THE COMPRESSOR WILL NOT ENTER SERVICE WITHIN ONE WEEK OF BEING RECEIVED, COMPRESSOR OIL MUST BE ADDED THROUGH THE GAS INLET SO THAT ITS LEVEL IS AT LEAST AS HIGH AS THE BOTTOM OF THE INLET CAVITY. -
Page 6: Identifying Your Compressor
Identifying Your Compressor LeROI gas compressors have a nameplate that provides valuable information on your compressor. This information is needed for ordering parts and conversion kits, as well as for accessing warranty information and understanding the design of the compressor. Below is a Model Designation chart to help you identify your compressor. -
Page 7: Understanding Your Compressor
Understanding Your Compressor Your compressor is either a LG (Low Pressure) or HG (High Pressure) single stage, positive displacement, oil-flooded screw compressor. There are two basic general configurations; geared (Figure 1) and non-geared (Figure 2). Figure 1 - geared compressor Figure 2 -Typical non-geared compressor Oil-flooding provides cooling, lubrication and sealing in the compressor. -
Page 8: The Compressor System
The Compressor System The LeROI gas compressor is one part of the compressor system. The compressor combined with the driver forms the heart of the system. However, the other vital elements are essential to ensure the heart of your system continues to operate. Suction Scrubber (with filtration, if necessary) This is required to prevent the carry over of liquids into the compressor. - Page 9 The Compressor System (Continued) Oil Filter It is extremely important that the oil injected into the compressor be as clean as possible. The oil filter should be generously sized to handle full oil flow, and should have a filter element that will remove particles down to 10 micron. If the compressor is in an application where continuous operation is important or where the filter will get dirty in a short period of time, it is recommended that a dual filter arrangement be used.
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Page 10: Oil Flow And Orifice Sizing
Oil Flow and Orifice Sizing As mentioned previously in this manual, rotary screw compressors require oil lubrication of the bearings, cylinder and rotors. Bearing lubrication is necessary for long life. Cylinder and rotor lubrication does three things: 1. Reduces friction between the rotors 2. - Page 11 Oil Flow and Orifice Sizing Pumps are installed at the factory based on packager instructions or specified operating conditions. Every LeROI compressor is tested at the factory to ensure reliable operation. After testing, the standard orifice or an orifice specified by the customer is installed in the unit.
- Page 12 Temperature/Viscosity/Pressure (Continued) For Most Situations: Temperature rise - From oil injection to gas discharge: 30 – 40 For heavy gas streams, a 30-40 °F temperature difference may not be possible Temperature rise – From oil injection to discharge bearing oil drain: 15 WARNING! NEVER EXCEED 20 F BEARING RISE Oil pressure difference –...
- Page 13 Field Evaluation of Pump & Oil Injection Orifice Size Temperature measurements at points A, B, and C should Equipment & Measurement Location be made on sections of pipe or tube (not fittings) as close to the compressor as possible. Although other permanent instrumentation is necessary for monitoring overall package Pressures at points D and E should be as close to the performance, the following are specifically for the...
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Page 14: Variable Vi Adjustment
Variable VI Adjustment Variable Vi is used to minimize the power required by the compressor. It does not change flow directly, but can allow an increase in flow through more efficient use of power. Vi is the volume compression ratio of a compressor: V1 / V2. The internal Vi of the compressor is determined by the size of the discharge port. - Page 15 and P must be in PSIA, and be at the compressor inlet and discharge flanges. Be sure to account for package pressure drops, which decrease the inlet pressure and increase the discharge pressure at the compressor flanges. As a quick reference, for a typical natural gas with k = 1.26, the pressure ratios that correspond to available internal Vi’s are: P2 / P1 Since there are three available internal Vi settings, each must cover a range of ideal application...
- Page 16 Figure 10: For MEDIUM Vi, turn the inner valves counterclockwise until they are fully out. DO NOT FORCE THE VALVES. Once they “touch” the end of their stroke reverse them by 1/16 of a turn. This also applies when closing valves. Figure 11: For LOW Vi, in addition to turning the valves for MEDIUM, turn the...
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Page 17: Versatrol Capacity Control
Versatrol Capacity Control Versatrol capacity control is used to regulate compressor flow and reduce power requirements. Versatrol consists of a set of pressure actuated valve assemblies mounted on the side of the compressor. When opened, these valves allow gas to leave the compression cycle and return to the compressor inlet prior to compression and delivery, thus reducing flow and horsepower. - Page 18 Versatrol Capacity Control Continued Actuation: The Versatrol valves can be operated with pressurized air, gas or lubricating fluid depending on whether it is step or stepless control. The actuation pressure should be the same or nearly the same as the compressor discharge pressure. The valves should be opened in the 1-2-3-4 sequence and closed in the 4-3-2-1 sequence, except the HG12.
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Page 19: Oil And Related Items
Oil and Related Items The lubrication system is vital for reliable operation of LeROI gas compressors. Following these guidelines about oil and related items will ensure years of reliable service. Start-Up: Prior to start-up the compressor should be pre-lubed. Oil Filter: Check after first 100 hours. -
Page 20: Installation
Installation The compressor and prime mover must be mounted on a rigid frame so that the drive, piping, etc. are not subject to strain and/or misalignment. Mounting holes are provided to securely attach the compressor. The mounting surface must be a smooth, level surface that will support the weight of the compressor and handle the associated vibration. - Page 21 Installation (Continued) Drive: Several types of drive couplings may be used. However, direct flexible and universal joint types are recommended. When using a direct flexible coupling follow the coupling manufacturer’s instructions. As a general rule, for this type of coupling, the alignment should be as near “in line” as possible.
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Page 22: Installation - Component Location
Installation - Component Location The components (Figure 17) of a gas compressor system should be mounted on the frame to make servicing the unit as convenient as possible. Oil piping and hoses should be located and fastened to prevent accidental damage. All moving parts (coupling, belts, fans, etc) must have guards or shields installed. -
Page 23: Operation And Preventive Maintenance
Operation and Preventive Maintenance Satisfactory performance of a stationary screw compressor requires a good preventive maintenance program. The following information is provided as a guide for such a program. Start Up: Service all equipment (filters, moisture separators, prime mover, etc.) following the equipment manufacturer’s instructions. -
Page 24: Service Procedures - Components
Service Procedures - Components BEFORE REMOVING ANY COMPONENTS SHUT THE UNIT DOWN, CLOSE ALL INLET AND DISCHARGE SHUTOFF VALVES, RELIEVE ALL PRESSURE BY “PUMPING OUT”. MAKE CERTAIN THE PRESSURE SYSTEM REMAINS VENTED TO ATMOSPHERE. DISABLE, LOCKOUT AND TAG THE PRIME MOVER. Compressor Service: The compressor for these units is serviced only as a complete assembly using a new or factory rebuilt compressor. - Page 25 SOME FITTINGS OR OIL PASSAGES MAY HAVE A RESTRICTING ORIFICE. IF ONE IS PRESENT, INSURE ORIFICE IS REINSTALLED. Remove the seal retainer and seal assembly as described in the maintenance manual for the unit being serviced. Discard the old seal parts. (Figure 1) Clean the seal retainer and seal cavity in the bearing retainer thoroughly.
- Page 26 On the shaft area, where the seal is to be located, polish the shaft using a number 100 grit silicon carbide emery cloth (P/N 204-2385). Wrap a strip of emery cloth around the shaft. Grasp the emery cloth and use a rotary motion to polish the shaft.
- Page 27 CAUTION TO MAKE CERTAIN THAT THE FLEXIBLE SECTION OF THE SEAL ADHERES TO THE SHAFT IN THE CORRECT LOCATION, IT IS NECESSARY TO COMPLETE THE ASSEMBLY ONCE STARTED. Lubricate the carbon ring section of the seal assembly with clean compressor oil. CAUTION DO NOT USE OTHER TYPES OF OIL OR GREASE.
- Page 28 Service Procedure Components Figure 21-Compressor Input Shaft Seal Figure 22- Minimum Pressure Check Valve (Small) Minimum Pressure/ Check Valve Service The minimum pressure valve may be purchased as an assembly if required. Service parts are available, however, to repair/overhaul this valve. This valve may be serviced as follows: Make certain the unit cannot be started and that all the pressure has been removed from the system.
- Page 29 Service Procedure-Components Remove the spring from the body. Save spring shim(s) (washers) (if any) for reuse. Insert a suitable tool (wood stick) into the inlet port of the valve and push the piston and the valve assembly upward and out of the body. Remove the check valve piston from inside the larger piston.
- Page 30 Service Procedure-Components (Continued) Changing Minimum Pressure Valve Spring This section contains the instructions to replace a high-pressure spring in a minimum pressure valve with a low-pressure spring. High Pressure Cover Spring Body Low Pressure Spring Piston Spacer Stack Figure 24 - MPV Parts. Figure 25 –...
- Page 31 Service Procedure-Components (Continued) Changing Minimum Pressure Valve - Continued Figure 28 – Ten Spacers Installed in Piston. Figure 29 – Installation of Spring Part No. 24-810. Either end may be installed down. Figure 30 – Installation of Cover. Keep cover fairly level during installation, tightening bolt on either side a little at a time so cover does not tilt.
- Page 32 Service Procedure-Components (Continued) Oil Separator Service An oil separator may be removed as follows: 1. Make certain the unit cannot be started and that all pressure has been removed from the system. 2. Disconnect the piping from the minimum pressure valve. 3.
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Page 33: Rebuild Kits
Rebuild Kits Please refer to the engineering print below to order a rebuild kit for your unit. (Check the Website for latest revision.) -
Page 34: Website
Website LeROI-RCT has a website that contains useful tips, features, sizing information, and technical data. We encourage using and exploring the website to learn what tools are available to you. Visit us at www.leroigas.com... -
Page 35: Contact List
Contact List Below is a list of contacts in case you need any assistance. In order to provide you with the latest information this list is also available on the website: www.leroigas.com Compressor Sales / Pricing / Applications / Specifications / Compressor Sizing Maro Johnson Phone: 281-693-1950... - Page 36 CANADA Compressor Sales / Pricing/ Applications/ Specifications / Compressor Sizing Phone: 403-808-8377 Fax: 403-945-1910 Email: sales@leroigas.ca...
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Page 37: Service Diagnosis
Service Diagnosis MALFUNCTION PROBABLE CAUSE REMEDY High Discharge Insufficient or incorrect oil. Fill, or drain and re-fill oil reservoir to correct Temperature level with correct oil. Operating above rated pressure or at Operate at correct pressures. excessive ratio. Excessive inlet temperature. Lower inlet temperature. -
Page 38: Warranty
ROTARY COMPRESSION TECHNOLOGIES, INC d.b.a. LEROI GAS COMPRESSORS WARRANTY FOR ROTARY SCREW GAS ENDS USED IN NON-CONSUMER APPLICATIONS O.E.M. & GAS Manufactured LeROI-RCT warrants its rotary screw compressor products and parts to be in compliance with their respective specifications and free from defects in materials and workmanship during a warranty period ending the earlier of (i) 12 months after the product start up date, or (ii) 18 months after the original date of shipment of the product by LeROI-RCT. - Page 39 THIS PAGE INTENTIONALLY BLANK...
- Page 40 It Pays to Use Genuine LeROI Parts Provided by Rotary Compression Technologies, Inc Rotary Compression Technologies 211 East Russell Road Sidney, Ohio 45365 Phone: 937-498-2550 Fax: 937-492-3424 sales@leroigas.com www.leroigas.com...
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