$ffiMVEGH

MANUAL
GAS & REFRIGERATION COMPRESSOR

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COI.IPRESSOR SERYICE HAHUAL

INDEX TO SECTIOH

Page Ho.

Section Section

Foretrord

Description

2.1 Compressor 2.2 Compression Cycle 2.3 Gas System ?.4 0il System 2.5 0ils
Section
3

4q ,t4 r5
6

Instal I ation

I
$

Section

3.1 Ai ignment of Compressor Coupl ings 3.2 Alignment Tolerance 3.3 Dowe11 ing 3.4 Piping 3.5 External Arrangement Draw'ings First Start Up 4.1 First Start 4.2 Use of Compressor as a vacuum pump
Hormal 0peration

I
o
B

,10 ,11

L?

12,13

Section

5.1 5.2
Section
6

Normal Start Normal Stop

Dmrn

14
T4

Precautions During Shut

6.1 Procedure on Shut Down 6.2 Inhibiting 0i1s

Section
7

15 15

i{ai ntenance

$ Section
B

.l .Z 7.3 7 .4 7.5
7

General Comments Preparation for Annual Inspection Djsmantl ing Procedure for Annual Inspection Check i ng C1 earances Re-Assembly after Annual Inspection

16

i6
16 L7
1B

0verhaul

8.1 B.? 8.3 8.4

Section
9 9
9

General

Dismantl ing Compressor for l'lajor 0verhauls Re-Assembly Compressor after 0verhaul Compressor General Arrangements

Comments

19

19,20 20,21 ?2,?3

Special Instructions

.1 .2 9.3 9.4
Spares

Torque Spec i fi cati ons P rocedure f or F i tt'i ng Lockrvashers Special Tool Li st Component l,Jei ghts

Lq 25

26

c^^+:^JtJl.-LIUII

ln IU

10.1

Compressor Recommended Spares Li st

L/

Page

-0
COMPRESSOR

COMPRESSOR SERVICE MANUAL

SECTION

1-

FOREWORD
YOUR

READ CAREFULLY BEFOtrE INSTALLING AND STARTING

These instructions have been prepared to ensure that your compresSor gives lorrg and satisfactory service. The entire manual should be read before reverlrng to any one section for specilrc inf ormation One copy should be given to the personnel responsible for installing and operating the compressor.

a
+

ts

All requests for information. services or spares should be directed

to:-

HOWDEN CCM PRESSORS LIM ITED SERVICE DEPARTMENT, 133 BARFILLAN DRIVE, G LASGOW G52 1 BE

Telephone Number. 041 -BBZ 3346 ROCOMP Telex Number'.778711

Ail enquiries should be accompanied by the Howden Contract Number and the Compressor Serial Number, taken from the nameplate on the side of the compressor body.
B

Page

SECTION

2-

DESCRIPTION

?.1
a

cot-tPREss0Rs

The Howden

0il injected Screw Compressor is a positive disp'lacement, capacity conirolled, oil flooded rotary machine.
Compression is achieved by the meshing shafts housed in a casing.

of

two

hel'ical rotors on para'I1e1

The accurately mach'ined helical rotors are called Male and Female. The male (driving) rotor has four lobes which mesh with six flutes in the female (driven) rotor, both rotors having the same outside djameter. Each rotoris supported by two plain white metal thjck walled journal bearings fitted adjacent to the compression chamber.

As the lubricating or'l is at discharge pressure plus 30 the bearinEs act as shaft seals within the compressor.

p.s.i Q xg/cnZ)

-$

Rotor end thrust is accomodated by a balance piston on the male rotor and tilting pad thrust bearings on both male and female rotors.One side of the bal ance pi ston 'is subject to o'i'l pressure (gas outl et pressure pl us 30 p.s.i), the other side is at suction pressure and therefore the balance piston opposes the normal rotor end thrust and assists the thrust bearing loading on the male rotor. The male rotor has lobes of approximate'ly circular arc sections formed helically along the rotor length and these mesh with corresponding flutes on the female rotor. When the interlobe space aiong the rotor iength is fi11ed, the rotation of the rotors moves the end of the I obes past the 'i nl et port, so seal 'i ng the i nterl obe space. As the rotors continue to rotate the intermeshing of the lobes on the discharge side of the compressor progressively reduces the space occupied by the gas causing compress'ion. Compression continues until the interlobe becomes exposed to the outlet port in the casing and gas is discharged.
See Secti on 2.?
-

Capac'ity controi is achieved by means of a slide valve in the casing operated by a piston in a hydraulic cyf inder mounted on the compressor.
The Piston
B

actuated by lubricating oi1, fed from the compressor lubricating oi1 manifold, to one or other side of the ptston, moving the slide valve and altering the point jn the rotor length at which compression begins. Th'is allows internal gas recirculation, thus controlf ing the capacity from 100% down to 10% with approximately proportjonate saving in
p

is

owe

r.

Various methods of hydraulic cy1 inder control are available and the appropriate literature provided by the compressor set supplier, should studied before carry'ing out any work on this equipment.

be

2.2
I obes

COI{PRESSIOH CYCLE

Fig 1. Gas js drawn in to fill the interlobe space between adiacent

Fig 2. As the rotors rotate the interlobe space moves Past the inlet port so sealing the
j n ter'l obe space.

.^
B

Page

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SECTION

Z-

DESCRIPTIOI{

_t&

Fig 3. Continued rotation progressively reduces the space occupied by the gas causing
compression

Fig 4.

space becomes exposed to the outlet port the gas is di scharqed

l.{hen

the interl

obe

2.3

DESCRIPTION OF GAS SYSTEI'{ FOR REFRIGERATI0?{ C0MPRESS0R SET(Fig 5)

A
.

STAI{DARD

I
&

Gas

is drawn into the compressor throuqh a non-return valve and then a strainer fitted directly on the inlet flange and discharged into an oil tank/separator. The non-return valve is necessary to prevent the compressor be'i ng 'motoreC' 'in the reverse d'i rect'ion when i t 'is stopped wi th h'igh gas pressure at the outl et. If necessary a second non-return val ve is positioned at the outlet of the tank to prevent the entry of gas or 1 i quid refri gerant.
Primary separation of the oil mjxed with the gas is achieved in the tank, secondary separation takes place in a wi re mesh el ement separator positioned close to the tank outlet

In some separator designs the wire mesh is repl aced by a separator cartridge.
The separated

&

oil drains'into the oil tank. A further secondary separator vessel may also be fitted where a very high separation efficiency i s requi red. The oil separated i s usual 1y dra ined into the compressor through a small bore pipe which can be fitted with a protective filter and an i sol ati ng va1 ve. 2.4
DESCRIPTIOH OF OIL SYSTEI'{ FOR A STAHDARD REFRIGERATI0N C0MPRESS0R SET (Fig 5)

0i1 at outlet pressure is

drawn from the tank by the oi1 pump, passed through a cooler and micronic filters to the manifold where it is fed to the bearings, balance piston, shaft seal, compression chamber and hydraul actuator.

IC

1.{hen

liquid refrigerant iniection is used there is no oil cooler. A differential pressure relief valve in the system before the filters, majntains a manifold pressure in the range of 30 p.s.i (2 Xg7crTl1. !{hen the compressor operates on a continous duty, duplex micronic filters may be fitted, allowing one f ilter e1ement to be changed while the other is in
n^^-:+i^vPcr qLruil-

Approved I ubrj cati ng oi I s

Section

2'u

for refri

gerati on compressors are I i sted under

oage
4

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2.5
Fis

BECOMMENDED LUBRICATING OILS. Details of recommended oils are given in (Fig.6) and (Fig. 7). dependanl on application APPROVED LUBRICANTS - REFRIGERATION COMPRESSORS

AMMONIA AND R22

vrsco
srTY ROWO( )o

PE

CtFrC
Y

PcrFrc HEAT
(1

POUR POINT

rLASH
POINT

cLos o
FLASH
PO

MATiUIAC IURER

| {7E
rso
GRADE' ri
E

CENTISTOKES

No.l

GRAVIT

5"Cl
o

IIJT

40"c
67

100"c t.3
7.3

ro00c
310
Jr5

200"

l 5"Cl

(caUKg

RC

OL

B.P

IPT 68
CLAVUS 68 CAPELI.A

68

48.5
4

o.901

o.437
o.4 39

34

-42
24

183

HLI
XACO/C

68

68

8.5

o.895 o.902

-30

111

rE

A LT

wF68
Z

68
E

6?

6.3
7.4

285
300

0.440
o.4 39

-60
34

204

ERIC

ES

SO

68 ARCTIC

68

65

8.6
45

o.89s o.895 0.9?0

207

MOBIL

300
ICEMATIC

63
56

250

o.438 o 433 0.450 o 438

o 430

-34 -36

-44

r90
183

CASTROL

299
uNls{-) 4GS
s

5.9 5.8

245
268 300
4

-54
48

SUN

59

3.8

o.925

-40
33

168

CULF

ESKTTO 6B 6ALF

68 6g

5.5 68

.18 5

a9B

212

cH EVRON

6.7

305

o c31

-48

200

ll 2) 3)

The vrscosriy ol lhese olls,s between ISO 46 g'trCe and ISO 6B qrarle Kcal,'tg'C.1 Bru/lb"F.1 I9K,/trg"C The exisleoce ol lhis l;st does not erclude the use ol olher o,ls. bul arO.oval lo( o,ls not included above musl
1

'

be oblained [.om

Howden Compressors Lld . before use

Fig 7

APPROVED LUBRICANTS - REFRIGERATION COMPRESSORS R12 PROPANE AND PROPYLENE (\/here discharge pressure exceeds 1OO psia - (7.O31 Kg/cm^) See Note 1 Belor^r
VISCOSiTY
s
P

ECTFTC

PCIFIC
H

POUR
POIN T

closEo
FLASH POINT

MANUFACTURER

TYPE

CENIISTOKES

REDWOOO NO.1

GRAVITY

EAT

rso

(15.C1 40. c
144

$
B
ENRCOL

RAD

lo0'c
21

oo'c
630 650

200"F
126

{1

50CI

Kcal/(g'C
o.44

oc
235
259

BP
SilELL

GCS
C ORE

508

150

l 060
1.060 054

39

NA

I
SYMLUsE sA 1 40

150

148

r26
155
i o.1

o44
o.4 6

40

IEXACO
ESSO

180 150 158

7AO

30

2e0 240

rG
22

150

690 695 670 610

1.0a9
1.012

o.+4

33

GLYCOYLE r,10BlL

r50
150 150

161

?2

106

048
0.44

29

ALPHA

CASIROL
CULT

sN6
TS

150

23 26

104

1 008 1 067

40 ?2

255 230

695

rr, r6s
il 2) J) at A 5l (g/cm') amneral o,l {forn F,g6mayLeuse'J lOOFSIA{7Oll m,rec *,1h no.mal m,riefal o,1s ln meTi,slaGe planl5 !11 slaget musl lhe'elore 6or be must polyqtycol llu,ds aod ihese tubrlcanl, afe u5e a CoiYgltcol liurd NH) V,sccs,ty o{ und,luted lubrrcanl !; e on rn,riat s1a.ti is 5i9^,l,cantly h,ghe, lhao lha! ol .acommeoded m ner.l orlt lo' R22 and neaalsJ,i *he^ des,g.,ng lrrb:rc;rrcn syster-s a g oil tur.p molor, , lier otessute dloi ..,.tia--.lece la. !h,s rrcrg3rec v!9ac't\,r: !r'releds.hareep,eseere,slesrthan 't 1 .,: ,.1,'a- - ] rJ lL'a .. ,i l! I:,::"4 ISO 150 gr3'Je 3'd ISO 22O g'ade ' Ihe v,scos,tv ol lh,5 orl rs bel*e4n

Page

-te
COMPRESSOR SERVICE MANUAL

SECTION 3
3.1

INSTALLATION

*e
.$'A

coupling. Commence alignment by setting the faces of the coupling halves parallel in the vertical plane. The units will nov; be parallel in the horizontal ptane a"no further adjustment to obtain the correct centre heights, will require equal si-rinrrning under each foot of tie unit being adlusted. The units are now positioned vertically and horizontally. Further adjustment to obtain the correct coupting gap, radial and facial alignment, will only require movement of one unit on the existing shim slze. Coupling gap dimensions should be set with the couplings held in a repeatable position, i.e hard together or hard apart. This ensures that each coupli"ng half is removed to the same axial position as each check is made. The actual coupling gap should be correct when the shafts are in their normal running condition lf the combined float of the driving and driven shaft exceeds the coupling gap tolerance, the value and direction of float to? Ootn shafts will be shown on the General Arrangement Drawing When setting the gap the axial f Ioat of each shaft shoutd be determined and the,.hard toEether,, or "hard apart" dimension calculated

Section 3.2. lf a compressor set is supplied, the coupling alignment tolerances and any special instructions regarding allowances for expansion or movement during running will be sio*n on the General Arrangement Drawing and must be adhered to. During aliinment checks both half couplings should be rotaied together from 0o to 900, lg0o, 27oo aad 3600 and readings of radial and facial alignment recorded. Turning both half couplings together ensures that readings are recorded at the same point on each hJlf coupling, thus eliminating the effect of any irregularities on the outside diameters. or faces of the half

The couplings supplied vrith this compressor must be aligned using the method described below as follows:lf a compressor only is supplied the coupling alignments tolerance ligures can be seen under

ALIGNMENT OF COMPRESSOR COUPLINGS

Example:-

Compressor directly driven by a turbine Compressor Shaft Ftoat 0.002" (0.05mm) Turbine Shaft Float 0.010" (0.250mm)

e q

Normal running posrtion of compressor shaf i is towards the turbine and the turbine normally runs thrusting tovrards the compressor.
Bequired Gap 0.125" (3.175mm)

0 137" (3.475mm).

if the gap is checked with the couplings "hard apart" it should be 0.i25,,(3.175mm) + 0.010 (0.250mm) for Turbine shaft Float and + 0.002'; (0.05mm) for Compressor Shaft Float i e.

lf the gap is checked rvith the couplings "hard together" it should be 0.125"'(3.175mm).
NOTE:

lf a "limited f Ioat" coupling is used w'ith an electric motor whose shaft has no thrust bearing the gap must be correct rvith the rnotor shaft on its magnetic centre ln this instance the faclal alignment check should be mace rotating the,ii-lverihaif coupiing oniy, as ihe orive (motor) hrlf e clrplin3 i: ncl lccatecj :xialiy oi pi-ufcri.Li';, Ly a "cioublc cioox'nretirocj which avorc.Js tire problem of repeated axial position"

rl
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t I

3.2
Flg
8

ALIGNMENTTOLERANCE

The maximum acceptable lrne-up tolerance for couplings on compressor installations is as follows:_
Radial Tolerance

Eccentncity = !/. T l.R. on circumference

RADIAL TOLERANCE

----'
FACE TOLER

A)
B)

Applicaticn Motor to Gearbox or Compressor, i.e. couplings operating up to 3,6O0 r.p m. Gearbox to Compressor, i.e. couplings operating above 3,600 r.p.m.

Radial Toierance 0.15 mm (0.00,6")T l

R

Face Tolerance
A)

T.l.R. 0.005 mm/cm dia. of coupling.

T.l.R. 0.0005"/inch dia. of coupling.

B)

0.10 mm (0.0O4")T.t

B)

I
s

T.l.R. denotes Total lndicator Reading oblained by clockgauqe.

3.3 DOV/ELLING Only one unit of any assembly vrill be dowelled before despatch. Dowels should be fitted to ease re-alignment when components are removed for overhaul.
3.4 PIPING

Before installing the piping, the compressor inlet and outlet ports should be inspected to nsure no did is present. AII plping should be supported so lhai no strain is transmitted to the compressor casings. The piping should be inspected for cleanliness before installation. As each pipe is connected to the cornpressor, the coupling alignment should be checked to ensure that no alteration has taken place. lf alignment has altered, the compressor is being strained and the piping supports must be
e

dju sted.

sirainer lternianrntlr,, f lttcC direcil.,,cr-- iitc ccirpre ssoi- iriiei.

It is not sufficient merely to re-align the drive unit as this will not correct the strain being imposed on the compressor. oii injected i'efrigeration compi'essors inusi have a suction

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COI'IPRESSOR
I

SERYICE

I{AHUAL
UP

SECTIOH

4-

FIRST START

-fI

,6

4.1

FIRST START

Installation of the compressor w'ill have been carried out in accordance with Section 3 of this manual however the commissioning engineer should ascertajn that the correct procedures have been fol'tow6O, in particular the cgupling ai ignment must be checked, then proceed as fol lows:-' 1) Disconnect the coupling between the dri've anC the compressor and check that the direction of rotation is correct to drive thf compressor in a clockwise direction looking on to the compressor input snait. 2) Fill the oil tank with lubiicating oil of the correct grade to the required level as indicated on the tank level sight 91iss. 3) Ensure that the manifold and oil pipes to the compressor are clean then start the lubricating oi1 pump motor to circulate the ojl and clean the
lubricating oi1 pressure differential relief valve should be set to give a 30 p.s.i Q Kg/cnz) oil manifold differential pressure at . correct operating temperature, with clean oil filter elements fitted. 5) Check the operation of the safety trips by running the drive unit disconnected from the compressor and mechanicaliy operating the trips, check that the actual settings are in accordance with the contract specification. The lubrica!ing oil differential pressure trip can be set at 12 p.s.i (0.85 Kg/cn?) 5y partiatiy-ctosing rhe oit fitter outlet isolation valve and thereby reducinq the differential oi'l pressure. As the filters become dirty the differential ojl pressure yjll drop to these figures which are the minimum accepted vaiue. 6) Check that the compreisor turns freely and reconnect the coupling between the drive unit and the compressor. 7) Check that the cooling water is turned on to the lubricating oi1 coo'ler, r'f f i tted. B) check that ali gas inlet and ouilet isolating valves are open. 9) Start the Iubricating oii pump motor. N0TE: The conipressor should be unrcaded prior to start up. If the compressor is started without first being unloaded a higher starting .l 'l
The

4)

system.

c
e

i0) Start the drive unit and check that al1 gauges are indicating correctly. 11) Run the compressor for 30 minutes at minimum gas flows and check that all readings are normal, then operate the capacity contro'l valve to the required positjon, this position will be indicated on the dial mounted on the hydraulic cylinder. if possible check the slide valve control over the full ranqe of capacity. 4.2 USING THE COI"IPRESSOR AS A YACUUII AIR PU}IP IH A REFRIGERATION SYSTEFI
vacuurTl pump is available to evacuate the plant prior to charging with Jf n9 rigerant, the compressor may be used for th.i_s purpose. Close an isolating valve downstream of the compressor ojl tank and arranse a vent at the hiqhest point available, situated between the oj'l tank and
Ref

torque

wi

be requi red.

i sol

ati ng

va1

ve.

l.It'th the suctjon isolating valve open, start the compress0r, air will be drawn from the plant and djscharged through the vent thus evacuating the p1ant. Under these condit'ions some oil vapour carry over may be seen in the discharged a'ir. Initialiy the compressor discharge presiure wili be f ai r'ly hl gh but thi s wi I I drop as the pl ant i s evacuated.

Page l2

i0

COI'IPRESSOR SERYICE I.IAHUAL

SECTION

4-

FIRST START UP

the plant is evacuated close the suction valve and stop the compressor is closed. The vent valve .un no*-ue-cioseo. The plant is now evacuated but the compressor jtself contains air at atmospheric pressure. This can be removed as follows:When

inrnediately the valve

valve a small amount allowing Refrigeiant into the .o*p..rro. ,ut displac_ing the remaining air. When-Refrigerant starts to pass through the vent, close the vent line valve. The comfressor set'is now charged with Refrigerant with the minimum quantity of irapped air.
HOTE

0pen the val ve on the vent 'l i ne which a j r was di scharged. Af ter -through the plant has been charged with Refrigerant open the suction isolat.ing

0 6

If a suction

this switch to allow the

low pressure

trjp is fitted it may be necessary to disconnect compressor suction pressure to fal I .

e
6

&

Page 13

\l

t
t

-re

COMPRESSOR SERVICE MANUAL SECTION 5 NORMAL OPERATION

5.1

1) 2) 3) 4) 5)

NORIITAL START

Check the level of the oil in the tank. check that ari necessary gas, oir and water varves are open. Start the lubricating oil pump motor. Ensure the capacity contror varve is in the fuily unroaded position. Start the drive unit and check that all gauges ire indicating normal readings.

5.2

1) Stop the drive unit. 2) After the compressor stops, the control system should be operated to move the slide valve into the off load position unless the control system does this automatically. 3) After the compressor stops rotating, stop the lubriiating oir pump motoi. Close gas all and water isolating valves. !) The compressor is then
ready for start up sequence.

NORMAL STOP

I
;-6

NOTE

A log should be kept of the instrument readings so that deviations from correct conditions can be readily observecJ by the *nglnee, in charge ot the installation. running

_s

Page

14

ii
6.1

COIIPRESSOR SERVICE I,IAI{UAL SECTION

6 _ PRECAUTIONS DURIXG SHUTDOI.{N

PROCEDURES ON SHUT DOI{I{

The Howden

0il Iniected Screw Compressor cperates on an oil/gas mixture and periods short of shut down will not adversely affect the compressor. if the compressor is shut down for an extended period the lubricating oi1 pump shoul d be operated for approximately ten mi nutes week'ly, to di strr'bute oi I throughout the set.
1f the shut down period is three months or more the above procedure can be repeated at weekly intervals, but the compressor set should also run for
one hour each three months,

drained

a'lternatively the normal lubricating oil can be replaced with inhibiting oi1, and the set run for one hour. If the compressor has been run on inhibiting oi1 thjs should be repeated at three month'ly intervals during the shut down period. Approved oils are shown in Section 6.2.

off,

0
6

HOTE

1) Before putting the compressor set into normal operation, the inhibiting oil must be removed and the system filled wjth normal oil. ?) During shut down period'in cold conditions any water cooled items of
plant should be drained, or the cooling water flow majntained to
prevent damage due to freezing.
6

.2

IHHIBITI}IG OiLS

APPROYED FOR USE h{iTH HOHDEH SCREH COI,{PRESSORS

The

Howden Screw Compressor

following is a list of approved inhib'iting oils suitable for use on the pricr to a lengthly period of shut down.
10

lL 1175 ttobil - Armo 524

Esso

Shell Ensis

Caltex Preservation

0il

10H

e q

&

COI'IPRESSOR

SERYICE

I{ANUAL

SECTIOH

7-

I,{AI}TTENANCE

7.1

GE}IERAL COI'I'IE}ITS

The component parts of this compressor are large and heavy and considerable dif f icul ty w'i11 be encountered 'if maintenance/overhaul is attempted w'ithout

the use of a manipulator

frame

The compressor is designed to give long periods of trouble-free operation with the minimum of maintenance, however, an annual inspect'ion js reconmended to check if there is any significant wear on thrust bearings, slide valve guide block or PTFE seals. Should wear be found these components must be rePi aced.

Refer to the sectional arrangement drawings supplied. All fasteners should be torqued to the specified value as stated in Sect'ion 9.1 using appropriate torque wrenches. All lockwashers, tabwashers, 0 R'ings and PTFE seals must be renewed on assemblY.
I

Sectjon 9.2 describes I ockwasher assembly procedure. Special tool s to faci I'i tate di smantl i ng and assembly can be provi ded. These are I i sted under Section 9.3. Detai.l s can be provided on request. Sectjon 10 detajls part numbers

of

normal'ly replaceable components.

7.2
taken.

PREPARATION FOR AHNUAL INSPECTIOH

Before doing any work on the compressor the following precautions should
1

be

. Isolate the drive unit. DepressLtrise and purge the system. Djsconnect the drive couPl ing. ? . Pl ace a receptacl e under the outl et end of the compressor to catch any 3. o'il which may drip when the hydraulic cylinder or the outlet end cover are removed. (A dra'in pluq is fjtted on the underside of the inlet and outlet casing to facjl itate oil drainage). 4. Insure all I ifting tackle in good condition.
E 9
7

.3

DISI'TANTLITIG PROCEDURE FOR ANNUAL IHSPECTION

Commence

djscharge end wjth hydraulic actuator. Extract the 4 off cap screws holdjng the a'luminium cover to the cylinder Cover and remove" Extract the 15 off cap screws securing the cylinder cover to the hydraul ic cylinder and remove the cover complete with limit switches and the i"ndicator spindle which are attached to it. The cylinder c0ver weighs

at

I 20K9.
I'lo

te : -

The

indicator spindle has to clear a guide block whjch moves along a spiral groove in the spindle. care must be taken to avo'id damage to either spindle or gu'ide curing either removal 0r assembly. Mark the spi nd1 e to ensure correct assembly -

Page

16

COI"TPRESSOR

SERYICE

I,{AI{UAL

SECTION Remove

7 _ I'TAINTENANCE

the actuator stop sleeve,'if fjtted, from the cylinder bore. Section 9.3 and pu11 the sl ide iii tfr. piston withdrawal gear listed under js of the cyljnder. clear piston locknut the until valve assembly i.lithdraw the piston remove. and and locknut pi!ton lockwasher Untoct the 50 Kg' piston weighs The from the cyf inder. push the piston rod and slide valve towards the inlet to the limit of its
travel
.

Support the weight of the actuator cylinder. The actuator cyf inder weighs S0b' f g so a crane or chai n bl ock wi I I be requi red ' Extract the 16 bol ts and spri ng washers securi ng the cy'l 'inder and usi ng the jacking holes provided in the flange, iack out the cylinder.
REITOYIHG THE OUTLET EHD COYER

Extract most of the set pins securing the outlet end cover.

Fit a shackle to the liftjng eye on the top of the cover with a sI ing. The outlet end cover weighs 900 Kg'
Knock

and support cover

out the dowel Pins locati ng the cover to the outlet end casing, extract the rema'ini ng set Pi ns and remove the cover. Take care not to damage the piston rod.
REI.iOVI}IG THE SLIDE YALYE

l,l.ith the out'let cover removed the sl ide valve can be drawn to a pos'ition where i t j s sti l'l supported by the val ve gu'ide, to a1l ow sl i ngi ng ' The slide valve and piston rod weigh 400 Kg. Support the valve by means of a sf ing and puiI clear.
The compressor has now been dismantled enough

to allow inspection' By inspection of the rotors visuai a bore, valve the shin.ing a torch from
be ach'ieved.
New

can

0 Rings and PTFE seals shou'ld be fjtted prior to re-assembly on the piston and piston rod guide in the cylinders'

7.4
GUlDT

CHECKIHG CLEARAHCES
BLOCK

'l The gui de bl ock ocates the sl'irle val ve and shoul d be checked for wear' The jmits 49.991/49.965 mm' wi dth of the gu'ide bl ock shou'ld be within the I Should the dimension fal I outside these I imj ts i t must be repl aced.

THRUST BEARiNG FLOAT

I\,1ount

a dia'l test indicator to a su'itable point on the casing with the (t'124) eyebolt ipi.afe touch'ing the end of the male rotor. Using a suitab'le Th'is hard inlet. to rotor the pull in tne tapped h6le of the inlet shaft Set Kg" 1200 weighs rotor male will ..qrire some form of tackle since the and hard jndicator outlet to rotor to zero and puslr the the dial test l.ecorri Liie r.ead rrig. Tir is rcriii iirg i s iltc rtal c l"otci' fl cat arC shoul d be w1thin the range 0.450/0-35mm page
17

COHPRESSOR

SERYICE

}'IA}IUAL

SECTION 7 _

T.IAIHTEHAI{CE

this procedure for the female rotor. To do thjs the female rotor cover, R51132, weighing 55 Kg will have to be removed.
Repeat

Should the rotor float be greater than 0.450 nm the thrust assemb'ly should be dismantled and the other bearjngs checked for wear. In this case proceed as for maior overhaul, see Sectjon 8.
7

.5

REASSEI'{BLY AFTER AHHUAL I}.ISPECTIOH

Ensure the gu'ide block

is in posit'ion on the slide valve bore. Lift the slide valve into position and push it all the way home. Take care to support the slide valve unt'il a'll its weight is taken by the guide.

-e

Lift the outlet end cover, with a new 0 Ring, into position and locate with dowel pins. Take care not to damage piston rod. Secure with set pins. Fit a new 0 ring and PTFE sleeve in the piston rod guide on the actuator cylinder. Fit two new 0 rings'into their recesses on the cylinder body. rlt two lengths of screwed rod (M24) into opposite holes in the outlet end cover. The rods must be at least 350 mm 1ong. Lift the cyl"inder over these rods and locate in pos'ition. The rods w'ill act as gu'ides. I'lB: 0n no account al I ow the screwed rods to support the wei ght of the
cy1

i nder.

Fit suitable washers and nuts to the rods

securj ng wi th set pi ns.

and pu11

the cyf inder home,

the

pull the piston rod out until ihe end is clear of the cylinder. Re-fit piston to the piston rod and secure with new locknut and lockwasher.
Re-fit the actuator
$

stoP.

Careful1y f ift the cy1inder c0ver into position conrplete with actuator spindle making sure the guide fits jnto the correct spira'l gro0ve whjch has been marked pieviously. Secure with cap screws and re-fit cover assemb'ly"

I
Page iB

CCfiPRESSOR SERYICE Ii{ANUAL SECTION

B_

OYERHAUL

8.1

GE}IERAL COI''T{EHTS

Although a yearly inspection is reconrmended it is essential that a major overhau'l is- carried out when approxjmately 4 years operation has been
reached.

Should bearing wear be excessive before this then a major overhaul will be iequired earlier. To carry out a major overhaul the compressor will have to be removed from the bed to a cl ean workpl ace and mounted on a manipul ator frame.

8.2

DISI'{ANTLIHG

PROCEDURE

The compressor is first sections 7.2 and 7.3.

REI'IOYIHG
--*

to be dismantled as for annual inspection under

THE IHPUT SHAFT SEAL

the cap After the driven half coupling and key have been removed, extract provided and screws from the shaft end'cover and using the iacking holes (80 Kg) ihe "T" bar iacking tools remove the shaft cover. by removjng the seal jng washer and the statjonary seat- Aga'in Follow th'is ;t"" the shaft tt e ,;i;; -tak'ing iacking iool s withdriw the seal housing. Pul'I._out "l': caie not to damage the carbon face- Usjng the ieal ^iacking. the balance piston and balance p'iston sleeve (if fitted) withdraw tools
from the

inlet

end

casing. (Ba1ance piston 20 Kg)

INSPECTION OF THRUST BEARI}IG ASSEI{BLY

Release the locking plates on the rotor shaft end p1ate, remove the three the B hex screws from the reverse bolts and the shafi end plate. Remove j I oati ng seal and seal retai ni ng w th f ete thrust p'late and remove comp'l Extract the reverse thrust bearings' packers. p1ate. Remove the adiust'ing gh Kg) 50 ' itn. tf,.rst bearr'ngs wei

Draw

hex the thrust collar from the shaft and remove the key. Remove the 8 (The bearing. thrust main the with hous'ing screws and lift out the thrust irous'ing and bearing compl ete we j ghs 200 Kg) ' being Visually inspect the thrust pads for damage or wear, if they are notand oil clean in dipped then ,.un.*edthey should be cleaned'in solvent, place. wrapped in greaseproof paper or clean cloth until re-assembly takes
RET,IOYII{G

IHLET END CASING

out the dowel pins Fit a shackle at the top of the inlet casing" Knock weight w]th the crane' the locatjng the casing to the main casing. Support the casing slide Remove the 44 set Iins from the inlet casing and careful'ly it" w'ith seal ring 0 over the extended shaft of the male rotor taking the The jnlet casr'ng weighs 1053 Kg.
D:ao ruJr. I +O

LUTTITKL))UK )LKI ILL SECTIOH

TU\NUAL

8-

OVERHAUL

RE}TOVAL OF ROTORS

l.li

th the 'inl et casing and thrust assembl ies removed and the compressor securely fastened to the manipulator frame rotate the compressor tjll the .inlet ena is uppermost. Screw an eyebo'lt into the end of the male rotor and lift clear'of the casing slow'ly turning it clockwise to ease the rotor
form past the female. The rotors weigh 1 tonne each.
Repeat

for the female rotor.

vee

Always support rotors by the.ir iournals on soft (preferably wooden) bl ock s. Never allow rotors to rest on their tip sealsThe i nl
spec i

screws.

et

and Hi th
s

outlet

a1 tool

end journal bearings are held in position by set these removed the bearjngs can be pressed out using the I isted in Section 9.3.

Check the The

journal bearing clearances are within the tolerances 0.28/0.34mm. if outw'ith th'is speciticitton fit new bearings in preparation for re-assembly.

iournal bearings weigh 100 Kg each'

RE-ASSE}'{BLY AFTER OVERHAUL

8.3
Smear

the outlet end bearing boresj w'ith lubricat'ing oil and turn the compressor body vertical w'ith the nl et end upperrnost. Carefully lift the seri a'l

in the female rotor. Carefully lift in the male turning anti-clolt*ise to allow the rotors to mesh. Ensure the rotor lobes mesh at
numbers.
.

Turn the compressor back hcrjzontal and, having smeared the bearing bores w.ith oi'l carbf ul 1y f i t the i nl et casi ng wi th a new 0 ri ng over the rotors Locate the inlet iasing in position with dowel pins, fit the bolts and secure them. (see torque specjfication in Section 9).
ASSEMBLY OF THRUST BEARIHGS

T ;

Fi

main

thrust beariig, thrusi collar w"ith key and thrust housing bolts to required setting' push the rotor hard to outl et and mount a di al i ndi cator' at a conven'ient place with the spindle horizontal and the dial set to zero. push the rotor hard to inlet until the thrust collar comes up hard against the pads and note the reading. Thjs reading is the 0UTLET END, HARD T0 INLEi CLEARANCT and should be 0.650/0.600 mm. To obtain the correct clearance shims should be added or packers ground as required. Final readjnqs must be taken with housing bolts and rotor plate bolts torqued io
the requj red setti
ngs.

outl et end casi ng. Fl't t thrust housi ng wr'th adjusti ng washers to therotor end piate. Torque

washers. Leave the Fit the reverse thrust bearing and p'1ate with adiusting set the dial to and bolts slackened back. Push the rotor hard to outlet reading' Thjs check i..o. Torque the bo:lts to the required valug 9ld and the d be shoul , HARD T0 0uTi tT cLtARAl'lCt rearti ncr i s ihe 0uTl,tT
Ef,JD

0.250/A.200

mm.

Page

COI.IPRESSOR

SERVICE

I{AHUAL

SECTI0NB-oYERHAUL

Again the correct clearance should be obtained by adding sh'ims packers as requj red.

or grinding

Repeat this procedure wjth the other rotor. The origina'l readings, taken on assembly in the factory, will be shown under contract detajlsRenew

the floating seals and rotor end piate locking plates. Ensure all bolts are correctiy torqued and fitted with loctjte 275 which should also be used to I ocate the thrust col I ar to the shaft.
RE-ASSEI-{BLY OF OUTLET EHD COYER AilD HYDRAULIC CYLINDER

Proceed as described

in Section 7.

RE-ASSET'{BLY OF INPUT SHAFT SEAL

1. Fit balance piston sleeve (if required) and balance piston making sure i t fi ts over the dowel . 2. Locate seal driv'ing pjn into hole in balance piston' 3. Lubricate shaft seal and assemble to rotor shaft. Ensure I't fl'ts over
drj vi ng pi n.

4. Carefully fit stationary seat into shaft cover locatjng it 5. Fit shaft cover in position and secure with cap screws.

on dowel.

t g

Paqe

21

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Pnee 23
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_

COI'IPRESSOR

SERYICE

I{ANUAL

SECTIOH

9-

SPECIAL I}ISTRUCTIO}IS

9.i

ToRQUE SPECIFICATI0T{S as

Torque specifications are

FrG 104
PART NO.

detai 1 ed per Tabl e Fi g. 104.

HRVT51O COI.PRESSOR

T0RqUE SPECIFICATIOHS FOR FASTEHERS OH

DESCRIPTlON

Lbs.FT
4

IORQUE

Kg.l'1

G16032

Slotted Cheese Head Screw 68A x 1 1/4" 1G

Hex Nut
M30 M24

G24102
G24103 I
I

Hex Nut
UNC

G2501

Hex Socket Head Cap Screw N0.10

x 5/8"

liBB 583 41

164
BO

LG.

G250 37

Hex Socket Head Cap Screw l{o.10

UNC

x 3/8" LG.

G26002

Hex Socket Set Screw (Grub Screw) with Cup Pojnt

G26006

Steel Hammer Drive Screw No.6 1/4" LG

G26030
G26037

c LU Hex Socket Head Cap Screw MB x 20 r

Hex Socket Head Cap Screw M24 x

)1
LL

? J

583
583

BO

45
G26038
ry
B

LG

Hex Socket Head Cap Screw

M24

BO

70
G260 39

LG l'116

Hex Socket Head Cap Screw

t71

t+
?4

45
G27002
G27012

LG

Hex Head Screw Ml6

Hex Head Screw M30 Hex Head Screw ll24 Hex Head Screw M10

x 50 LG

777

x
x

120 B0

LG

liBB

tb4
BO

GZ70l3
G270
15

LG

x 30 LG
LG

4i

6
BO

G270i6
G?7017 G27018

Hex Head Screw 1124 x 60

Hex Head Screw M24

x 70 LG
tG

30J
1/ n
1

BO

liex l{ead Screvr 1"120 x 50

Stud
1430

47 154
BO

G2800 G2800

I
2

to Drawi ng LCV332l/A
to
Drawi ng LCV332l/B

IBB

Stud

t'124

583

age

24

COI{PRESSOR

SERYICE

HANUAL

!9.?
PROCEDURE FOR

sEcTI0N 9 FITTII{G

SPECIAL IHSTRUCTIoHS

LOCKI{ASHERS

This instruction applies to all lockwashers used on Howden Compressors for the purpose of reta'ining'in pos'ition the locknuts locating the bearings, thrust collars, pistons etc. A typical example of the items concerned is
shown below

(rtg.

105).

**11
il
II

Fi 9.105
Assemt-rly Method:

Fis lO5

In all cases where this type of lockwasher is used the components must be assembled without the lockwasher and torqued to the prescribed value. The locknut must then be removed, the lockwasher d'ipped in oil and placed on

the shaft, the locknut replaced and aga'in torqued to the pr^escribed value. This assembly process limjts the amount of relative movement between the locknut and the lockwasher under torque, and avoids the possibility of the inner tang being damaged.

9.3

SPECIAL TOOLS FOR THE

COI'{PRESSOR

Tools can be provjded as deta'i1ed per (fig.106) for ease of dismantling/assembiy however, they are not a mandatory requirement.
Fig.106
t

'ilRVT510

LIST OF SPECIAL

TOOLS

i oescnrPlroN
I I
socrEr
sPANNER saANNER

Bo HH LocKlluT 100
MM

I sEr on ltrrntc socrrrs coupntsiNe to ttt'i, to MM I I zo ulr, z+ NN :o ltu socrErs plus nnrcHrr I I I ExtrNsioN enRs to" a s" I srr or RLLnN rrvs compRrstNe - o Ftlt, B tltt, to ttM I I I rz rru, zq H[1

socrrr

LocKNUT

I I
I

ennr

No

I
I

stooieJ
s10015J

I
I

I I
I

z-' Pacle ^-

COI'IPRESSOR

SERYICE

I'IAHUAL

SECTIO}I

9-

SPECIAL IHSTRUCTIONS

9.4

COMPOHEIT I{EIGHTS FOR I{RYTs1O COI.IPRESSOR

l,leights detailed below to allow correct

lifting facilities to be used"

I coueourur
I
rNlrr
Nnr-r

l .ourlrr cASING
cASTNG
COYER

RoToR
OUTLET

I
I

wrrcHT-(Kg)
-2652-

'

zw
1053
1

I
t
t

RoToR
ROTOR

tB6

FEMALE

I
l-

r'rarr

RoToR covER

BALANCE PISTON

sucr roN -BRG '( 2 of f )'

rrmnlr

RoroR

covER
I2.OFF)
OFF)
-

DISCHARGE-BRG THRUST HSG

(2

I I
I

nrv 'niRUSr'PLATE (z

orr) -

Inolusrrrucnnic(zorr)
rHnusr sPACTR (z orr) rHnusr colLAR (2 oFF)

-'

j -- -g,e 4:B I

I
I

I
q
9

runusr Pi-ATE "('2 oFF)

1 ''zs '6.2
1i0 l
I

I ersroru noo
I i
ncrunroR
cvt- t runrn

'

PrsToN
sToP

CYLINDIR END COVER

I
)
I I

"'

iie
516

I slroe vALYE I sL rrr vALVr sToP

257
cc JJ 200

I I

srr

scRrils

rHnusr eacs

ct

\ -#

Hage r0