SECTION 5 3628, 442B, 452B & 4628 MAINTENANCE Contents Page GENERAL RECOMMENDATIONS Disassembly . Reassembly COUPLING GUARI Disassembly .... Reassembly COUPLING, WWORAUL iG FIT T¥PE Disassembly Reassembly ............ COUPLING, KEYED TYPE Disassembly ...... Reassembly co END COVER & COUPLING GUARD ADAPTERS” Disassembly ..., Reassembly oe... THRUST & JOURNAL BEARINGS Thrust Bearing Axial Clearance Check Seen soul Thrust Bearing Disassembly ... Be ee eee Journal Bearing Disassembly poogcooaneod 5-6.6 Bearing Inspection Sopéquodgupobacantt 5-6.7 Checking Journal Bearing Clearances ............46+ 5-6.10 Journal Bearing Shoes Reassembly ...........0.+ 5-6.11 a Journal Bearings Reassembly ...........0es005 5-6.11 Thrust Bearing Reassembly .......sescseeeseeee 56.12 REPLACEMENT ROTOR - INTERNALS INSTALLATION Sizing Thrust Disc Bushing Spacer ... 2 57,7 Impeller - Diffuser Overlap Dimensions . + 527.3 INNER OIL SEALS Disassembly .... 58.1 Inspection ++ 58.2 Reassembly + 508.4 PULLER BLOCKS, SHEAR RING & INLET HEAD Disassembly Reassembly INTERNAL BUND Bundle Removal ..... Bundle Installation . INTERNAL BUNDLE ASSEMBLY Disassembly .. Upper Half Bundie Removal Rotor Removal ...., Bundle Dismanti ing Reassenbly ..... dopsconos Internal Bundie Assembly Axial Dimensions Bundle Reassenbly . : Rotor Installation .. Internal Bundle Top Hi Inlet Ring ........+. O-Rings & Backup Rings Page 1SECTION 5 3628, 442B, 452B & 4628 MAINTENANCE Contents Page RADIAL & AXIAL PROXIMITY PROBES Disassembly Reassembly EMBEDDED TEMP! Disassembly . Reassembly Page 2MAINTENANCE FIGURES INDEX Description Typical Coupling Guard Typical Oil Spray Tube Position Hydraulic Fit Coupling Hub Tools Shaft Bore Adapters Expander & Pusher Pumps Assembly Hydraulic Fit Coupling Dimensions Keyed Coupling Hub Puller Plate Typical Coupling Hub Positioning Bracket Keyed Fit Coupling Dimensions Thrust & Journal Bearings Guide Studs for Bearing Removal Typical Rotor Assembly Thrust Disc Tools Typical Thrust Bearing Bearing Entering Sleeve Thrust Disc Dimensions Thrust Disc Spacer Dimensions Inner 041 Seats Inner Seal Parts Puller Seal Ring - Bearing Shoes Assembly Seal Ring - Bearing Shoes Assembly Tool Inlet Head Puller Shear Ring Segments Inlet Head Lifter Bundle Slings & Puller Plate *Continuously Lubricated Couplings Figure 5-1A* 5-2 5-4 5-5 5-7 5-8 5-10.1 Page 5-0.1MAINTENANCE FIGURES INDEX The following drawings are Parts Lists Illustrations to be used in conjunc- tion with these maintenance procedures Description Unit Assembly Case Assembly Internals Assembly Radial & Axial Proximity Probes Assembly Temperature Sensors Assenbly Nunber 620-022 620-023 620-028 611-826 615-725“ GENERAL RECOMMENDATIONS It is recommended that a DRESSER-CLARK Service Representative be present when major disassembly is undertaken. A. Disassembly 1 2. 10. 1. cv 13. Care should be exercised in keeping dirt or any foreign material out of working parts of the compressor. A11 piping, tubing, and compressor openings should be covered during maintenance periods. Tools and components should not be rested on or above compressor where they may drop into any openings. Extreme care must be used in handling bearing and seal parts, as well as the rotor assembly. Internal parts having shaft labyrinths must be handled and stored with care. Studs and bolts may have sharp threads and should be worked around with care. Before starting any maintenance work, be sure that all electric Power is off and fuel, steam valves, etc., closed on the driving equipment. An inspection and replacement of the journal and thrust bearings and inner seals may be conducted without removing the inlet or dis- charge heads. Al matchmarks on mating pieces, dowels and fitted keys must be re- turned to their original locations when the compressor is reassem- bled to insure correct. assembly. All inlet guides are numbered in mating halves and numbered to the case. Care must be used that the inlet guides and diaphragms are not mixed during reassembly. The gaskets and O-ring seals are of importance for the best perfor- mance of the compressor. They must be inspected closely and new ones ‘installed if there is the slightest question as to their condition. Refer to the Specifications Section in this manual for design clear- ances throughout the compressor. All threads are right hand unless otherwise noted in text. Whenever the compressor is dismantled and replacement parts installed, check all clearances and record for future reference. Refer to the Parts Lists Section in this manual for detailed cross- sections of the compressor before starting any dismantling of unit. If two or more compressors have been furnished and are being driven ‘in-line’, the thru-drive units must be lifted from the base for internal bundle removal. Bearing and seal assembly, disassembly, and inspection can be made at each compressor by removal of normal interference. TO PULL THE THRU-DRIVE UNIT INTERNAL BUNDLE: Page 5-1.1a, Assuming the equipment is at ambient temperature, obtain and record the cold alignment (both ends). >. AIT piping interference which would interfere with the compres- sor removal from the base must be uncoupled. ¢. The compressor must be hoisted from the base and set down on amply sized steel sawhorses at ground level. Maintenance dis- assembly/assembly can be carried out here. Caution Shim stock used for alignment must be carefully match- marked to given locations. Wire individual shim stock piles together. Upon compressor reassembly to the base, cold alignment must agree with that found in Step 13.a. B. Reassembly. a The need for cleaning the internal components or casing will be de- termined by inspection, Normally, washing a11 parts with a good grade of solvent and blowing out with clean, dry compressed air Should be adequate. Note Do not wash O-rings or gaskets in a solvent. This will cause them to swell and deteriorate. Inspect all the O-rings and gaskets; they must be in first class Condition. If there is any doubt it is strongly recommended that they be renewed. Refer to the "Special Lubricants" given in the Specifications Section for the recommended lubricants for use on O-rings and backing rings. Inspect al] labyrinths, machined surfaces, etc., for nicks or burrs before and during reassembly, All pipes, tubing and volute openings should be covered during any dismantling or opening of the case. If this has not been adhered to, a careful cleaning of all such pipes and openings must be done. Attention must be given to all matchmarking of keys, diaphragms, inlet guides, coupling bolts, etc., to ensure correct reassembly. Measure and record all running clearances possible. Determine that they are within recommended limits given in the Specifications Sec- tion. Record for future reference. Page 5-1.2COUPLING GUARD - Refer to Fig. 5-1, The coupling guard is the totally enclosed type. Fig. 5-1. TYPICAL COUPLING GUARD A. Disassembly 1 Disconnect the piping interference from the coupling guard. Cover the standing ends of the piping to prevent ingress of dirt, etc. Remove capscrews 9 which attach the gland 7 to the coupling guard 1. Carefully pull the gland and O-ring 8 back onto the coup] ing guard adapter. Remove the capscrews § and nuts 6 from the coupling guard splitline while supporting the lower half of the guard at the free end. Remove bolts 12 and lift the upper half off and move to storage area. The upper half may be vertically split and can be removed in sections if necessary. Remove the splitline gasket 4; save if in serviceable condition. Page 5-2.18. Remove remaining bolts 12 and carefully remove the lower half juard. Use care not to bend or damage the oi] supply tubing 15 ised’ with continuously lubricated couplings only). It is recommended the coupling guard halves be bolted together while in storage to protect the splitling surface. The gland 7, O-ring 8 and gasket 18 must remain on the coupling guard adapter and driver until the coupling spacer is removed. _ Be Reassembly 1 2. The gland 7, O-ring 8 and gasket 18 must be placed on the coupling guard adapter and driver before assembling the coupling spacer. Once the coupling is completely reassembled, carefully place the lower half guard into position with gasket 18 in place. Install bolts 12 to hold the guard in place at the driven end. Provide a temporary support at the compressor end. a. If the coupling is the continuously lubricated type, position the of] supply tubes approximately 1/8 inch (3.2 mm} from the coupling of] inlet as shown in Fig, 5-1A. 1/8 In. (3.2mm) Coupling Spacer 3° With Rotation 1/8 In. (3.2mm) t= Coupling Sleeve O17 Spray Tubing { Fig. 5-18, TYPICAL OIL SPRAY TUBE POSITION Install the splitline gasket 4 and carefully place the upper half guard onto the lower half aligned to dowel 2. Install bolts 12 at the drive end hand tight. Install the splitiine capscrews 5 and nuts 6. Tighten firmly. Now cross-tighten bolts 12 to ensure guard is squarely seated on the driver. Carefully remove the O-ring 8 from the adapter and push into the guard bore at compressor end. Use care not to twist or damage the O-rings. Push the gland 7 firmly against the O-ring and secure with capscrews 1. Once the compressor is operating, check for of1 leaks. Tighten the splitline and gland capscrews as necessary. Reconnect the piping removed during disassembly. Be sure the piping is clean and use sound gaskets. Page 5-2.2re HYDRAULIC FIT TYPE COUPLINGS Refer to the Coupling Data Sheets in the Specifications Section and the manufacturer's data in the Auxiliary Equipment Section for the model, size and shaft taper dimensions for each coupling. A. DISASSEMBLY, Refer to Figs. 5-2, 5-3, and 5-4 1. Inspect the coupling for matchmarks; spacer to sleeves and sleeves to hubs. Rig a sling around the spacer piece. Refer to the manufacturer's instructions and remove the coupling spacer. Also, remove the disc packs if a diaphragm type coupling is provided. Observe whether the spacer bolts and nuts are numbered to a given location. Store the nuts on the bolts from which they were removed. Wire the disc packs, when used, together to prevent their becoming mixed. Protect the coupling center components from corrosion or other damage and store safely. Loosen the setscrew in the face of the coupling locknut. Remove the locknut with a face spanner. The coupling hub can now be removed. ON SA Nil Fig. 5-2. COUPLING HUB TOOLS Wipe the coupling hub face and shaft end carefully to remove all oil. With a micrometer depth gauge, measure the hub overhand on the shaft to four decimal points and record. Hub must be returned to this dimension (+0.010 -0.000 in/+0.254 -0.000 mm), when re- installed. Page 5-3.1es) Use extreme care during the following steps to keep dirt, filings, etc., from the hydraulic oil and all components used for disassenbly. Wrap'the shaft taper in heavy paper which has been well greased ‘once the coupling hub is removed. Apply the same protection to the hub and stow safely. Refer to Fig. 5-2. Procure the coupling hub remover components from the Special Tools. Clean the tools carefully and install them as illustrated. a. Be certain that the backup rings 5,8 are placed on the low pressure side of the O-rings 4,7 as shown. b. Be certain the coupling nut 3 is seated against the shaft shoulder. c. The holder 13 is teflon lined and is provided to aide in handling the larger size components to keep then square with the shaft during assembly. d. When the coupling hub is mounted at the thrust bearing end and ‘the rotor fs equipped with a hydraulic fit thrust disc, special adapters are provided for the shaft bore. The “blind” adapter is to be used during coupling hub removal; the "thru" adapter is for thrust disc removal. rx | ELS “BLIND” ADAPTER FOR COUPLING "THRU" ADAPTER FOR THRUST HUB REMOVAL / ASSEMBLY DISC REMOVAL/ASSEMBLY Fig. 5-3, SHAFT BORE ADAPTERS Refer to Fig. 5-4. Procure the expander pump 14 and all the tubing/fittings illustrated from the Special Tools. Clean and install the connector 5 at the shaft center. Blow out all the tubing, fittings, etc., with solvent/compressed air, then blow dry. WARNING These tool assemblies incorporate high energy apparatus and extreme care must be taken in the assembly, mainten- ance and operation of the tools. Never substitute other parts for those provided. The coupling nut and pusher ring are safety code color "Orange". Page 5-3.2Fig. 5-4. PUSHER & EXPANDER PUMPS 10. Instal1 the tubing between the pusher ring 6, Fig. 5-2, and pump 4. Refer to the pump manufacturer's instructions in the Auxiliary Equipment Section and fill the pumps with hydraulic oi] and purge all the air from the lines. Pressurize the pusher ring with pump 4 so that the ring is just touching the coupling hub. Pressurize the hub bore with expander pump 14 to 10,000 psig (703 kg/em@, 68.9 Pa) initially then in 1,000 psig (70 kg/em2, 6.9 MPa) increments until the coupling hub 48 loose on the bushing. It may be necessary to maintain the bore pressure for fifteen to twenty minutes to allow for coupling hub expansion. Do not exceed 30,000 psig (2109 kg/cm2, 206.9 MPa) maximum bore pressure. NOTE Record the hydraulic bore pressure at which the coupling hub is "loose" on the shaft taper. For subsequent re- moval or assembly, the bore can be initially pressurized to this value to reduce maintenance time. Page 5-3.3nu. 1. 13. Us 10. un. 12. Rev. 1 Release the bore pressure. Disconnect the tubing from the shaft and pusher ring. Return the pumps to tools storage. Remove the nut and pusher ring from the shaft and return to tools storage. Pull the coupling hub from the shaft. Wrap in heavy paper to pro- tect the hub bore and store safely. Reinstall the coupling locknut. Wrap the shaft taper with heavy paper or sheet gasketing, and tape or wire in place. REASSEMBLY, Refer to Figs. 5-2 and 5-4. Al] the coupling components are on hand and are clean and service- able. Procure the pump assembly illustrated on Fig. 5-4, and the assembler/remover tools shown on Fig. 5-2. Clean these components carefully. Remove the protective cover from the shaft taper and the hub locknut. Clean the taper and drillings carefully. Inspect the bore of the coupling hub and the shaft taper for high spots, burrs or signs of fretting from the previous operation. If evident, carefully remove with a stone or fine emery paper. Do not use a file. Check the contact of the coupling hub on the shaft taper with Prussian Blue or an equivalent; at least 80% contact should be obtained. Assemble the coupling hub on the shaft without O-rings 9, 11 and backing rings 10, 12 (Fig. 5-2), Hub must be metal-to-metal and "square' with the shaft. Very carefully measure the distance from the face of the coupling hub to the end of the shaft. Record the dimension found. This is the coupling hub shaft overhang with the hub metal-to-metal on the taper without the O-rings, Step 5. Pull the hub from the shaft and then reassemble, with O-rings 9, 11 and backing rings 10, 12 installed as shown on Fig. 5-2. Refer to the Special Tools and assemble the hydraulic pump compo- nents, Fig. 5-4, and coupling hub pusher components, Fig. 5-2, as illustrated. Observe that the coupling nut is seated firmly against the end of the shaft. Vent all air from the tubing. Use the pusher pump and move the coupling hub to the position found in Step 6. The O-rings will extrude if the hub bore is pressurized before the coupling is pushed metal-to-metal on the shaft taper. Install a dial indicator to observe the coupling hub axial travel. Set the indicator dial to zero. Refer to the chart on page 5-3.6 for the axial travel required. Set the pusher pump relief valve (integral part of pump) at 8000 psig (562.4 kg/cm, 55.12 MPa). Increase the pusher pump pressure to 500 to 1000 psig (35 to 70 kg/em2, 3.4 to 6.9 MPa). Page 5-3.413. 14, 5. w. Ww, 18. 19. 20. 21. 22. Rev. 1 Pressurize the coupling hub bore to 10,000 psig (703 kg/cm?) (68.9 MPa) while maintaining the pusher pump pressure. CAUTION Do not allow the coupling hub to move off the shaft taper. Gradually increase the bore pressure and pusher pressure to move ‘the coupling hub to its assembled positign. The maximum allowable bore pressure is 30,000 psig (2109 kg/cm“) (206.9 MPa). Record the axial travel observed on the indicator. Release the expander punp bore pressure gradually (at 5000 psig, (351 kg/cm) (34.5 MPa) intervals) while maintain the coupling hub position with the pusher pump pressure. Wait a minimum of 10 minutes between intervals while releasing the bore pressure. When the bore pressure reads zero, maintain the pusher pressure for an additional 5 minutes then release the pusher pressure. Final coup- Ting hub position should be within the Timits. shown on the chart on page 5-3.6. Remove the pumps and pusher components and return to the tool house. Remeasure the coupling hub shaft overhang; should agree with dimen- sion recorded in Step A.5, page 5-3.1. As a second check, the dimension obtained in Step 8.6, minus dimension measured in Step B.18, should equal the axial travel, dimension 'C', listed in the chart on page 5-3.6. Install the coupling locknut with a face spanner and lock with the setscrew provided. Before continuing the coupling reassembly, install the coupling guard adapter and gaskets then place the guard O-ring and gland on the adapter. Complete the coupling reassembly. Refer to the manufacturer's instructions contained in the Auxiliary Equipment Section. Once the coupling is reassembled, install the coupling guard. Page 5-3.5Assembled Position Before Pull-up, Metal-To-Metal Position HYDRAULIC FIT COUPLING DIMENSIONS ‘iverson oa DiNENSION dovexston “<” rvewsion a7 | ommension ca | pimasion c+ Beats Diameter at | Couting war Bore | Aviat Trove? Reqvtrag |f snare Oiamecer at | coupling a Bore | Antal Trove) tagutred| Kntge Ene Taner" | RC Large fn Foe bentge rte Entye foe taper | At Carpe tnt For benign Foe Toctes BOE | treme GREE | tres BOB motions SS | ssttintare “SE | witteners “3285 10 Ta oor Ear) x Le 1.10 18 0.0% 00 am aw 2.00 Lams 0.086 0.00 soon re 2280 nae om 219 sme 2.00 2.800 2.494 ore 2.50 ome 3.008 2.000 zo oe 16.208 n.022 1300 sae os 900 mor nats a0 ns ano . 00 won 4.000 101.600 ware 104.775 e156 14.200 nese v.23 ws. 121.000 w6.721 70 ia. 182.400 2.070 7.060 may 190.500 190,068 mr mm misc mm 4.000 m0 mu mm so. ue Dimension “C" is the Dresser Clark standard pull-up reconmendation. Refer to the Coupling Data Sheet in the Specifications Section of this manual for the Specific axial travel required for each coupling hub. The dimensions given on ‘the Coupling Data Sheet must be used when different from dimension "C* given in the table. Rev. 03/85 Page 5-3.6KEYED TYPE COUPLINGS Refer to the Coupling Data Sheets in the Specifications Section and the manu- facturer's data in the Auxiliary Equipment Section for the model, size and shaft taper dimensions for each coupling. A. Disassembly ~ Refer to Fig. 5-6 1 2. Inspect the coupling for matchmarks; spacer to sleeves and sleeves to hubs. Rig a sling around the spacer piece. Refer to the manufacturer's instructions and remove the coupling spacer. Also, remove the disc packs if a diaphragm type coupling is provided. Observe whether the spacer bolts and nuts are numbered to a given location. Store the nuts on the bolts from which they were removed. Wire the disc packs, when used, together to prevent their becoming mixed. Protect the coupling center components from corrosion or other damage and store safely. Loosen the setscrew in the face of the coupling locknut. Remove ‘the locknut with a face spanner. The coupling hub can now be re- moved. Wipe the coupling hub face and shaft end carefully to removal all oi]. With a micrometer depth gauge, measure the hub overnang on the shaft to four decimal points and record. Hub must be returned to this dimension (+0.010 -0.000 in/+0.254 - 0.000 mn), when re- installed. Refer to Fig. 5-6. Procure the coupling hub puller plate from the Special Tools and install on the coupling hub as illustrated. Threaded puller holes are provided in the face of each coupling hub. COUPLING PULLER Fig. 5-6. COUPLING HUB PULLER PLATE Pace 5-4.17. Turn in" on the capscrews in small increments until the coupling hub is "loose" on the shaft taper. 8. Remove the puller plate and then coupling hub. Protect the hub against corrosion or other damage and store safely. Reassembly ~ Refer to Figs Keyed type coupling hubs are mounted on the shaft tapers with a light interference fit. The design interference fit is given on the Coupling Data Sheet contained in the Specifications Section of this manual. Refer to the chart on page 5-4.4 to determine the axial travel required to move the coupling hub from a metal-to-metal fit on the shaft taper to its assembled position. This chart is for a 1/2 inch per foot shaft taper only. The axial travel can also be determined by multiplying the interference fit dimension by the shaft taper ratio. For example, a shaft with a 3/4 inch per foot taper and a 0.0015 inch interference fit, the axial travel required would be: 5-7 & 5-8 Design Interference Fit .... - 0.0015 Shaft Taper Ratio ........... = 1/16 Axial Travel Required (0.0015 x 16) . 0.024 Coupling hubs which are a "straight" fit on the shaft are to be located axially to the dimensions given on the coupling drawing in the Main Drive or Auxiliary Equipment Section of the manual. 1. All the coupling components are on hand, and are clean and service- able. 2. Remove the protective cover from the shaft taper and the hub Tock- nut. Clean the taper carefully. 3. Inspect the bore of the coupling hub and the shaft taper for high spots, burrs or signs of fretting from the previous operation. If evident, carefully remove with a stone or fine emery paper. Do not use a file. 4. Check the contact of the coupling hub on the shaft taper with Prussian blue or an equivalent; at least 80% contact should be ‘ob- tained. 5. Check Fit of the coupling key in shaft keyway, Sides should be metal-to-metal (plus 0.002/minus 0.000 inches). 6. Install the hub on the shaft taper and rap lightly with a soft face mallet to assure the hub is metal-to-metal on the taper. 7. Fabricate a bracket similar to that shown on Fig. 5-7 and attach it to the coupling hub with capscrews threaded into tapped puller holes in the hub face. Refer to the coupling drawings in Auxiliary Equipment Section for dimensions of hub and puller hole locations. 8. Adjust the locating screw with a feeler gauge for the design axial travel. Lock the screw in position with a jam nut. Page 54.2Position Before Pullup po Axial Travel Required 7 GN. 10. ul. 12. 13. 14, Fig. 5-7. TYPICAL COUPLING HUB POSITIONING BRACKET Remove the coupling hub from the shaft and immerse it in an oil bath or similar controlled temperature and allow to heat soak at approximately 300°F (149°C) to expand the hub bore approximately 0.003 to 0.005 greater than the shaft diameter. Do not apply an open flame to the coupling hub when heating. Caution: Use heavy duty asbestos gloves when handling the hub. Promptly install the hub on the shaft with the positioning bracket. Move the hub onto the shaft taper until the locating screw is seated against the shaft. Apply a cool air blast to the inboard end of the coupling hub to anchor that end first. Allow the hub to cool to ambient temperature, then remove the positioning bracket. Install the coupling locknut. Secure the locknut with the setscrew provided. Before continuing the coupling reassembly, install the coupling guard adapter, then place the guard O-ring and gland on the adapter as outlined in Step B.1, page 5-5.1. Complete the coupling reassembly. Refer to the manufacturer's in- structions contained in the Auxiliary Equipment Section. Once the coupling is reassembled, install the coupling guard; Step B, page 5-2.2. Page 5-4.3DIMENSION "A’ | DIMENSION “B" Coupling Hub Bore Shaft Diameter At Large End At Large End HInches + 0.0000} MM + 0.0000]Inches + 0.0005 | MM + 0.0127 = 0.0005 = 0.0127) = 0.0000 = 0.0000 DIMENSION "Cc" Axial Travel Required For Design Fit Inches + 0,010 | MM + 0.254 = 0.000 = 0.000 1.500 1.4985 38.0619 0.0192 0.4877 2.000 1.9985 50.7619 0.0240 90.6096 = 2500 2.4980 63.4492 0.0312 0.7925 000 2.9980 76.1492 0.0360 0.9144 3.500 3.4975, 88.8365, 0.0432 1.0973 4.000 101.600 3.9975 101.5365 0.0480 1.2192 4.500 114.300, 4.4970 114.2238 0.0552, 1.4021 4.969 126.213 4.9660 126.1364 0.0600 1.5240 5.000 127.000 4.9970 126.9238 0.0600 1.5240 5.500 139.700 5.4965, 139.6111 0.0672 1.7069 6.000 152.400 5.9965 152.3111 0.0720 1.8288 6.500 165.000 6.4960 164.9984 0.0792 2.0117 7.000 177.800 6.9960 177.6984 0.0840 2.1336 7.500 190.500 7.4955 190.3857 0.0912 2.3165 Inches + 0.000 | MM + 0.0000 | Inches + 0.001 | MM + 0.0254 | Inches + 0.010 | M+ 0.254 = 0.001 = 0.0254 ~ 0.000} — - 0.0000 = 0.000 = 0.000 8.000 203.200 7.9955 203.0857 0.0960 2.4384 8.500 215.900 8.4950 215.730 0.1032 2.6213 9.000 228.600 8.9950 228.4730, 0.1080 2.7432 9.500 241.300 9.4985, 241.1603 0.1152 2.9261 10.000, 254.000 9.9945, 253.8603 0.1200 3.0480 10.500 266.700 10.4940, 266.5476 0.1272 3.2309 11,000 279.400 10.9940 279.2476 0.1320 3.3528 11:500 292.100 11.4935, 291.9349 0.1392 3.5357 12-000 304-800, 11,9935 304.6349 0.1940 3.6576 Assembled Position ¢C Before Pull-up, Metal-To-Metal Position NS Fig. 5-8. COUPLING DIMENSIONS ~ KEYED HUBS Dimension “C" is the Dresser Clark standard pull-up recommendation for keyed couplings on 1/2 inch/foot shaft taper. Refer to the Coupling Data Sheet in the Specifications Section of this manual for the coupling and shaft diameters for each coupling hub. The dimensions given on the Coupling Data Sheet must be used when different from dimensions given in this table. For tapers other than 1/2 inch/foot, or equipment other than Dresser Clark, refer to the graph on page 5-4.5 to determine the axial travel required to in- stall the coupling hubs. Page 5-4.4” AXIAL TRAVEL REQUIRED FOR ASSEMBLY (Inches) NON-HYDRAULIC FIT (KEYED) COUPLING HUB POSITIONING CHART Note: These curves are based on 0.0005 inch interterence fit per inch of shaft dieneter at large end of taper. 0.160 0.040 10.006 0.007 0.000 0.001 0.002 0,003 0.008 0.005 DESIGN INTERFERENCE FIT (Inches) Page 5-4.5” END COVER & COUPLING GUARD ADAPTERS A. Disassembly 1 The compressor may be equipped with a shaft end seal labyrinth or baffle at the coupling end. These are used with a grease-packed coupling or when it is necessary to keep lubricating oi] in the bearing chambers separate from the coupling oi]. Remove the laby- rinth or baffle. Use care not to damage the labyrinth knife edges and store safely. Remove all the external piping interference from the adapters. Cover the piping ends to prevent ingress of dirt, etc. Remove the capscrews and pull the blind end cover and gasket from the service end. Refer to page 5-6.1 and remove the temperature detector tubing be- tween the bearing housings and adapters. Tag the tubing for loca- tion and store safely. Refer to page 5-12.1 and disconnect the radial and axial proximity probes leads. Pull the leads through the adapters into the bear- ‘ing chambers. Refer to page 5-13.1 and disconnect the embedded temperature detec- tor leads. Loosen the packing glands and carefully pull the leads into the bearing chambers. Remove the capscrews and pull the end cover adapter and coupling guard adapter. Remove and save the gaskets if in serviceable condition. The thrust and journal bearings are now accessible; refer to page 5-6.1. 8B. Reassembly a The adapters, cover and seal, can be installed by reversing the disassembly procedures. Be sure all of the gaskets used, are in good condition. Makeup the temperature detector tubing between the bearing housings and adapters and the radial and axial proximity probe lead connec- tions before installing the end covers. Reassemble the external piping to the adapters; be sure all gaskets and O-rings are in serviceable condition. Page 5-5.1THRUST & JOURNAL BEARINGS A, Thrust Bearing Axial Clearance Check - Refer to Fig. 5-9. 1, The coupling guard, coupling, end cover and adapters have been re- moved. 2. Observe that all capscrews which attach the bearings to the heads are tight. Observe that the capscrews securing the journal bear- ‘ing housing halves are tight. JOURNAL BEARING qugust ¢ Journat Beagincs TT Sec, See Fig. 5-9. THRUST & JOURNAL BEARINGS 3. The thrust bearing clearance is the actual distance that the rotor will travel from one extreme to the other in an axial direction. 4. To check the amount of thrust clearance, attach a dial indicator to the inlet head, preferably at the service (thrust bearing) end of the compressor. With the spindle of the indicator contacting the end of rotor shaft, apply force enough to the opposite end =~ of the shaft to move it one direction completely its limit of travel. Set indicator to zero reading and thrust the shaft in the opposite direction. The amount read on the dial indicator is the total clearance. Record the clearance. Page 5-6.1NOTE Normally there is no gasket or shim provided for adjusting ( the thrust bearing clearance. If the clearance is exces- sive, the thrust bearing components must be inspected to determine the "worn" pieces and new parts installed. Refer to the Specifications Section in this manual for the design thrust bearing clearance. If the thrust bearing clearance is less than the minimum given in the Specifications, it is permissible with Dresser Clark Engineering approval, ‘to in- stall a suitably sized paper gasket (0.010 in./0.254 mm, maximum) between the bearing housings. WARNING ‘The oi1 supply to the bearings is via portings through the head and housings. When a gasket is used, it must be made such there is no obstruction to the oi] flow to the bearings. B. Thrust Bearing Disassembly ~ Refer to Figs. 5-9, 5-10, 5-1] & 5-12 1. Remove the temperature detector tubing, radial and axial proximity probes and loosen the embedded type temperature detector leads packing glands, if not previously removed; refer to pages 5-12.1 and 5-13.1 for procedure. 2. Refer to Fig. 5-9. Remove two of capscrews 12 at the 2:30 and 9:30 o'clock positions and install the guide studs for bearing removal as illustrated, Fig. 5-10. Fig. 5-10. GUIDE STUDS FOR BEARING REMOVAL 3. Remove the remaining capscrews 12 and pull the thrust bearing = cover 1 off onto the guide studs. Carefully pull the cover along the guide studs until clear of the shaft end then move to storage area. The seal ring 18 will be removed with the cover. The out- board thrust bearing 19 may adhere to the cover. As soon as the cover is out, ensure that the outboard thrust bearing remains in housing 2 bore. Page 5-6.2At the workbench: Use “snap-ring" pliers and remove the retaining ring 17 then pull the seal ring 18 from the cover bore; store safely. Carefully pull the outboard thrust bearing 19 from the housing 2 bore. Handle with care as the thrust shoes are babbitt faced. Wrap the thrust bearing in heavy paper and store safely. Refer to Fig. 5-11. Loosen the setscrews 6 which secure the thrust disc retainer nut 3. Refer to the Special Tools and procure the special spanner wrench. Remove the retainer nut 3. The split Ting 5 halves will be uncovered with nut removal. Remove the split ring; complete Step 6 then reinstall the split ring halves taping them in place if necessary. Fig. 5-11. TYPICAL ROTOR ASSEMBLY Measure the distance from the outboard end of the shaft split ring groove to the face of the thrust disc with a depth gauge. Record the dimension. The thrust disc must be returned to this position when reassembled and using the same rotor and internals. If a spare rotor or changeout internals are being installed, it may be necessary to resize the thrust disc spacer 9. Page 5-6.37. The thrust disc is a heavy interference fit on the bushing 4 and must be hydraulically removed or installed. The bushing is a ( sliding fit on the shaft and can be easily pulled or assembled fon the shaft once the disc is “loose”. In order to remove the thrust disc from the bushing, proceed as follows: Use extreme care to keep dirt, etc., from the hydraulic oi1 and components used for thrust disc removal. Refer to the Special Tools Section and procure the thrust disc removal components shown on Fig, 5-12. a. Before installing the tools, matchmark the thrust disc to the bushing and also the bushing to the shaft so that it can be reassembled in the same radial position. PUSHER & EXPANDER PUMPS ASSEMBLY Fig. 5-12. THRUST DISC TOOLS b. Install the pusher nut 3, pusher ring 6 and adapter ring 9 on the shaft as illustrated, Fig. 5-12, being sure the O-rings and backup rings are in place. Be sure the pusher nut is fully seated against the end face of the shaft shoulder. NOTE If the compressor rotor is driven from the thrust end and has a hydraulic fit coupling hub, two special adapters are provided with the Special Tools and are to be inserted into the shaft bore. One adapter is "blind" and is used during the coupling hub removal and assembly. The other adapter is “thru” and is used during the thrust disc removal and assembly, The “blind” adapter directs the hydraulic of] to the coupTing hub bore while the "thru" adapter blanks off the drillings to the hub and allows the flow to be directed to the thrust disc bore. c. Assembly the tubing/fittings between expansion and pusher pumps as illustrated, Fig. 5-12, being sure the tubing/ fittings are clean. The expansion pump is to be connected to the shaft and the pusher pump to the nut. Page 5-6.4WARNING These tool assemblies incorporate high energy apparatus and extreme care must be taken in the assembly, operation and maintenance of the tools. Never substitute other parts for those provided. The hydraulic tubing and related parts are painted safety code color "Orange". d. Refer to the pump manufacturer's instructions in the Auxiliary Equipment Section of the manual to fill the pumps with hy- draulic ofl and purge the hydraulic system of all air. e. Pressurize the pusher ring 6 with the pusher pump 4 so that the adapter ring 9 is just touching the thrust disc. Pres- sure the disc bore with expansion pump 14 to 10,000 psig (703 kg/em2) (68.9 MPa) initially then in 1,000 psig (70 kg/cm2) (6.9 MPa) increments until the disc is loose on the bushing. It may be necessary to maintain the bore pressure for fifteen to twenty minutes to allow for thrust disc ex- pansion. Do not exceed 30,000 psig (2109 kg/cm) (206.9 MPa) maximum. Nore Record the hydraulic bore pressure at which the thrust disc is "Joose" on the bushing. For subsequent removal or assembly, the bore can be initially pressurized to this value to reduce maintenance time. f. Release the pusher pump pressure by reversing the pump and allow the thrust disc to move axially on the bushing. g. Release the bore pressure. Disconnect the tubing from the shaft and nut and return the pumps to tools storage. Remove the nut, pusher ring and adapter, and return them to tools storage. h. Refer to Fig. 5-11. Pull the thrust disc 2 from the bushing 4. The thrust disc is finish ground on both sides and warrants careful handling. Remove the split ring 5 halves, then pull the bushing 4 and bushing spacer 9 from the shaft. IMPORTANT The bushing spacer 9 locates the rotor assembly in relation to the stationary internal components. If the spacer should be damaged, the replacememnt spacer must be identical in thickness as the original when using the same rotor and internals. Mea- sure the thickness of bushing spacer with a micrometer to four decimal points and log for permanent record. If new internals or a different rotor are installed, the bushing spacer may have to be resized; refer to page 5-7.1 for procedure. Page 5-6.510. ne ib Journal Bearings Disassenbly - Refer to Figs Refer to Fig. 5-9. Carefully remove the inboard thrust bearing 20. Again use care no to damage the babbitt faced shoes. Remove the capscrews 14 which attach the thrust housing 2 to the Journal housing 3. Insert two capscrews in the tapped holes pro- vided in the thrust housing 2. Pull the housing out onto the guide studs, Fig. 5-10, until an eyebolt can be inserted in the lifter hole at top center. Rig the eyebolt to the hoisting equipment; center the housing on the studs and guide it out until clear of the shaft. Set down in ‘the storage area. Coat all of the thrust bearing parts with oil; protect against damage and store safely. 5-9 & 5-10. At either end: Refer to the Special Tools and procure the two guide studs. {nstall the studs in place of two capscrews 10/12 as illustrated, Fig. 5-10, Firmly tighten the studs in the head Remove the capscrews 10/13 which attach the journal bearing hous- ‘ing to the head. a. Install two capscrews in the puller holes provided in the face of the bearing housing 1/3. Slowly pull the housing assembly out onto the guide studs until an eyebolt can be installed in the lifter hole provided at top center. b. Rig the hoisting equipment to the eyebolt. Adjust the hoist to center the housing on the guide studs then remove the assembly to the workbench. c. To remove the bearing cage 2/4, cover 3/5 and shoes 5,6/7,8 from the housing 1/3, proceed as follows: 1) Remove the splitline capscrews to separate the halves of the bearing housing. Use care in handling as the upper half of the cage partially shrouds two of the lower half bearing shoes. 2) The bearing cage halves can be lifted directly out. The upper half cage is secured with two holding screws 6/9 which must be removed first. 3) Place the cage/cover/shoes assembly down on a flat surface with the cover facing up. Remove capscrews 4/6 and lift the cover off Page 5-6.64) Use iayout dye and matchmark each bearing shoe to the cage. Remove the shoe pivot screws 7/9 and pull the bearing shoes from the cage. 5) The insert liners 8/10 can be rotated out of the bearing cage and cover, An anti-rotation screw 9/11 is provided dn the Tower half cage and cover which must be renoved inst. d. Repeat Steps 1 a., b., and c. to remove the opposite end jour- nal bearing assembly. D. Bearing Inspection - Refer to Fig. 5-9. 1, Journal Bearing Shoes - Inspect the babbitt lining for scratches, grooves and evidence of a good bond to steel backing. Radial scratches and grooves can be tolerated if the edges can be blended into the normal surface, and the load bearing area is not appreci- ably redcued. Axial grooves tend to disrupt formation of an oil film and the shoe should not be reused. A poor bond can be iden- tified by fine hairline cracks or portions of the babbitt lining broken away from the shoe. Reject such shoes. Inspect the backs of shoes carefully for scuffed areas in way of the pivot point. Such areas can be smoothed out with an oil wetted emery cloth. = 2. Bearing Cage - Inspect the seating surfaces carefully for nicks and burrs. Dress off any found with a fine cut file. 3, Bearing Housings - Inspect rail fit to cage and ‘marry’ to mating piece. Entire seating surfaces must be free of nicks and burrs. 4, Thrust Bearings (Inboard/Outboard) - The thrust shoe assemblies are not normal maintenance items. It is recommended that the thrust bearings be replaced as complete assemblies; however, the thrust bearing shoes can be replaced at the site if worn or dam- aged, All thrust bearing shoes when assembled must be the same thickness within 0.0005 in. (0.013 mm). Inspect the base rings carefully for cracks radiating from the retaining screw holes. Observe that while shoes are "loose" on the base ring, the pivot and retaining screws forbid removal from the base ring. Thrust shoe babbitt faces should all show equal wear with wear indicated in the same general location on each shoe. Assuming a clean oi] at design pressure/temperature, tool marks should still be visible over the entire shoe surface. ‘Scratches or grooves at 90° to rotation can disrupt the oil films required for good lubrication and may tend to increase loading on other shoes. Reference can be made to the operating log sheets on changes in "thrust bearing oi1 ‘out! temperatures", If a marked increase has been noted with a generally constant compressor operating condition, it is strongly Teconmended that the thrust bearing be replaced with new. Page 5-6.7Retaining Pin Peened Over After Flats Are Set Paraltel To Radial Centerline Leading (Thin) Edge aN Must Point Into Rotation ken Ingtatied In Housings, Retaining Pin Section "A= AY ROTATION co Fig. 5-12A. TYPICAL THRUST BEARING a. If necessary, the thrust bearings can be disassembled at the work bench as follows; refer to Fig. 5-12A. 1) Place the thrust bearing assembly on the bench with the base ring facing up. Protect the babbitt faced thrust shoes from damage, 2) Remove the machine screws from the base ring, then invert the assembly so the thrust shoes are facing up. 3) Number the thrust shoes so that they can be kept in the same radial position on the base ring and to each other. 4) Pull the thrust shoes radially until clear of the retein- ing pins. 5) The retaining pins are a “metal-to-netal” fit (0.000 to 0.003 in,/0.000 to 0.076 mm Toose) in the base ring and are not a maintenance item unless damaged. If replacenent pins are required, invert the base ring and set on wooden blocks sufficiently high to drive the retaining pins out. NOTE The retaining pins were peened over at assembly. It may be necessary to drill the head slightly to remove peened — area, if they cannot be easily tapped out with a punch. ( 6) Protect the parts against corrosion or other damage and store safely. Page 5-6.8db. The thrust bearing is to be reassembled as follows: 1) Clean all of the thrust bearing parts with a non-flamable solvent and blow dry with air. 2) Check the base ring on a surface plate and with a micro meter for warpage or uneven wear. Base ring end faces must be parallel and square with OD (outside diameter) within 0.0005 in, (0.013 mm). 3) If replacement retaining pins are to be installed, place the base ring on the bench, slotted side down. Piace the pins in the base ring so that the flats on each pin are perpendicular to the outside diameter of the base ring. Turn the base ring over and using a peening tool, secure each pin to the base ring. 4) Invert the base ring on the bench, and using a straight edge across opposite retaining pins, check that the flats are parallel to each other and perpendicular to the outer diameter of the base ring. Repeat Step 2) for the base ring. 5) Measure the thickness of the thrust bearing shoes. All of the shoes in the assembly must be the same thickness within 0.0005 in. (0.013 mm). The design thickness of the thrust bearing shoes is given in the Specification Section; replace the shoes if thickness if 0.005 in. (0,13 mm) Tess than the minimum, If the set of thrust shoes are not within the 0.0005 in, (0,013 mm) tolerance: a) Measure the thickness of all the thrust shoes to de- termine the thinnest shoe. Each shoe which does NOT measure within 0.0005 in. (0.013 mm) should be rubbed with a 320 grit cloth on the babbitt face. b) Each thrust shoe must then be lapped on a lapping Plate using "Time-Saver" yellow Tapping compound mixed with a light machine oi] to forma paste. c) Apply lapping paste to both the thrust shoe babbitt face and the lapping plate. Rub the shoe on the plate using the paste as a lubricant. This will gradually both clean and smooth the babbitt surface. d) Clean off the shoe periodically and measure its thick- ness until it is within proper tolerance. Always clean the shoe with a non-flammable solvent then blow dry with air. e) Once all the thrust shoes are within tolerance, pro- ceed as follows: . 6) Turn the base ring over so that it is setting on the retain- ‘ing pins; tapped holes for machine screws will be facing up. Page 5-6.97) Carefully slide the thrust bearing shoes between the re- taining pins with the countoured side up and using care note to damage the babbitt face. CAUTION Be certain to use the correct part number thrust shoe. Shoes are not interchangeable between the inboard and outboard thrust bearings. 8) Line up the hole in the thrust shoe with the tapped hole in the base ring then install the machine screw. Tighten firmly and stake to secure. NOTE Install the thrust shoe in the radial position from which it was removed. Replacement shoes are to be installed in the position of the worn component. If axial proximity probes or embedded type temperature detectors are used, refer to the actual Thrust Bear- ‘ing Assembly drawing in the Parts Lists Section to radially locate these thrust shoes. 9) Turn the thrust bearing assembly over and observe that the shoes are free to tilt on the base ring but still secured by the retaining pins and the machine screws. 10) Thoroughly coat the bearing with oi] and wrap in heavy paper until reassembly in the compressor. E, Checking Journal Bearing Clearances - Refer to Fig. 5-9. ie In view of the type of construction of this bearing (tilting pad) a diametral clearance check is difficult and is not considered to be of any real value. The bearing shoes and cage are machined to fine tolerances and hand fitting to obtain a given clearance is not necessary. The journal bearing shoe design radial thickness is given in the Specifications Section of this manual, It is recommended the shoes be measured and replacements installed if the thickness is less than the minimum listed. Careful visual inspection of each bearing shoe will indicate if replacement with a new shoe is required. Inspect each shoe for scoring, poor bonding or loss of babbitt, etc. If any doubt exists, it is recommended that replacement shoes be used. NOTE It is not always necessary to replace a complete set of bearing shoes. If, for example, the babbitt bond is poor on one shoe, then replace that shoe and reuse the remain- ing shoes if visual inspection indicates their good con- dition. Do not intermix the shoes between sets at each end of the compressor. Page 5-6.10Journal Bearing Shoes Reassembly - Refer te 1. All journal bearing components are on hand and clean, Install the bearing shoes in the cage halves in the position from which they were removed. 2. Instal1 cage cover then install the centering screws through the cage and drive up tight. Stake the screws with a prick-punch to prevent backing out. Journal Bearings Reassenbly - Refer to Figs. 5-9 & 5-10. Al] components comprising the journal bearings are on hand, have been ‘inspected, cleaned and found serviceable. CAUTION The rotor assembly is being supported by the inner labyrinth seals. Do not apply any axial loading on the rotor shaft while so supported. 1. Journal bearing reassembly can start at either end. Install the ‘two guide studs in the tapped holes for capscrews 10 or 12 at the 2:30 and 9:30 o'clock positions as shown in Fig. 5-7. 2. The journal bearings are to be preassembled at the workbench; refer to Fig, 5-9. a. Rotate the insert liners into the bearing cage and cage cover. Secure the bottom half liners with the anti-rotation screws provided. b. Refer to Step F and install the journal bearing shoes in the cage. Install the cover and stake the centering screws to Jock in place. c. Place the lower half journal bearing housing on the bench with the splitline horizontal and chock to prevent rolling. d. Place the lower half cage/cover/shoes assembly in the lower half housing observing dowel in cage is aligned to the slot at bottom vertical center in housing. e. Place the upper half cage/cover/shoes into the upper half housing and secure with the splitTine holding screws. f, Place the upper half housing assembly onto the lower half. Install the splitline capscrews and run up hand tight. Use care in installing as the upper half cage partially shrouds two of the lower half bearing shoes. g. Place the O-ring 14 or 21 in the groove in the housing. Use care not to twist or damage the O-ring. Thoroughly coat the O-ring with oi1. h. Instal1_an eyebolt in the lifter hole provided at top center of the housing and rig the assembly to the hoist. Page 5-6.113. Refer to the Special Tools and procure the bearing entry sleeve and place on the shaft as illustrated, Fig. 5-13. Before install- ‘ing the sleeve, carefully inspect its 0D (Outside Diameter) for burrs which could damage the babbitt lined bearing shoes. Thorough ly lubricate the sleeve OD and the shoes, Use at the 2nd section end only when compressor is driven from Ist section, Fig. 5-13. BEARING ENTERING SLEEVE 4, Clean the shaft bearing journal then oi] liberally. Carefully align the bearing assembly to the guide studs at the end of the shaft. 5, Carefully push the assembly over the guide rods until necessary to remove the hoist and eyebolt. The entry sleeve will keep the bearing centered on the shaft. Bottom the housing against the head and install and snug up capscrews 10 or 13. Remove the- entry sleeve. 6. DO NOT DRIVE EITHER THE HOUSING SPLITLINE CAPSCREWS OR AXIAL CAP- SCREWS UNTIL THE OPPOSITE END JOURNAL BEARING 1S INSTALLED, 7, Repeat Steps 1 through 5 at the opposite end journal bearing. 8. At both ends: . Drive up the bearing housing splitline capscrews. b. Drive up the axial capscrews cross tightening to assure the housings are pulled up square. ‘Thrust Bearing Reassembly - Refer to Figs. 5-9, 5-10, 5-11 & 5-12, 1. Refer to Fig. 5-10 and install the guide studs in two of the tapped holes in the head for capscrews 12, Fig. 5-9 at two equally spaced positions if not in place. Page 5-6.12Install an eyebolt in the lifter hole provided at top center of thrust bearing housing 2. Rig the hoisting equipment to the eye- bolt and carefully guide the thrust bearing housing over the shaft and onto the guide studs, Push the thrust housing firmly against the journal bearing housing removing the hoist and eyebolt when necessary. Install capscrews 14 and tighten firmly. Inspect the inboard thrust bearing 20 base ring carefully for cleanliness and observe all shoe faces are clean and smooth. Care- fully guide the bearing into the thrust housing 2 bore aligned to the locating dowel in the housing face. NOTE Base ring to housing bore clearance is small; keep plumb to avoid 'cocking'. Squirt of1 on all shoe faces. If a spare or replacement rotor or internals have been installed, it will be necessary to determine the correct thickness of thrust disc bushing spacer. The spacer positions the rotor assembly axially in relation to the stationary internal bundle components. Refer to page 5-7.1 for procedure. Place the spacer on the shaft. Place the O-ring seals in the shaft grooves under the bushing. Instal1 the bushing on the shaft with spacer rim inboard. Observe the bushing and bushing spacer are fully seated against the shaft shoulder and radially aligned to the matchmark on the shaft. Very carefully measure the distance from the outboard face of the bushing spacer flange to the outboard end of the shaft groove for ‘the split ring, Dimension 'A', Fig. 5-14. Refer to Fig. 5-14, Measure and record the thrust disc thickness, dimension 'T', Fig, 5-14, THRUST DISC DIMENSIONS Page 5-6.1310. un, 12, 13. 14, 15, 16. VW. 18, 19. 20. a. 22. Place the thrust disc onto the bushing without the O-rings (metal- to-metal). The thrust disc must be square with the shaft within 0.0005 in, (0.013 mm) F.I.R. Note matchmarks, thrust disc to bushing and bushing to shaft, are in radial alignment. Now measure the distance from the outboard face of thrust disc to the outboard end of the split ring groove in the shaft; dimension ‘BY, Fig, 5-14, Remove the thrust disc; install the O-rings in the disc bore, then reinstall the disc on the bushing, Use care not to damage the O-rings while installing the disc. Temporarily install the split ring halves, taping in place if neces- sary, Refer to the Special Tools and install the hydraulic pump components and thrust disc pusher components as outlined in Step B.7.b., c., and d. Use the pusher pump and move the thrust disc to the position found in Step 9 (dimension 'B'), The O-ring seals in the disc bore will extrude if the bore is pressurized before the disc is metal-to- metal on the bushing, Install a dial indicator to observe the thrust disc axial travel. pecs ceuuivedt(eteene ton) Daa(iteetcek | etalea h fain (8 aT), Set the pusher pump relief valve (integral part of pump) at 8000 psig (562.4 kg/cm2, 55.2 MPa), Increase the pusher pump pressure to 500 to 1000 psig (35 to 70 kg/cm@, 3,4 to 6.9 MPa), Pressurize the thrust disc bore to 10,000 psig (703 kg/cm®, 69 MPa) while maintaining the pusher pump pressure. CAUTION: Do not allow the thrust disc to move off the bushing taper Gradually increase the bore pressure and pusher pressure to move the thrust disc to its assembled position 'E' (thrust disc is seated firmly against the bushing shoulder). The maximum allowable bore pressure is 30,000 psig (2109 kg/cm, 207 MPa). Measure and record dimension 'C' and axial travel dimension 'D'. Dimension 'C' should be the same as recorded in Step B.6, Page 5-6.3 if the same components are installed. Release the expander pump bore pressure gradually (at 5000 psig, 351 kg/emé) (34.5 Pa) intervals) while maintaining the thrust disc position 'E' with the pusher pump pressure. When the bore pressure reads zero, maintain the pusher pressure for an additional five minues, then release the pusher pressure. Recheck the axial travel, Dimension 'D', If the same as Step 1 Remove the hydraulic tubing and pusher components. Page 5-6.1423. 24, 25. 26. 27. Measure and record dimension 'C'; should be the same as recorded in Step B.6, if the same components are installed. As a final check, dimensions 'C plus T' will equal 'A'. Refer to Fig. 5-11 and remove the tape, if used, from the split ring 5, Clean and reinstall the split ring in the shaft groove outboard of bushing. Ring can be made to adhere to the shaft with several dabs of grease until the retaining nut 3 is installed. NOTE If a new or replacement bushing or spacer has been installed, it may be necessary to grind the split ring thickness to suit at assembly, Measure distance from outboard end of bushing to back of split ring shaft groove. Grind the split ring to the dimen- sion found plus 0,000 minus 0,003 inches (plus 0.000 minus 0.08 mn), Finish grind must assure the sides are parallel and square with the bore within 0.0005 inches (0.013 mn) F.1.R. (fully in~ dicated reading). Install the retaining nut 3 and lock in place with setscrew 6. Check the "run-out" of the thrust disc as follows: a. Secure a dial indicator to the bearing housing with the indi- cator button bearing against the face of the thrust disc near its outside diameter. b. Force the rotor assembly against the inboard thrust bearing shoes and rotate the shaft through 360°. If the disc 'run- out! exceeds 0.0005 in. (0.01 mm) F.I.R. (fully indicated reading), remove the thrust disc, bushing and spacer. Check each on a surface plate and with a micrometer for warpage or uneven wear, Replace with new parts if necessary. The rotor must not drift axially while being rotated if this test is to be effective. NOTE If a replacement thrust disc is used, it must be the same thickness as the original so that the thrust bearing axial clearance remains the same. The same applies if new thrust bearing assemblies are installed. If a replacement bushing spacer is used, the spacer must be ground to the same thickness as the original if the same rotor and internals are used. When a replacement rotor or internals are installed, the bushing spacer must be resized; refer to page 5-7.1 for procedure. If the thrust disc runout is satisfactory, proceed as follows: Page 5-6.1528. 29. 30, 3i. 32. 33. Refer to Fig. 5-9. Carefully place the outboard thrust bearing 19 in the thrust housing 2 bore taking care to note position of dowel hole in the base ring to dowel in the thrust cover 1. Be sure the thrust bearing is clean and thoroughly coat the thrust shoes and disc with oil. Observe there is no burrs on either the thrust bearing base ring or cover surfaces which will be seating the thrust bearing. Insert the seal ring 18 in the thrust bearing cover 1 bore and se~ cure with retaining ring 17. Carefully guide the cover over the shaft onto the guide studs with dowel in cover aligned to mating hole in the housing face. Push ‘the cover firmly against the housing noting dowels in cover enter mating holes in the housing and outboard thrust bearing. Insert capscrews 12 and cross-tighten them to ensure the assembly is pulled up square. With the bearings completely reassembled, recheck the thrust bear- ‘ing axial clearance, Page 5-6.1. If satisfactory, rotate the shaft by hand using the coupling locknut and a spanner wrench. No tight spots should be felt. The end cover and coupling guard adapters, radial and axial prox- imity probes and temperature detector tubing can not be installed. Page 5-6.16REPLACEMENT ROTOR - INTERNALS INSTALLATION A. Sizing Thrust Disc Bushing Spacer - Refer to Fig 1 5-15 When a spare or replacement rotor and/or internals are being installed it will be necessary to determine the correct thickness of the thrust disc bushing spacer. The spacer positions the rotor axially in re- Jation to the stationary internal components. a. The internal bundle lower half is completely assembly, Sec- tion 5-11. b. Carefully lower the rotor into the lower half bundle until it is resting on the internal labyrinth halves. Leave the slings rigged so that they support most of the rotor weight. Refer to page 5-7.3 and measure the overlap on each impeller at each side of the bundle splitline and average the results. Position the rotor axially so that the overlaps are as near optimum as possible. With the optimum overlap determined, carefully push the rotor toward the intake or Ist section end its limit of travel. Use a dial indi- cator to measure this distance and record the dimension found. Now push the rotor its limit of travel toward the discharge or 2nd section end again using a dial indicator to measure and record the dimension found. The minimum allowable total axial movement (end float) of the rotor is 0.250 in. (6.35 mm). CAUTION Do not apply excessive load to the end of rotor when determining ‘the axial movement. Lower the rotor until supported by the internal labyrinths then com- plete the compressor reassembly through installing the inboard thrust bearing, page 5-6.13, Step H.3. To determine the correct thickness of the bushing spacer, proceed as follows: a. Push the rotor assembly its limit of travel toward the intake or Ist section end (until stopped by the internal components). b. Now, using a dial indicator, carefully position the rotor to the dimension found in Step’3 to obtain the optimum impeller to diffuser overlaps. ; c. Carefully measure the distance (to four decimal points) from the face of the inboard thrust bearing shoes to the shaft shoulder seating the bushing spacer, dimension 'A', Fig. 5-15. d. Now measure the thrust disc bushing flange thickness, dimension "BY, Fig. 5-15. Page 5-7.1e. The bushing spacer thickness, dimension 'C', will then be 'A' minus "B' + 0,010 in, (0.254 mm). Thrust Disc Inboard Thrust. Bearing Bushing Ys Split Ringp Dimension 'C' = 'A' minus ‘B' plus 0.010" (0.254 mm) Fig. 5-15. THRUST DISC SPACER DIMENSIONS CAUTION The thrust disc bushing spacer faces after finish grind must be parallel and square with the spacer bore within 0.0005 in. (0.01 mm) F.1,R. (fully indicated run-out). Grind all metal from the surface of the spacer seating against the shaft shoulder. Use extreme care not to deform the spacer when anchoring it for grinding. f. Obtain a new spacer and grind spacer thickness to dimension found. Refer to page 5-6.10 and complete the thrust and journal bearing reassembly. Check the thrust disc run-out if a new spacer or bushing is installed, Page 5-7.2(CLIzeIZD) DIVISION WALL IMPELLER - DIFFUSER PASSAGE OVERLAPS & AXIAL CLEARANCES( INNER OIL SEALS ~ Refer to Fig, 5-16. It is necessary to complete the thrust and journal bearing disassembly proce- dures to provide access to the inner oi1 seal components. Seal assembly components rank with the thrust and journal bearings for optimum compressor operation. Handle and store all parts carefully. Seal disassembly can start at either end. It is recommended that one assembly be removed be- fore starting disassembly at the opposite end. This precaution is required only for pulling the inner labyrinth but is reconmended for complete disassem- bly. Seal components (except for labyrinths) are interchangeable between the drive and service ends of the compressor. Some parts are a light lapped fit to adjacent parts; therefore, the assemblies should not be intermixed. Fig. 5-16. INNER OIL SEALS ASSEMBLY A, Disassembly 1. Obtain bumper type puller from the special tools. Thread the rods into the puller holes provided in the face of the outer labyrinth 6 as illustrated in Fig. 5-17, 2. Carefully bump the labyrinth from the housing 1 bore. When free, pull the labyrinth off the shaft. Use care not to damage the labyrinth knife edges. 3, Repeat Steps 1 and 2 and remove the outer housing 1. 4, Remove the outer seal ring 6 and bearing shoes 8 by hand. Use care not to damage the babbitt-lined seal ring or shoes. Do not allow the ring or shoes to "drag" over any shaft shoulders or threads. Page 5-8.19. 10. Pull the inner seal ring 9 from the shaft using the same care as for the outer seal ring-bearing shoes. The seal ring can be pulled with the inner housing 3 if necessary. Remove the inner housing as outlined in Steps 1 and 2. If the seal ring remained in the housing, push the housing back into the head bore as soon as the ring seats on the next smaller shaft diameter. Remove the ring, then the housing. Fig. 5-17. INNER SEAL PARTS PULLER The inner labyrinth 4 can now be removed. Provide a temporary support for the rotor and raise the shaft to just relieve the weight on the labyrinth knife edges. Repeat Steps 1 and 2 and carefully bump the labyrinth from the head bore. When free, remove the rotor support and pull the labyrinth off the shaft. Use care not to damage the labyrinth knife edges. Repeat Steps 1 through 7 and remove the opposite end seal assembly. Protect all of the seal components from corrosion or other damage and store safely. C, Inspection - Refer to Fig. 5-16. Ve Seal Rings: Clean the seal rings carefully and wipe dry. Inspect the babbitted bore carefully for scratches, grooves, etc. Radial scratches and grooves can be tolerated in the rings if moderate in area and sharp edges can be removed. Axial grooves are cause for rejection. Place the rings on a flat surface and measure ID (In- side Diamenter) for wear. Replacement is recommended if wear brings Page 5-8.2the clearance above the maximum listed in the Specifications Sec- tion. Record the clearances found. Vertical seats on the rings abut respectively against the bearing and seal housings. These seats are provided with a light lap fit to remove tools marks. Inspect carefully and lap only if necessary. Use a fine oil mix compound. Clean the rings carefully, protect against corrosion and wrap in heavy paper. Bearing Shoes: Remove the centering screws 15 through the outer seal ring 6 outer periphery. Pull the shoes from the ring after matchnarking their radial position in the seal ring. Inspect the bearing shoes babbitt lining for scratches, grooves and evidence of a good bond to steel backing. Radial scratches and grooves can be tolerated if the edges can be blended into the normal surface, and the load bearing area is not appreciably reduced. Axial grooves ‘tend to disrupt formation of an oil film and the shoe should not be reused. A poor bond can be identified by fine hairline cracks or Portions of the babbitt lining broken away from the shoe. Reject such shoes. Inspect the backs of shoes carefully for scuffed areas in way of the pivot point. Such areas can be smoothed out with an oi] wetted emery cloth. In order to equalize wear on the bearing shoes, each shoe can be advanced one position in the direction of rotation. Reinstall the bearing shoes in the seal ring, Replacement bearing shoes are to be installed in the position of the worn component. Install the shoe centering screws. CAUTION Refer to Fig. 5-18, Bottom the centering screws, then, using a depth gauge, determine the clearance between the bottom of the screw head and the counterbored hole in the seal ring. There must be a minimum 0.015 in. (0.38 mm) clearance which allows the bearing shoes to "tilt" freely during operation. The bear- ing shoes must NOT be locked rigidly to the seal ring. If the capscrews are too short to obtain the design clearance, install replacement capscrews. Rework the length of replacement cap- screws as necessary to obtain the design clearance. Shoe Retainer Screw 0.015" (0.3eMM) Seal Ring Minimum Bearing Shoe Fig. 5-18. OUTER SEAL RING-BEARING SHOES ASSEMBLY Page 5-Labyrinth: Measure the ID for wear as described for the seal rings and record clearance to the applicable journals. Inspect the 0D (Outside Diameter) and flanged end faces for nicks and burrs. Dress off any found with a fine cut file. Housings: Inspect the OD carefully for nicks and burrs. Dress off any found with a fine cut file. Dowels: Be sure all are tight. O-rings: It is strongly recommended that all the O-rings used in the seal assemblies be replaced with new at each scheduled overhaul. Reassembly - Refer to Figs. 5-16, 5-17 & 5-19. 1. Although the inner components are interchangeable between the first and second section ends, care must be taken not to mix these parts because the seal rings are lapped to their respective housings. AN] the seal components should be clean and the head bore and shaft Journals wiped off before starting assembly. Renewal of all O-rings is strongly advised because their perfect condition is necessary for best seal performance. Extreme care should be taken when in- serting the housings and labyrinths to avoid tearing or shaving the O-rings. A light coating of oi7 on the O-rings will facilitate assembly. With the O-rings 13, 14 in place and alignment dowel 5 at top center, insert the inner labyrinth carefully to avoid damage to the knife edges. The puller rods may be used to guide the laby- rinth into the head bore. Align the dowel with the slot in the head and seat the labyrinth against the head shoulder. Nove, Once the labyrinth is on the shaft, provide a temporary support to center the shaft on its normal axis. Seat the labyrinth in the head bore then remove the temporary support. The rotor is now supported on the labyrinth knife edges, Do not "bump" or rotate the rotor while so supported. With O-rings 11, 13in place, insert the seal housing 3 with the loca- ting dowel hole at top center. Be certain that the dowel slips into ‘the housing and that the housing seats against the labyrinth. Carefully guide the inner seal ring 9 over the shaft and into the seal housing bore. Be certain that the dowel is aligned with the slot in the housing so that the ring seats against the housing shoulder. Coat the shaft seal ring journal with oi] before install- ‘ing the seal ring. NOTE If new seal rings are used, they must first be lapped to their respective housings. Page 5-8.4Refer to the Special Tools and procure the seal ring-bearing shoes assembly tool. Inspect the sleeve OD (Outside Diameter) for burrs, etc., which could damage the babbitt lined bearing shoes and seal ring. Dress off then thoroughly coat the sleeve 0D and the shaft seal ring journal with oil, Place the sleeve on the shaft as lustrated in Fig. 5-19. mh Fig. 5-19. SEAL RING-BEARING SHOES ASSEMBLY TOOL Carefully place the outer seal ring 6 bearing shoes 8 assembly on ‘the sleeve and push into the housing 3 bore aligning the dowel in the seal ring to the slot in the housing. Bottom the ring then remove the sleeve. With O-rings1Zin place, install the outer housing 1 as outlined in Step 3. Be certain dowel enters mating hole in inner housing 3eand that outer housing is seated against the inner housing. With O-rings 18 in place, install the outer labyrinth 16. Be certain dowel 17 enters mating slot in housing 1 and that the labyrinth is seated against the outer housing. Repeat Steps 2 through 8 for the opposite end seal assembly. The thrust and journal bearings can now be installed; refer to Section 5-6. Page 5-8.5PULLER BLOCKS, RETAINING & SHEAR RINGS & SERVICE END HEAD General Both bearing and seal assemblies have been removed. The inlet head is retained against internal pressures by means of segmented retaining and shear rings seating in an annulus turned in case core. This sequence must be followed closely, since some of the segmented ring components could be loose to drop ‘onto the exposed rotor shafting. A. Disassembly - Refer to Figs. 5-20, 5-21 & 5-22 1. Loosen the puller nuts. Use the pusher nuts and force the inlet head "in" away from the retaining ring then remove the puller blocks, nuts and studs. haprégsot cake penn i A Hui Putter wat usher hit ae RE oy) Fig. 5-20. INLET HEAD PULLER - Refer to Fig. 5-21. Remove the capscrews through the upper left- hand retainer ring segment ‘A'. Use the jackscrew found in the segment radial center to force the retainer segment out of the annulus. It may be necessary to back off the jackscrew and drive the retainer segment into the annulus to free up. Apply penetrating oi] if found to be rusty. Use a hardwood block for driving the segment back into the annulus. Remove the segment when loose. 3. Remove the upper right hand retainer ring segment 'D' in the same manner. During the removal of this retainer segment, observe tight- ness of the top shear ring segnent ‘A” which will be completely uncovered by retainer segment removal. If the shear ring top seg- ment appears to be loose, hold in place with a wooden wedge, etc. DO NOT ALLOW TO FALL OUT OF ANNULUS. Page 5-9.1i 3/32 wep Remove the topmost shear ring segment 'A'. If 'frozen' in the annu- lus, use a hardwood block to free up. When free, pull straight back and out. Shear ring segments are heavy; handle with care. An eye- bolt is provided in the segment radial center for handling. 5 radian aA Eis? ap Fig. 5-21. RETAINING & SHEAR RING SEGMENTS Remove the remaining retainer ring to shear ring capscrews. Work retainer segments 'B' and 'C’ out of the annulus as described in Step 2. Remove the right and left hand shear rings 'B' and ‘D' as described ‘in Step 4. Remove the bottom shear ring segment 'C'. This segment is provided with a dowel at bottom center engaging slots in the head and casing. Handle carefully. Clean the exposed case bore carefully and lubricate to reduce fric- tion while pulling the head. Reinstall the puller blocks, studs and puller nuts. Firmly tighten ‘the jam nut to lock the stud in the face of the head. Using the puller nuts, pull the head as far as possible to break the head-to-case seal and then remove the puller blocks and studs. Refer to the Special Tools and procure the head lifter. Bolt the lifter to the head with the bolts as illustrated in Fig. 5-21. Page 5-9.2B. 12. 13, 4, Rig a chain fall into a hoist hook that is capable of sustaining the head weight; refer to the Specifications, Section 6, for the approximate weight. Also, rig the chain fall into a sling made fast to the lifter using a screw type shackle. Adjust the chain fall to “float” the head in the case bore. Taking care to keep ‘the head centered, pull straight back until clear of the shaft end. Move the head to the storage area and set down on wood blocks ‘inboard face down. The lifter can remain bolted to the head. Cover with a drop cloth, etc. NOTE It is strongly recommended that a chain fall capable of safely handling weight of the inlet head be rigged into a hoist hook. Be so doing, minute vertical ad- justments can be made. This is particularly true if rigging to the head when the assembly to be hoisted is contained wholly or partially within the case. The drive end head is not a normal maintenance item but should be removed during plant turn-around periods to renew the O-rings. The internal bundle assembly is now accessible; refer to page 5-10.17. Fig. 5-22, INLET HEAD LIFTER Reassembly - Refer to Figs. 5-20, 5-21 & 5-22. General The head lifter, Fig. 5-22, is installed. All the head passages (oi] and gas) have been cleaned with compressed air/solvent and the seal bore Cleaned. All the passages have blown dry with compressed air and covered Page 5-9.3to prevent entry of contaminates during assembly. Seal bore lands and grooves have been inspected with a small mirror and are clean. Reassem- bly can start at either end. a 2. 10. ll. Hoist the head/lifter to a vertical position. Observe that a good balance is obtained. When installing the intake end head note, the O-ring is installed in the face of the first stage inlet guide. Install the O-rings and backup rings on the head. Be sure the back- up ring is placed outboard of the O-ring (on the low pressure side). Carefully align the head to the shaft and case bore. With good balance, the head can be pushed in manually until the O-rings start to seat. Refer the Fig. 5-20 and install the puller blocks, studs and nuts. Lock the stud in place with the jam nuts and leave the puller nuts “loose”. Check the depth of the head from the end of the case and make plumb. With the head plumb: Use the inboard pusher nuts and bottom the head in the case bore. Remove the head lifter. Procure segmented shear and retainer rings. Clean carefully and remove all nicks and burrs. Remove all jackscrews used for dis- assembly. Instal] bottom shear ring segment 'C' (contains dowels at butt ends and bottom center). Align bottom center dowe? to notch in head and case bore and slide under head to provide a.metal-to-metal contact. Obtain a retaining ring segment 'C' and try fit at bottom center. Entry into annulus should be made without difficulty. If difficulty is experienced. @) Note the puller nuts on the studs are “loose” then drive up ‘the pusher nuts to seat the head in the case bore. b) Try the retaining ring segment fit which should now be satis- factory. Install the remaining shear ring segments 'A, B and D' and then the retaining ring segments. Install the capscrews which attach the re- taining ring segments to the shear ring and tighten evenly. Use the pusher nuts to bottom the head in the case bore then check the clearance between the outboard end of the retaining ring and case annulus; should be within 0.003 to 0.005 in. (0.08 to 0.13 mm). If a replacement retaining ring is to be installed, it-must be ground at assembly to provide this clearance. Finish grind must ensure the end faces are parallel within 0.001 in. (0.025 mm) F.I.R. Page 5-9.4