RWB II ROTARY SCREW COMPRESSOR UNITS
INSTALLATION - OPERATION - MAINTENANCE
S70-200 IOM
Page 2
Contents
Maintenance
GENERAL INFORMATION .............................................22
NORMAL MAINTENANCE OPERATIONS......................22
GENERAL MAINTENANCE ............................................22
COMPRESSOR SHUTDOWN and START-UP ...............22
GENERAL INSTRUCTIONS FOR REPLACING
COMPRESSOR UNIT COMPONENTS. ..................23
OIL FILTER (OF-1) MAIN SINGLE/DUAL ....................... 23
STRAINER - DEMAND OIL PUMP .................................23
STRAINER - LIQUID INJECTION ................................... 24
COALESCER FILTER ELEMENT(S) ..............................24
CHANGING OIL ..............................................................24
DEMAND PUMP DISASSEMBLY ................................... 25
RECOMMENDED MAINTENANCE PROGRAM.............29
VIBRATION ANALYSIS ...................................................29
MOTOR BEARINGS........................................................29
OIL QUALITY and ANALYSIS .........................................29
OPERATING LOG ...........................................................30
MAINTENANCE SCHEDULE .........................................30
TROUBLESHOOTING GUIDE ........................................31
ABNORMAL OPERATION .............................................. 31
ANALYSIS and CORRECTION ................................31
SERVICING THE COLD-START VALVE .........................31
PRESSURE TRANSDUCERS - TESTING ......................31
PRESSURE TRANSDUCERS - REPLACEMENT ..........32
SV POSITION POTENTIOMETER
REPLACEMENT AND ADJUSTMENT .................... 33
VOLUMIZER® POTENTIOMETER
REPLACEMENT AND ADJUSTMENT .................... 33
TEMPERATURE and/or PRESSURE ADJUSTMENT .... 34
OIL LEVEL TRANSMITTER ............................................34
REPLACEMENT .............................................................34
TROUBLESHOOTING
RWB II COMPRESSOR ...........................................35
OIL SEPARATION SYSTEM ....................................35
HYDRAULIC SYSTEM............................................. 36
LIQUID INJECTION OIL COOLING SYSTEM ......... 37
DEMAND PUMP SYSTEM ......................................38
THERMAL EXPANSION VALVES ...................................39
JORDAN TEMPERATURE REGULATOR VALVE ...........40
BARE COMPRESSOR MOUNTING ...............................41
GREASE COMPATIBILITY..............................................41
NLGI Grease Compatibility Chart .................................... 41
P & I DIAGRAM ..............................................................42
PROPER INSTALLATION OF ELECTRONIC EQUIPMENT
IN AN INDUSTRIAL ENVIRONMENT ......................46
FORMS
OPERATING LOG SHEET .......................................49
COMPRESSOR PRESTART CHECKLIST ..............50
START-UP REPORT ................................................ 51
VIBRATION DATA SHEET........................................53
RECOMMENDED SPARE PARTS ................................. 54
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
Indicates a potentially hazardous situation or practice which, if not avoided, will result in death
or serious injury.
SAFETY PRECAUTION DEFINITIONS
Indicates a potentially hazardous situation or practice which, if not avoided, will result in damage
to equipment and/or minor injury.
NOTE:
Indicates an operating procedure, practice, etc., or portion thereof which is essential to highlight.
PREFACE .........................................................................3
DESIGN LIMITATIONS ...................................................... 3
JOB INSPECTION ............................................................3
TRANSIT DAMAGE CLAIMS ............................................ 3
COMPRESSOR and UNIT IDENTIFICATION ...................3
Installation
FOUNDATION ...................................................................4
RIGGING and HANDLING ................................................4
SKID REMOVAL................................................................4
MOTOR MOUNTING......................................................... 5
CHECKING MOTOR/COMPRESSOR ROTATION ............5
COMPRESSOR/MOTOR COUPLINGS
INSTALLATION .......................................................... 5
COUPLING ALIGNMENT PROCEDURE..........................7
HOT ALIGNMENT OF COMPRESSOR/MOTOR ..............9
OIL PUMP COUPLING .....................................................9
HOLDING CHARGE AND STORAGE...............................9
COMPRESSOR UNIT OIL ................................................9
OIL CHARGE ....................................................................9
OIL HEATER(S) ................................................................9
THERMOSYPHON OIL COOLING ................................. 10
LIQUID INJECTION OIL COOLING (Optional)................11
WATER-COOLED OIL COOLING (Optional)................... 12
LIQUID LINE SIZES/RECEIVER VOLUME ..................... 12
ECONOMIZER - HIGH STAGE (OPTIONAL)..................12
ELECTRICAL .................................................................. 14
MOTOR STARTER PACKAGE ........................................14
CURRENT TRANSFORMER (CT) RATIOS ....................15
MINIMUM BURDEN RATINGS ....................................... 15
BATTERY BACKUP ........................................................15
Operation
OPERATION and START-UP INSTRUCTIONS ..............16
TDSH COMPRESSOR ...................................................16
COMPRESSOR LUBRICATION SYSTEM ......................16
NO PUMP OIL SYSTEM ................................................. 16
COLD-START SYSTEM ..................................................16
DEMAND PUMP OIL SYSTEM ....................................... 17
COMPRESSOR OIL SEPARATION SYSTEM ................17
COMPRESSOR HYDRAULIC SYSTEM .........................18
VOLUMIZER® VOLUME RATIO CONTROL ................... 18
COMPRESSOR OIL COOLING SYSTEMS ....................19
SINGLE-PORT LIQUID INJECTION ............................... 19
RWB II BOOSTER OR SWING DUTY APPLICATION .... 19
DUAL-PORT LIQUID INJECTION ...................................19
LIQUID INJECTION ADJUSTMENT PROCEDURE ....... 19
SUCTION CHECK VALVE ............................................... 20
SUCTION CHECK VALVE BYPASS ................................20
LOW AMBIENT OPERATION ......................................... 20
POWER ASSIST KIT ...................................................... 20
INITIAL START-UP.......................................................... 21
INITIAL START-UP PROCEDURE ..................................21
NORMAL START-UP PROCEDURE .............................. 21
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