RWF ROTARY SCREW COMPRESSOR UNITS
INSTALLATION - OPERATION - MAINTENANCE
S70-600 IOM
Page 2
PREFACE .........................................................................3
DESIGN LIMITATIONS ......................................................3
JOB INSPECTION ............................................................3
TRANSIT DAMAGE CLAIMS ............................................3
COMPRESSOR and UNIT IDENTIFICATION ...................3
FOUNDATION ...................................................................4
RIGGING and HANDLING ................................................4
SKID REMOVAL................................................................4
CHECKING MOTOR/COMPRESSOR ROTATION ...........5
COMPRESSOR/MOTOR COUPLING INSTALLATION ....5
OIL PUMP COUPLING .....................................................5
HOLDING CHARGE AND STORAGE ..............................5
COMPRESSOR UNIT OIL ................................................5
OIL CHARGE ....................................................................6
OIL HEATER(S) ................................................................6
THERMOSYPHON OIL COOLING ...................................6
LIQUID INJECTION OIL COOLING (Optional) .................7
LIQUID LINE SIZES/RECEIVER VOLUME.......................8
WATER-COOLED OIL COOLING (OPTIONAL) ................8
ECONOMIZER - HIGH STAGE (OPTIONAL) ....................9
ELECTRICAL..................................................................10
MOTOR STARTER PACKAGE .......................................10
CURRENT TRANSFORMER (CT) RATIOS ....................11
MINIMUM BURDEN RATINGS .......................................11
BATTERY BACKUP ........................................................11
OPERATION and START-UP INSTRUCTIONS..............12
SGC COMPRESSOR .....................................................12
COMPRESSOR LUBRICATION SYSTEM .....................12
NO PUMP OIL SYSTEM .................................................12
COLD-START SYSTEM..................................................13
DEMAND PUMP OIL SYSTEM.......................................13
COMPRESSOR OIL SEPARATION SYSTEM ................13
COMPRESSOR HYDRAULIC SYSTEM ........................14
VOLUMIZER VOLUME RATIO CONTROL .....................14
COMPRESSOR OIL COOLING SYSTEMS ....................15
SINGLE-PORT LIQUID INJECTION ...............................15
BOOSTER OR SWING DUTY APPLICATION ................15
DUAL-PORT LIQUID INJECTION ..................................15
LIQUID INJECTION ADJUSTMENT PROCEDURE .......15
SUCTION CHECK VALVE BYPASS ...............................16
LOW AMBIENT OPERATION..........................................16
INITIAL START-UP .........................................................17
INITIAL START-UP PROCEDURE .................................17
NORMAL START-UP PROCEDURE..............................17
GENERAL INFORMATION .............................................18
NORMAL MAINTENANCE OPERATIONS .....................18
GENERAL MAINTENANCE ...........................................18
COMPRESSOR SHUTDOWN and START-UP...............18
GENERAL INSTRUCTIONS FOR REPLACING
COMPRESSOR UNIT COMPONENTS ...................19
OIL FILTER (OF-1) MAIN SINGLE/DUAL .......................19
STRAINER - DEMAND OIL PUMP .................................19
STRAINER - LIQUID INJECTION ...................................20
COALESCER FILTER ELEMENT(S) ..............................20
CHANGING OIL ..............................................................20
DEMAND PUMP DISASSEMBLY ...................................21
DEMAND PUMP ASSEMBLY .........................................22
TROUBLESHOOTING THE DEMAND PUMP ................23
PREVENTATIVE MAINTENANCE ..................................24
RECOMMENDED MAINTENANCE PROGRAM ............25
VIBRATION ANALYSIS ...................................................25
MOTOR BEARINGS .......................................................25
OIL QUALITY and ANALYSIS .........................................25
OPERATING LOG ...........................................................26
MAINTENANCE SCHEDULE.........................................26
TROUBLESHOOTING GUIDE ........................................27
ABNORMAL OPERATION ANALYSIS & CORRECTION 27
SERVICING THE COLD-START VALVE .........................27
PRESSURE TRANSDUCERS - TESTING .....................27
PRESSURE TRANSDUCERS - REPLACEMENT .........28
SV POSITION POTENTIOMETER
REPLACEMENT AND ADJUSTMENT ....................29
CAPACITY LINEAR TRANSMITTER
REPLACEMENT - SLIDE VALVE ............................29
VOLUMIZER® TRANSMITTER REPLACEMENT -
SLIDE STOP ............................................................30
TEMPERATURE SENSOR REPLACEMENT.................30
OIL LEVEL TRANSMITTER REPLACEMENT................30
TROUBLESHOOTING THE RWF COMPRESSOR ........31
OIL SEPARATION SYSTEM ....................................31
HYDRAULIC SYSTEM ............................................32
LIQUID INJECTION OIL COOLING SYSTEM .........32
DEMAND PUMP SYSTEM ......................................33
THERMAL EXPANSION VALVES ...................................34
JORDAN TEMPERATURE REGULATOR VALVE ...........35
MOTOR REPLACEMENT ...............................................36
BARE COMPRESSOR REPLACEMENT .......................36
GREASE COMPATIBILITY ..............................................36
P & I DIAGRAMS ............................................................37
WIRING HARNESS ........................................................41
PROPER INSTALLATION OF ELECTRONIC EQUIPMENT
IN AN INDUSTRIAL ENVIRONMENT .....................44
FORMS ...........................................................................47
RECOMMENDED SPARE PARTS .................................52
Contents
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.
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.
SAFETY PRECAUTION DEFINITIONS
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